vnx.su x trail t30 sm - Часть1 PDF

QUICK REFERENCE INDEX
A GENERAL INFORMATION
GI
General Information
B ENGINE
EM
Engine Mechanical
LU
Engine Lubrication System
CO
Engine Cooling System
EC
Engine Control System
FL
Fuel System
EX
Exhaust System
ACC
C TRANSMISSION/
TRANSAXLE
D DRIVELINE/AXLE
E SUSPENSION
MODEL T30 SERIES
F BRAKES
Accelerator Control System
CL
Clutch
MT
Manual Transaxle
AT
Automatic Transaxle
TF
Transfer
PR
Propeller Shaft
RFD
Rear Final Drive
FAX
Front Axle
RAX
Rear Axle
FSU
Front Suspension
RSU
Rear Suspension
WT
Road Wheels & Tires
BR
Brake System
PB
Parking Brake System
BRC
Brake Control System
G STEERING
PS
Power Steering System
H RESTRAINTS
SB
Seat Belts
SRS
I
BODY
BL
Body, Lock & Security System
GW
Glasses, Window System & Mirrors
RF
Roof
EI
Exterior & Interior
IP
Instrument Panel
SE
J AIR CONDITIONER
K ELECTRICAL
Supplemental Restraint System (SRS)
Seat
ATC
Automatic Air Conditioner
MTC
Manual AIr Conditioner
SC
Starting & Charging System
LT
Lighting System
DI
Driver Information System
WW
Wiper, Washer & Horn
BCS
Body Control System
LAN
LAN System
AV
ACS
Audio Visual, Navigation & Telephone System

Auto Cruise Control System
PG
Power Supply, Ground & Circuit Elements
L MAINTENANCE
MA
Maintenance
M INDEX
IDX
Alphabetical Index
2005 NISSAN EUROPE S.A.S.

All rights reserved. No part of this Electronic Service Manual may be reproduced or stored in a retrieval system, or transmitted in any
form, or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Nissan
Europe S.A.S., Paris, France.
http://vnx.su
A
B
C
D
E
F
G
H
I
J
K
L
M
FOREWORD
This manual contains maintenance and repair procedures for the NISSAN
X-TRAIL, model T30 series.
In order to assure your safety and the efficient functioning of the vehicle,
this manual should be read thoroughly. It is especially important that the
PRECAUTIONS in the GI section be completely understood before starting
any repair task.
All information in this manual is based on the latest product information
at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.
IMPORTANT SAFETY NOTICE

The proper performance of service is essential for both the safety of the
technician and the efficient functioning of the vehicle.
The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately.
Service varies with the procedures used, the skills of the technician and the
tools and parts available. Accordingly, anyone using service procedures,
tools or parts which are not specifically recommended by NISSAN must
first be completely satisfied that neither personal safety nor the vehicles
safety will be jeopardized by the service method selected.
NISSAN EUROPE S.A.S.

Service Operations Section
Paris, France
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ENGINE MECHANICAL
B ENGINE
SECTION
EM
ENGINE MECHANICAL
EM
CONTENTS
QR
PRECAUTIONS .......................................................... 5
Precautions for Drain Engine Coolant ...................... 5
Precautions for Disconnecting Fuel Piping .............. 5
Precautions for Removal and Disassembly ............. 5
Precautions for Inspection, Repair and Replacement ......................................................................... 5
Precautions for Assembly and Installation ............... 5
Parts Requiring Angle Tightening ............................. 5
Precautions for Liquid Gasket .................................. 6
REMOVAL OF LIQUID GASKET .......................... 6
LIQUID GASKET APPLICATION PROCEDURE..... 6
PREPARATION ........................................................... 7
Special Service Tools ............................................... 7
Commercial Service Tools ........................................ 9
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ...............................................11
NVH Troubleshooting Engine Noise ...................11
Use the Chart Below to Help You Find the Cause
of the Symptom. ..................................................... 12
DRIVE BELTS ........................................................... 13
Checking Drive Belts .............................................. 13
Tension Adjustment ................................................ 13
Removal and Installation ........................................ 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 14
Removal and Installation of Drive Belt Auto-Tensioner ..................................................................... 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 15
AIR CLEANER AND AIR DUCT ............................... 16
REMOVAL ........................................................... 16
INSTALLATION ................................................... 17
Changing Air Cleaner Filter .................................... 17
REMOVAL ........................................................... 17
INSTALLATION ................................................... 17
INTAKE MANIFOLD ................................................. 18
Removal and Installation (QR20DE) ...................... 18
REMOVAL ........................................................... 18
INSTALLATION ................................................... 19
INSPECTION AFTER INSTALLATION ................ 20
REMOVAL ........................................................... 21
INSPECTION AFTER REMOVAL ....................... 23
INSTALLATION ................................................... 23
EXHAUST MANIFOLD AND THREE WAY CATALYST .......................................................................... 25
REMOVAL ........................................................... 25
INSTALLATION ................................................... 26
OIL PAN AND OIL STRAINER ................................. 27
REMOVAL ........................................................... 27
INSTALLATION ................................................... 29
IGNITION COIL ......................................................... 31
REMOVAL ........................................................... 31
INSTALLATION ................................................... 31
SPARK PLUG ........................................................... 32
REMOVAL ........................................................... 32
INSPECTION AFTER REMOVAL (EXCEPT
RUSSIA) .............................................................. 32
INSPECTION AFTER REMOVAL (FOR RUSSIA) ..................................................................... 33
INSTALLATION ................................................... 33
FUEL INJECTOR AND FUEL TUBE ........................ 34
REMOVAL ........................................................... 34
INSTALLATION ................................................... 36
REMOVAL ........................................................... 39
INSTALLATION ................................................... 41
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ROCKER COVER ..................................................... 44

REMOVAL ........................................................... 44
INSTALLATION .................................................... 45
TIMING CHAIN .......................................................... 46
REMOVAL ........................................................... 46
INSPECTION AFTER REMOVAL ........................ 50
INSTALLATION .................................................... 51
CAMSHAFT ............................................................... 56
REMOVAL ........................................................... 56
INSTALLATION .................................................... 61
Valve Clearance ...................................................... 64
INSPECTION ....................................................... 64
ADJUSTMENT .................................................... 65
OIL SEAL .................................................................. 67
Removal and Installation of Valve Oil Seal ............. 67
REMOVAL ........................................................... 67
INSTALLATION .................................................... 67
Removal and Installation of Front Oil Seal ............. 67
REMOVAL ........................................................... 67
INSTALLATION .................................................... 68
Removal and Installation of Rear Oil Seal .............. 68
REMOVAL ........................................................... 68
INSTALLATION .................................................... 68
CYLINDER HEAD ..................................................... 70
On-Vehicle Service ................................................. 70
CHECKING COMPRESSION PRESSURE ......... 70
REMOVAL ........................................................... 71
INSTALLATION .................................................... 73
Disassembly and Assembly .................................... 74
DISASSEMBLY ................................................... 74
ASSEMBLY ......................................................... 75
Inspection After Disassembly ................................. 77
VALVE DIMENSIONS .......................................... 77
VALVE GUIDE CLEARANCE .............................. 77
VALVE GUIDE REPLACEMENT ......................... 77
VALVE SEAT CONTACT ..................................... 79
VALVE SEAT REPLACEMENT ........................... 79
VALVE SPRING SQUARENESS ......................... 80
VALVE SPRING DIMENSIONS AND VALVE
SPRING PRESSURE LOAD ............................... 80
ENGINE ASSEMBLY ................................................ 82
REMOVAL ........................................................... 82
INSTALLATION .................................................... 85
CYLINDER BLOCK ................................................... 86
DISASSEMBLY ................................................... 87
ASSEMBLY ......................................................... 91
How to Select Piston and Bearing .......................... 96
DESCRIPTION .................................................... 96
HOW TO SELECT PISTON .................................97

HOW TO SELECT CONNECTING ROD BEARING .......................................................................97
HOW TO SELECT MAIN BEARING ....................99
Inspection After Disassembly ................................ 104
CRANKSHAFT END PLAY ................................ 104
CONNECTING ROD SIDE CLEARANCE ......... 104
PISTON TO PISTON PIN OIL CLEARANCE ..... 104
PISTON RING SIDE CLEARANCE ................... 105
PISTON RING END GAP .................................. 105
CONNECTING ROD BEND AND TORSION ..... 106
CONNECTING ROD BIG END DIAMETER ...... 106
CONNECTING ROD BUSHING OIL CLEARANCE ................................................................. 106
CYLINDER BLOCK DISTORTION .................... 107
MAIN BEARING HOUSING INNER DIAMETER.108
PISTON TO CYLINDER BORE CLEARANCE . 108
CRANKSHAFT MAIN JOURNAL DIAMETER ... 109
CRANKSHAFT PIN JOURNAL DIAMETER ...... 110
OUT-OF-ROUND AND TAPER OF CRANKSHAFT ............................................................... 110
CRANKSHAFT RUNOUT .................................. 110
CONNECTING ROD BEARING OIL CLEARANCE ................................................................. 110
MAIN BEARING OIL CLEARANCE ................... 111
MAIN BEARING CRUSH HEIGHT .................... 112
CONNECTING ROD BEARING CRUSH
HEIGHT ............................................................. 112
LOWER CYLINDER BLOCK MOUNTING BOLT
OUTER DIAMETER ........................................... 112
CONNECTING ROD BOLT OUTER DIAMETER. 112
FLYWHEEL DEFLECTION (M/T MODELS) ...... 113
MOVEMENT AMOUNT OF FLYWHEEL (M/T
MODELS) ........................................................... 113
SERVICE DATA AND SPECIFICATIONS (SDS) .... 114
Standard and Limit ................................................ 114
GENERAL SPECIFICATIONS ........................... 114
DRIVE BELT ...................................................... 114
INTAKE MANIFOLD AND EXHAUST MANIFOLD ................................................................. 114
SPARK PLUG .................................................... 114
CYLINDER HEAD .............................................. 114
VALVE ................................................................ 115
CAMSHAFT AND CAMSHAFT BEARING ......... 118
CYLINDER BLOCK ............................................ 119
PISTON, PISTON RING AND PISTON PIN ...... 120
CONNECTING ROD .......................................... 121
CRANKSHAFT ................................................... 121
MAIN BEARING ................................................. 123
CONNECTING ROD BEARING ......................... 124
Tightening Torque ................................................. 124
YD22DDTi
PRECAUTIONS ....................................................... 127
Precautions for Draining Engine Coolant .............. 127
Precautions for Disconnecting Fuel Piping ........... 127
Precautions for Removal and Disassembly .......... 127
Precautions for Inspection, Repair and Replace-
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ment ..................................................................... 127

Precautions for Assembly and Installation ........... 127
Parts Requiring Angle Tightening ......................... 127
Precautions For Liquid Gasket ............................. 128
REMOVAL OF LIQUID GASKET ...................... 128
LIQUID GASKET APPLICATION PROCEDURE. 128
PREPARATION ....................................................... 129
Special Service Tools ........................................... 129
Commercial Service Tools .................................... 133
TROUBLESHOOTING ............................................ 135
NVH Troubleshooting Engine Noise ................ 135
Use the Chart Below to Help You Find the Cause
of the Symptom. ................................................... 136
DRIVE BELTS ......................................................... 137
Checking Drive Belts ............................................ 137
Tension Adjustment .............................................. 137
A/C COMPRESSOR BELT ............................... 138
ALTERNATOR AND WATER PUMP BELT ....... 138
Removal and Installation ...................................... 138
REMOVAL ......................................................... 138
INSTALLATION ................................................. 138
AIR CLEANER AND AIR DUCT ............................. 139
REMOVAL ......................................................... 139
INSTALLATION ................................................. 139
CHANGING AIR CLEANER FILTER ................. 140
CHARGE AIR COOLER ......................................... 141
REMOVAL ......................................................... 141
INSPECTION AFTER REMOVAL ..................... 141
INSTALLATION ................................................. 141
INTAKE MANIFOLD ............................................... 143
REMOVAL ......................................................... 143
INSTALLATION ................................................. 144
INSPECTION AFTER INSTALLATION ............. 145
CATALYST .............................................................. 146
REMOVAL ......................................................... 146
INSTALLATION ................................................. 147
EXHAUST MANIFOLD AND TURBOCHARGER . 148
REMOVAL ......................................................... 148
INSTALLATION ................................................. 149
INSPECTION AFTER INSTALLATION ............. 149
Disassembly and Assembly ................................. 150
DISASSEMBLY ................................................. 150
ASSEMBLY ....................................................... 150
INSPECTION AFTER DISASSEMBLY ............. 150
Turbocharger ........................................................ 151
ROTOR SHAFT CLEARANCE ......................... 151
ROTOR SHAFT END PLAY .............................. 151
TURBINE WHEEL ............................................. 152
COMPRESSOR WHEEL .................................. 152
TURBOCHARGER BOOST CONTROL ACTUATOR ................................................................ 152
TROUBLE DIAGNOSIS OF TURBOCHARGER. 153
OIL PAN AND OIL STRAINER ............................... 154

REMOVAL ......................................................... 154
INSTALLATION ................................................. 156
INSPECTION AFTER INSTALLATION .............. 158
GLOW PLUG .......................................................... 159
REMOVAL ......................................................... 159
INSTALLATION ................................................. 159
VACUUM PUMP ...................................................... 160
INSPECTION BEFORE REMOVAL .................. 160
REMOVAL ......................................................... 160
INSTALLATION ................................................. 161
Disassembly and Assembly .................................. 162
DISASSEMBLY ................................................. 162
ASSEMBLY ....................................................... 163
INJECTION TUBE AND FUEL INJECTOR ............ 164
REMOVAL ......................................................... 164
INSTALLATION ................................................. 166
FUEL PUMP ............................................................ 168
REMOVAL ......................................................... 168
INSTALLATION ................................................. 172
ROCKER COVER ................................................... 175
REMOVAL ......................................................... 175
INSTALLATION ................................................. 176
CAMSHAFT ............................................................ 177
REMOVAL ......................................................... 177
INSTALLATION ................................................. 181
Valve Clearance ................................................... 182
INSPECTION .................................................... 182
ADJUSTMENTS ................................................ 184
OIL SEAL ................................................................ 187
Removal and Installation of Valve Oil Seal ........... 187
REMOVAL ......................................................... 187
INSTALLATION ................................................. 187
Removal and Installation of Front Oil Seal ........... 188
REMOVAL ......................................................... 188
INSTALLATION ................................................. 188
Removal and Installation of Rear Oil Seal ............ 189
REMOVAL ......................................................... 189
INSTALLATION ................................................. 189
SECONDARY TIMING CHAIN ................................ 190
REMOVAL ......................................................... 190
INSTALLATION ................................................. 192
EM-3
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EM
PRIMARY TIMING CHAIN ...................................... 195

REMOVAL ......................................................... 197
INSPECTION AFTER REMOVAL ...................... 200
INSTALLATION .................................................. 200
CYLINDER HEAD ................................................... 206
On-Vehicle Service ............................................... 206
CHECKING COMPRESSION PRESSURE ....... 206
REMOVAL ......................................................... 207
INSPECTION AFTER REMOVAL ...................... 208
INSTALLATION .................................................. 209
DISASSEMBLY ................................................. 212
ASSEMBLY ....................................................... 213
INSPECTION AFTER DISASSEMBLY .............. 214
ENGINE ASSEMBLY .............................................. 219
REMOVAL ......................................................... 220
INSTALLATION .................................................. 222
CYLINDER BLOCK ................................................. 223
DISASSEMBLY ................................................. 224
ASSEMBLY ....................................................... 228
How to Select Piston and Bearing ........................ 234
DESCRIPTION .................................................. 234
HOW TO SELECT PISTON ............................... 235
HOW TO SELECT CONNECTING ROD BEARING .................................................................... 235
HOW TO SELECT MAIN BEARING .................. 237
Inspection After Disassembly ............................... 238
CRANKSHAFT END PLAY ................................ 238
CONNECTING ROD SIDE CLEARANCE ......... 239
PISTON TO PISTON PIN CLEARANCE ........... 239
PISTON RING SIDE CLEARANCE ................... 240
PISTON RING END GAP .................................. 240
CONNECTING ROD BEND AND TORSION ..... 241
CONNECTING ROD BIG END INNER DIAME-
TER ....................................................................241
CONNECTING ROD BUSHING OIL CLEARANCE ................................................................. 241
CYLINDER BLOCK TOP SURFACE DISTORTION .................................................................. 242
MAIN BEARING HOUSING INNER DIAMETER.242
PISTON TO CYLINDER BORE CLEARANCE . 243
CRANKSHAFT MAIN JOURNAL DIAMETER ... 244
CRANKSHAFT PIN JOURNAL DIAMETER ...... 244
CRANKSHAFT OUT-OF-ROUND AND TAPER.244
CRANKSHAFT RUNOUT .................................. 245
CONNECTING ROD BEARING OIL CLEARANCE ................................................................. 245
MAIN BEARING OIL CLEARANCE ................... 246
CRUSH HEIGHT OF MAIN BEARING .............. 246
CRUSH HEIGHT OF CONNECTING ROD
BEARING ........................................................... 246
MAIN BEARING CAP BOLT DEFORMATION ... 247
CONNECTING ROD BOLT DEFORMATION .... 247
OIL JET .............................................................. 247
OIL JET RELIEF VALVE .................................... 247
FLYWHEEL DEFLECTION ................................ 248
MOVEMENT AMOUNT OF FLYWHEEL ........... 248
Standard and Limit ................................................ 249
GENERAL SPECIFICATIONS ........................... 249
INTAKE MANIFOLD AND EXHAUST MANIFOLD ................................................................. 249
DRIVE BELTS .................................................... 249
CAMSHAFT ....................................................... 250
CYLINDER HEAD .............................................. 252
VALVE ................................................................ 252
CYLINDER BLOCK ............................................ 255
PISTON, PISTON RING AND PISTON PIN ...... 256
CONNECTING ROD .......................................... 257
CRANKSHAFT ................................................... 257
AVAILABLE MAIN BEARING ............................. 258
AVAILABLE CONNECTING ROD BEARING ..... 258
Tightening Torque ................................................. 259
EM-4
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PRECAUTIONS
[QR]
PRECAUTIONS
Precautions for Drain Engine Coolant
[QR]
PFP:00001
A
EBS00KN0
Drain engine coolant when engine is cooled.
Precautions for Disconnecting Fuel Piping
Before starting work, make sure no fire or spark producing items are in the work area.
Release fuel pressure before disassembly.
After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and Disassembly
EM
EBS00KN1
EBS00KN2
When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.
Exercise maximum care to avoid damage to mating or sliding surfaces.
Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Precautions for Inspection, Repair and Replacement
EBS00MRZ
Use torque wrench to tighten bolts or nuts to specification.

When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly as specified.
Replace with new gasket, packing, oil seal or O-ring.
Dowel pins are used for several parts alignment. When replacing and reassembling with dowel pins, make
sure that dowel pins are installed in the original portion.
Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.
Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
Release air within route when refilling after draining coolant.
Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine
stopped). Then make sure there are no leaks at fuel line connections.
After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust systems for leakage.
Parts Requiring Angle Tightening
EBS00KN5
Use an angle wrench (special service tool: KV10112100) for the final tightening of the following engine
parts.
Cylinder head bolts
Lower cylinder block bolts
Connecting rod cap bolts
Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angle
tightening)
Balancer unit
Do not use a torque value for final tightening.
The torque value for these parts are for a preliminary step.
Ensure thread and seat surfaces are clean and coated with engine oil.
EM-5
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EBS00KN3
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precautions for Assembly and Installation
PRECAUTIONS
[QR]
Precautions for Liquid Gasket
EBS00MRW
REMOVAL OF LIQUID GASKET
After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter (special service tool) and remove the
old liquid gasket sealing.
CAUTION:
Be careful not to damage the mating surfaces.
Tap seal cutter to insert it (1), and then slide it (2) by tapping on
the side as shown in the figure.
In areas where seal cutter is difficult to use, use plastic hammer
to lightly tap the areas where the liquid gasket is applied.
CAUTION:
If for some unavoidable reason tool such as screwdriver is
used, be careful not to damage the mating surfaces.
PBIC0275E
LIQUID GASKET APPLICATION PROCEDURE

1.
2.
Using a scraper, remove the old liquid gasket adhering to the liquid gasket application surface and the mating surface.
Remove the liquid gasket completely from the groove of the
liquid gasket application surface, mounting bolts and bolt
holes.
Wipe the liquid gasket application surface and the mating surface with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
PBIC0003E
3.
4.
Attach liquid gasket tube to the tube presser (special service

tool).
Use Genuine Liquid Gasket or equivalent.
Apply the liquid gasket without breaks to the specified location
with the specified dimensions.
If there is a groove for the liquid gasket application, apply the
liquid gasket to the groove.
PBIC2160E
As for the bolt holes, normally apply the liquid gasket inside
the holes. Occasionally, it should be applied outside the
holes. Make sure to read the text of service manual.
Within five minutes of liquid gasket application, install the mating component.
If the liquid gasket protrudes, wipe it off immediately.
Do not retighten mounting bolts or nut after the installation.
Wait 30 minutes or more after installation before refilling
engine oil and engine coolant.
CAUTION:
If there are instructions in this manual, observe them.
EM-6
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SEM159F
PREPARATION
[QR]
PREPARATION
Special Service Tools
PFP:00002
A
EBS00L7N
Tool number
Tool name
Description
KV10111100
Seal cutter
EM
Removing oil pan and timing chain case
D
S-NT046
Disassembling and assembling
ST0501S000
Engine stand assembly
1. ST05011000
Engine stand
2. ST05012000
Base
F
NT042
KV10106500
Engine stand shaft
H
NT028
KV10115300
Engine sub-attachment
ZZA1078D
KV10116200
Valve spring compressor
1. KV10115900
Attachment
2. KV10109220
Adapter
Disassembling and assembling valve

mechanism
Part (1) is a component of KV10116200, but
Part (2) is not so.
M
PBIC1650E
KV10112100
Angle wrench
Tightening bolts for bearing cap, cylinder

head, etc.
S-NT014
KV10117100
Heated oxygen sensor wrench
Loosening or tightening heated oxygen

sensors with 22 mm (0.87 in) hexagon nut
NT379
EM-7
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PREPARATION
[QR]
Tool number
Tool name
Description
KV10107902
Valve oil seal puller
1. KV10116100
Valve oil seal puller adapter
Removing valve oil seal
S-NT605
KV10115600
Valve oil seal drift
Installing valve oil seal

Use side A.
a: 20 (0.79) dia.
d: 8 (0.31) dia.
b: 13 (0.51) dia.
e: 10.7 (0.421) dia.
c: 10.3 (0.406) dia.
f: 5 (0.20) dia.
Unit: mm (in)
S-NT603
EM03470000
Piston ring compressor
Installing piston assembly into cylinder bore
S-NT044
ST16610001
Pilot bushing puller
Removing pilot converter
S-NT045
WS39930000
Tube presser
Pressing the tube of liquid gasket
S-NT052
KV11103000
Pulley puller
Removing crankshaft pulley
NT676
Quick connector release
Removing fuel tube quick connectors in

engine room
(Available in SEC. 164 of PARTS CATALOG:
Part No. 16441 6N210)
PBIC0198E
EM-8
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PREPARATION
[QR]
Commercial Service Tools
EBS00L7O
A
Tool name
Description
Spark plug wrench
Removing and installing spark plug
EM
C
S-NT047
Pulley holder
Crankshaft pulley removing and installing
ZZA1010D
Valve seat cutter set
Finishing valve seat dimensions
S-NT048
TORX socket
Removing and installing flywheel

Size: T55
J
PBIC1113E
Piston ring expander
Removing and installing piston ring
L
S-NT030
Valve guide drift
Removing and installing valve guide

Intake & Exhaust:
a: 9.5 mm (0.374 in) dia.
b: 5.5 mm (0.217 in) dia.
S-NT015
Valve guide reamer
1: Reaming valve guide inner hole

2: Reaming hole for oversize valve guide
Intake & Exhaust:
d1: 6.0 mm (0.236 in) dia.
d2: 10.2 mm (0.402 in) dia.
S-NT016
EM-9
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PREPARATION
[QR]
Tool name
Description
Oxygen sensor thread cleaner
Reconditioning the exhaust system threads

before installing a new air fuel ratio sensor
and heated oxygen sensor (Use with antiseize lubricant shown below.)
a = 18 mm (0.71 in) dia. for zirconia heated
oxygen sensor and air fuel ratio sensor
b = 12 mm (0.47 in) dia. for titania heated
oxygen sensor
AEM488
Lubricating oxygen sensor thread cleaning

tool when reconditioning exhaust system
threads
Anti-seize lubricant i.e.: (PermatexTM

133AR or equivalent meeting MIL
specification MIL-A-907)
AEM489
Manual lift table caddy
Removing and installing engine
ZZA1210D
EM-10
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NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

[QR]

NVH Troubleshooting Engine Noise
PFP:00003
A
EBS00L7P
EM
PBIC2768E
EM-11
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[QR]
Use the Chart Below to Help You Find the Cause of the Symptom.
EBS00L7Q
1. Locate the area where noise occurs.

2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
Operating condition of engine
Location
of noise
Top of
engine
Rocker
cover
Cylinder
head
Type of
noise
Front of
engine
Front
cover
Front of
engine
Reference page
After
warmup
When
starting
When
idling
When
racing
While
driving
Ticking or
clicking
Tappet
noise
Valve clearance
EM-64
Rattle
Camshaft
bearing
noise
Camshaft journal oil

clearance
Camshaft runout
EM-59
EM-58
Piston pin
noise
Piston to piston pin oil

clearance
Connecting rod bushing oil clearance
EM-104
EM-106
Piston
slap noise
Piston to cylinder bore

clearance
Piston ring side clearance
Piston ring end gap
Connecting rod bend
and torsion
EM-109
EM-105
EM-105
EM-106

Connecting rod bearing oil clearance
EM-106
EM-110
Slap or
knock
Crankshaft pulley
Cylinder
block
(Side of
engine)
Oil pan
Source of
noise
Before
warmup
Slap or
rap
Check item
Knock
Connecting rod
bearing
noise
Knock
Main
bearing
noise
Main bearing oil clearance

Crankshaft runout
EM-111
EM-110
Timing
chain and
chain tensioner
noise
Timing chain cracks

and wear
Timing chain tensioner
operation
EM-50
EM-46
Drive belt
(Sticking
or slipping)
Drive belt deflection
Tapping or
ticking
Squeaking or fizzing
Creaking
Drive belt
(Slipping)
Idler pulley bearing

operation
Squall
Creak
Water
pump
noise
Water pump operation
A: Closely related
B: Related
C: Sometimes related
: Not related
EM-12
http://vnx.su
EM-13
CO-21,
"WATER
PUMP"
DRIVE BELTS
[QR]
DRIVE BELTS
Checking Drive Belts
PFP:02117
A
EBS00KN7
EM
PBIC2622E
WARNING:
Be sure to perform this step when the engine is stopped.
Make sure that the indicator (notch on fixed side) of drive belt auto-tensioner is within the possible use
range (between three line notches on moving side).
NOTE:
Check the drive belt auto-tensioner indication when the engine is cold.
When new drive belt is installed, the indicator (notch on fixed side) should be within the range a in the
figure.
Visually check entire drive belt for wear, damage or cracks.
If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt.
Tension Adjustment
EBS00KN8
EBS00KN9
Belt tensioning is not necessary, as it is automatically adjusted by drive belt auto-tensioner.
Removal and Installation

REMOVAL
1.
2.
3.
4.
Remove splash guard on RH undercover.

Hold the hexagonal part in center of drive belt auto-tensioner
pulley with a box wrench securely. Then move the wrench handle in the direction of arrow (loosening direction of tensioner).
CAUTION:
Avoid placing hand in a location where pinching may
occur if the holding tool accidentally comes off.
Do not loosen the hexagonal part in center of drive belt
auto-tensioner pulley (Do not turn it counterclockwise). If
turned counterclockwise, the complete drive belt autotensioner must be replaced as a unit, including the pulley.
Insert a rod approximately 6 mm (0.24 in) in diameter such as
short-length screwdriver into the hole of the retaining boss to fix drive belt auto-tensioner pulley.
Loosen drive belt from water pump pulley in sequence, and remove it.
EM-13
http://vnx.su
PBIC2169E
DRIVE BELTS
[QR]
INSTALLATION
1.
2.
3.
4.
5.
6.
Hold the hexagonal part in center of drive belt auto-tensioner

pulley with a box wrench securely. Then move the wrench handle in the direction of arrow (loosening direction of tensioner).
CAUTION:
Avoid placing hand in a location where pinching may
occur if the holding tool accidentally comes off.
Do not loosen the hexagonal part in center of drive belt
auto-tensioner pulley (Do not turn it counterclockwise). If
turned counterclockwise, the complete drive belt autotensioner must be replaced as a unit, including the pulPBIC2627E
ley.
Insert a rod approximately 6 mm (0.24 in) in diameter such as
short-length screwdriver into the hole of retaining boss to fix drive belt auto-tensioner pulley.
Hook drive belt onto all pulleys except for water pump, and then onto water pump pulley finally.
CAUTION:
Confirm drive belt is completely set to pulleys.
Check for engine oil, working fluid and engine coolant are not adhered to drive belt and each
pulley groove.
Release drive belt auto-tensioner, and apply tension to drive belt.
Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
Confirm tension of drive belt at indicator (notch on fixed side) is within the possible use range. Refer to
EM-13, "Checking Drive Belts" .
Removal and Installation of Drive Belt Auto-Tensioner
EBS00KNA
PBIC2170E
1.
Drive belt auto-tensioner
2.
Water pump pulley
REMOVAL
CAUTION:
The complete drive belt auto-tensioner must be replaced as a unit, including the pulley.
1. Remove splash guard on RH undercover.
2. Remove drive belt. Refer to EM-13, "Removal and Installation" .
3. Release the fixed drive belt auto-tensioner pulley.
4. Remove drive belt auto-tensioner.
EM-14
http://vnx.su
DRIVE BELTS
[QR]
CAUTION:
Do not loosen the hexagonal part in center of drive belt auto-tensioner pulley (Do not turn it counterclockwise). If turned counterclockwise, the complete drive belt auto-tensioner must be replaced as a
unit, including the pulley.
INSTALLATION
EM
Note the following, and install in the reverse order of removal.
When installing drive belt auto-tensioner, be careful not to interfere with water pump pulley.
CAUTION:
If there is damage greater than peeled paint, replace drive belt auto-tensioner.
Do not swap the pulley between new and old drive belt auto-tensioner.
EM-15
http://vnx.su
AIR CLEANER AND AIR DUCT

[QR]

PFP:16500
EBS00KNB
PBIC3598E
1.
Air cleaner filter
2.
4.
Clamp
5.
Air duct
6.
PCV hose
7.
Clamp
8.
Bracket
9.
Mass air flow sensor
10. O-ring
Clip
3.
11. Air duct
Air cleaner case upper
12. Air duct (inlet)
13. Clip
14. Collar
15. Grommet
16. Resonator
17. Bracket (A/T models)
18. Mounting rubber
19. Collar
20. Grommet
21. Air cleaner case lower
REMOVAL
1.
2.
3.
4.
5.
Remove mass air flow sensor harness clamp.

Disconnect harness connector from mass air flow sensor.
Disconnect PCV hose.
Remove air duct (inlet), air ducts and air cleaner case/mass air flow sensor assembly disconnecting their
joints.
Add marks as necessary for easier installation.
Remove mass air flow sensor from air cleaner case upper, as necessary.
CAUTION:
Handle mass air flow sensor with following cares.
Do not shock it.
Do not disassemble it.
Do not touch its sensor.
EM-16
http://vnx.su

[QR]
6.
Remove resonator in fender lifting left fender protector, as necessary.

A
INSTALLATION
Align marks. Attach each joint. Screw clamps firmly.
Changing Air Cleaner Filter
EM
EBS0123Q
REMOVAL
1.
2.
Unfasten clips and lift up air cleaner case upper.

Remove air cleaner filter.
INSTALLATION
Installation is the reverse order of removal.
EM-17
http://vnx.su
INTAKE MANIFOLD
[QR]
INTAKE MANIFOLD
Removal and Installation (QR20DE)
PFP:14003
EBS00KNC
PBIC2172E
1.
Vacuum hose
2.
Intake manifold
3.
PCV hose
4.
Bracket
5.
Gasket
6.
Electric throttle control actuator
7.
Gasket
8.
Intake manifold support
9.
Gasket
10. Vacuum hose
EVAP canister purge volume con11.

trol solenoid valve
13. Bracket
14. Bracket
12. Vacuum hose
REMOVAL
1.
2.
3.
Release fuel pressure. Refer to EC-48, "FUEL PRESSURE RELEASE" (WITH EURO-OBD) or EC-559,
"FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).
Remove air cleaner case upper, mass air flow sensor and air duct assembly. Refer to EM-16, "AIR
CLEANER AND AIR DUCT" .
Remove quick connector caps, and disconnect quick connectors
at engine side and vehicle side. Refer to EM-34, "Removal and
Installation (QR20DE)" .
PBIC2175E
4.
a.
Remove electric throttle control actuator with the following procedure:

Disconnect harness connector.
EM-18
http://vnx.su
INTAKE MANIFOLD
[QR]
b.
Loosen mounting bolts in reverse order as shown in the figure,

and remove electric throttle control actuator and gasket.
CAUTION:
Handle carefully to avoid any shock to electric throttle
control actuator.
Do not disassemble.
EM
C
EMJ1612D
5.
6.
7.
8.
Disconnect harness, power steering piping, vacuum hose and PCV hose from intake manifold, and move
them aside.
Remove intake manifold support and gasket.
Disconnect sub-harness from fuel injector. Refer to EM-34, "Removal and Installation (QR20DE)" .
Loosen mounting bolts and nuts in reverse order as shown in
the figure, and remove intake manifold (with fuel tube and fuel
injector assembly) and gasket.
CAUTION:
Do not disassemble intake manifold.
Cover engine openings to avoid entry of foreign materials.
NOTE:
Disregard No. 6 when loosening.
PBIC2173E
9.
Remove fuel tube and fuel injector assembly from intake manifold. Refer to EM-34, "Removal and Installation (QR20DE)" .
10. Remove EVAP canister purge volume control solenoid valve from intake manifold, if necessary.
INSTALLATION
K
Intake Manifold
If stud bolts were removed, install them and tighten to the specified torque below.
L
: 10.8 Nm (1.1 kg-m, 8 ft-lb)

Check if gasket is not dropped from the installation groove of intake manifold.
Tighten in numerical order as shown in the figure.

NOTE:
No. 6 means double tightening of bolt No. 1.
PBIC2173E
EM-19
http://vnx.su
INTAKE MANIFOLD
[QR]
Intake Manifold Support
Tighten mounting bolt from A to B in order as shown in the figure.
NOTE:
Tighten A in the figure together with electric throttle control actuator. Refer to EM-20, "Electric Throttle Control Actuator" for the tightening procedure.
PBIC2628E
Electric Throttle Control Actuator
Tighten mounting bolts equally and diagonally in several steps

and in numerical order as shown in the figure.
Perform the Throttle Valve Closed Position Learning when harness connector of electric throttle control actuator is disconnected. Refer to EC-46, "Throttle Valve Closed Position
Learning" (WITH EURO-OBD) or EC-557, "Throttle Valve
Closed Position Learning" (WITHOUT EURO-OBD).
Perform the Idle Air Volume Learning and Throttle Valve
Closed Position Learning when electric throttle control actuator
is replaced. Refer to EC-46, "Idle Air Volume Learning" (WITH
EURO-OBD) or EC-557, "Idle Air Volume Learning" (WITHOUT
EURO-OBD).
EMJ1612D
INSPECTION AFTER INSTALLATION

Make sure there are no fuel leaks at connections with the following procedure:
1. Apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then make sure
there are no fuel leaks at connections.
NOTE:
Use mirrors for checking on invisible points.
2. Start engine. With engine speed increased, make sure again there are no fuel leaks at connections.
CAUTION:
Do not touch engine immediately after stopped as engine becomes extremely hot.
EM-20
http://vnx.su
INTAKE MANIFOLD
[QR]
EBS011TH
EM
J
PBIC2174E
1.
Bracket
2.
PCV hose
3.
Intake manifold collector
4.
Gasket
5.
6.
Intake manifold rear support
7.
EVAP canister purge volume control

solenoid valve
8.
Vacuum hose
9.
Intake manifold
10. Vacuum reservoir tank
11. VIAS control solenoid valve
12. Vacuum hose
13. Bracket
14. Intake manifold support
15. Vacuum reservoir tank bracket
REMOVAL
1.
2.
3.
Remove quick connector caps, and disconnect quick connectors
at engine side and vehicle side. Refer to EM-39, "Removal and
PBIC2175E
4.
Remove electric throttle control actuator with the following procedure:
EM-21
http://vnx.su
INTAKE MANIFOLD
[QR]
a.
b.
Disconnect harness connector.

and remove electric throttle control actuator and gasket.
CAUTION:
Handle carefully to avoid any shock to electric throttle
control actuator.
Do not disassemble.
EMJ1612D
5.
6.
7.
Disconnect harness, vacuum hose and PCV hose from intake manifold collector, and move them aside.
Remove intake manifold rear support and intake manifold support.
Loosen mounting bolts and nuts in reverse order as shown in
the figure, and remove intake manifold collector and gasket.
CAUTION:
NOTE:
SBIA0230E
8. Disconnect power steering piping from intake manifold, and move them aside.
9. Disconnect sub-harness from fuel injector. Refer to EM-39, "Removal and Installation (QR25DE)" .
10. Loosen mounting bolts and nuts in reverse order as shown in
the figure, and remove intake manifold (with fuel tube and fuel
injector assembly) and gasket.
CAUTION:
NOTE:
SBIA0231E
11. Remove fuel tube and fuel injector assembly from intake manifold. Refer to EM-39, "Removal and Installation (QR25DE)" .
12. Remove EVAP canister purge volume control solenoid valve from intake manifold collector, if necessary.
13. Remove vacuum reservoir tank and VIAS control solenoid valve from intake manifold, if necessary.
EM-22
http://vnx.su
INTAKE MANIFOLD
[QR]
INSPECTION AFTER REMOVAL
Surface Distortion
Using straightedge and feeler gauge, check the surface distortion of both the intake manifold collector mating surface and the
intake manifold mating surfaces.
Limit
EM
: 0.1 mm (0.004 in)
If it exceeds the limit, replace intake manifold and/or intake manifold collector.
D
KBIA0235E
INSTALLATION
Intake Manifold
: 10.8 Nm (1.1 kg-m, 8 ft-lb)

NOTE:
SBIA0231E
Intake Manifold Collector

NOTE:
SBIA0230E
Electric Throttle Control Actuator
Tighten mounting bolts equally and diagonally in several steps

and in numerical order as shown in the figure.
Perform the Throttle Valve Closed Position Learning when harness connector of electric throttle control actuator is disconnected. Refer to EC-46, "Throttle Valve Closed Position
Learning" (WITH EURO-OBD) or EC-557, "Throttle Valve
Closed Position Learning" (WITHOUT EURO-OBD).
Perform the Idle Air Volume Learning and Throttle Valve
Closed Position Learning when electric throttle control actuator
is replaced. Refer to EC-46, "Idle Air Volume Learning" (WITH
EURO-OBD) or EC-557, "Idle Air Volume Learning" (WITHOUT
EURO-OBD).
EM-23
http://vnx.su
EMJ1612D
INTAKE MANIFOLD
[QR]
Make sure there are no fuel leaks at connections with the following procedure:
1. Apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then make sure
NOTE:
2. Start engine. With engine speed increased, make sure again there are no fuel leaks at connections.
CAUTION:
EM-24
http://vnx.su
EXHAUST MANIFOLD AND THREE WAY CATALYST

[QR]

PFP:14004
A
EBS00KND
EM
I
PBIC2750E
1.
Heated oxygen sensor 1
2.
Exhaust manifold and three way cat3.

alyst assembly
4.
Three way catalyst cover
5.
Exhaust manifold cover (lower)
7.
Exhaust manifold cover (upper)
6.
Gasket
REMOVAL
1.
a.
b.
Remove heated oxygen sensors with the following procedure:

Disconnect harness connector of each heated oxygen sensor, and harness from bracket and middle
clamp.
Using heated oxygen sensor wrench (special service tool),
remove heated oxygen sensors.
CAUTION:
Be careful not to damage heated oxygen sensor.
Discard any heated oxygen sensor which has been
dropped from a height of more than 0.5 m (19.7 in) onto a
hard surface such as a concrete floor; replace with a new
one.
KBIA0094E
2.
3.
4.
Remove exhaust front tube. Refer to EX-2, "EXHAUST SYSTEM" .

Remove alternator. Refer to SC-12, "CHARGING SYSTEM" .
Remove exhaust manifold cover (upper).
EM-25
http://vnx.su

[QR]
5.
Loosen nuts in reverse order as shown in the figure to remove

exhaust manifold and three way catalyst assembly.
NOTE:
Disregard No. 6 and 7 when loosening.
KBIA0045E
6.
7.
Remove gasket.
CAUTION:
Remove exhaust manifold cover (lower) and three way catalyst cover from exhaust manifold and three
way catalyst assembly.

Surface Distortion
Using straightedge and feeler gauge, check the surface distortion of exhaust manifold and three way catalyst assembly mating
surface.
Limit
: 0.3 mm (0.012 in)
If it exceeds the limit, replace exhaust manifold and three way

catalyst assembly.
KBIA0046E
INSTALLATION
Exhaust Manifold
: 14.7 Nm (1.5 kg-m, 11 ft-lb)
Tighten nuts in numerical order as shown in the figure.

NOTE:
No. 6 and 7 mean double tightening of bolts No. 1 and 3.
KBIA0045E
Heated Oxygen Sensor

CAUTION:
Before installing a new heated oxygen sensor, clean exhaust system threads using heated oxygen
sensor thread cleaner and apply anti-seize lubricant (commercial service tool).
Do not over torque the heated oxygen sensor. Doing so may cause damage to the heated oxygen
sensor, resulting in the MI coming on.
EM-26
http://vnx.su
OIL PAN AND OIL STRAINER

[QR]

PFP:11110
A
EBS00KNE
EM
I
PBIC2177E
1.
Oil level gauge
2.
Oil level gauge guide
3.
O-ring
4.
Oil pan (upper)
5.
Cylinder block
6.
O-ring
7.
Oil filter
8.
O-ring
9.
Drain plug washer
10. Oil strainer
11. Drain plug
12. Oil pan (lower)
13. Rear plate cover
REMOVAL
WARNING:
To avoid the danger of being scalded, do not drain the engine oil when the engine is hot.
1. Remove RH and LH undercovers.
2. Drain engine oil. Refer to LU-8, "Changing Engine Oil" .
3. Remove oil pan (lower) with the following procedure:
a. Loosen mounting bolts in reverse order as shown in the figure.
KBIA0096E
EM-27
http://vnx.su

[QR]
b.
Insert seal cutter (special service tool) between oil pan (upper)
and oil pan (lower).
CAUTION:
Be careful not to damage the mating surface.
SEM365EA
4.
5.
a.
b.
c.
d.
e.
Remove oil strainer.

Remove oil pan (upper) with the following procedure:
Remove drive belt. Refer to EM-13, "DRIVE BELTS" .
Remove A/C compressor with piping connected. And locate it aside temporarily with ropes or equivalent
not to disturb the following work. Refer to ATC-144, "Removal and Installation of Compressor" .
Remove oil level gauge guide.
Remove exhaust front tube and its support. Refer to EX-2, "EXHAUST SYSTEM" .
Set a suitable transmission jack under transaxle and hoist
engine with engine slinger, and then remove center member.
Refer to EM-82, "ENGINE ASSEMBLY" .
PBIC0257E
f.
g.
Remove rear plate cover, and four transaxle joint bolts. Refer to MT-17, "TRANSAXLE ASSEMBLY" (M/T
models) or AT-413, "REMOVAL AND INSTALLATION" (A/T models).
Loosen bolts in reverse order as shown in the figure.
NOTE:
Disregard No.12 and 17 when loosening.
SBIA0233E
h.
Insert seal cutter (special service tool) between oil pan (upper)
and cylinder block, and slide it by tapping on the side of the tool
with a hammer.
CAUTION:
Be careful not to damage the mating surface.
SEM365EA
6.
Remove O-rings at front cover side.
EM-28
http://vnx.su

[QR]
A
Clean oil strainer if any object attached.
INSTALLATION
1.
a.
Install oil pan (upper) with the following procedure:

Use a scraper to remove old liquid gasket from mating surfaces.
Also remove the old liquid gasket from mating surface of cylinder block.
Remove old liquid gasket from the bolt holes and threads.
CAUTION:
Do not scratch or damage the mating surfaces when cleaning off old liquid gasket.
EM
E
MEM108A
b.
Apply a continuous bead of liquid gasket with a tube presser

(special service tool: WS39930000) as shown in the figure.
CAUTION:
Apply liquid gasket to outside of bolt hole for the positions
shown by arrows.
SBIA0253E
c.
d.
Install new O-rings at front cover side.

CAUTION:
Install avoiding misalignment of O-rings.
Tighten bolts in numerical order as shown in the figure.
No. 12 and 17 mean double tightening of bolts No. 1 and 2.
NOTE:
Refer to the following for locating bolts.
M6 20 mm (0.79 in)
M8 25 mm (0.98 in)
M8 45 mm (1.77 in)
M8 100 mm (3.97 in)
: No. 18, 19
: No. 1, 2, 3, 11
: No. 4, 10, 13, 14, 15, 16
: No. 5, 6, 7, 8, 9
M
SBIA0233E
e.
f.
2.
3.
Tighten transaxle joint bolts. Refer to MT-17, "TRANSAXLE ASSEMBLY"

"REMOVAL AND INSTALLATION" (A/T models).
Install rear plate cover.
Install oil strainer.
Install oil pan (lower) with the following procedure:
EM-29
http://vnx.su
(M/T models) or AT-413,

[QR]
a.

Also remove old liquid gasket from mating surface of oil
pan (upper).
SEM958F
b.

SBIA0254E
c.
KBIA0096E
4.
5.
Install oil pan drain plug.

Refer to the figure of components of former page for installation direction of washer. Refer to EM-27,
"Removal and Installation" .
Install in the reverse order of removal after this step.
NOTE:
Pour engine oil at least 30 minutes after oil pan is installed.

1.
2.
3.
4.
Check engine oil level and adjust engine oil. Refer to LU-7, "ENGINE OIL" .
Start engine, and make sure there is no leaks of engine oil.
Stop engine and wait for 10 minutes.
Check engine oil level again. Refer to LU-7, "ENGINE OIL" .
EM-30
http://vnx.su
IGNITION COIL
[QR]
IGNITION COIL
PFP:22448
A
EBS00KNF
EM
G
KBIA1974J
1.
Ignition coil
2.
Spark plug
Rocker cover
REMOVAL
1.
2.
3.
Disconnect harness connector from ignition coil.

Remove ignition coil.
CAUTION:
Do not drop or shock it.
INSTALLATION

K
EM-31
http://vnx.su
SPARK PLUG
[QR]
SPARK PLUG
PFP:22401
EBS00KNG
KBIA1974J
1.
Ignition coil
2.
Spark plug
3.
Rocker cover
REMOVAL
1.
2.
Remove ignition coil. Refer to EM-31, "IGNITION COIL" .

Remove spark plug with spark plug wrench (commercial service
tool).
CAUTION:
Do not drop or shock it.
SEM294A
INSPECTION AFTER REMOVAL (EXCEPT RUSSIA)

Use standard type spark plug for normal condition.
Hot type spark plug is suitable when fouling occurs with standard type spark plug under conditions such as:
Frequent engine starts
Low ambient temperatures

Cold type spark plug is suitable when spark plug knock occurs with standard type spark plug under conditions
such as:
Extended highway driving
Frequent high engine revolution

Make
NGK
Standard type
LFR5A-11
Hot type
LFR4A-11
Cold type
LFR6A-11
EM-32
http://vnx.su
SPARK PLUG
[QR]
Check plug gap of each spark plug.

Standard
:1.0 - 1.1 mm (0.039 - 0.043 in)
If out of standard, adjust or replace spark plug.

Use a wire brush for cleaning, if necessary.
EM
C
SMA476
INSPECTION AFTER REMOVAL (FOR RUSSIA)

Use standard type spark plug for normal condition.
Hot type spark plug is suitable when fouling occurs with standard type spark plug under conditions such as:
Frequent engine starts
Low ambient temperatures

Cold type spark plug is suitable when spark plug knock occurs with standard type spark plug under conditions
such as:
Extended highway driving
Frequent high engine revolution

Make
NGK
Standard type
PLFR5A-11
Hot type
PLFR4A-11
Cold type
PLFR6A-11
Gap (Nominal)
: 1.1 mm (0.043 in)
CAUTION:
Do not drop or shock spark plug.
Do not use wire brush for cleaning.
If plug tip is covered with carbon, spark plug cleaner may
be used.
Cleaner air pressure:

Less than 588 kPa (6 kg/cm2 , 85 psi)
Cleaning time:
Less than 20 seconds
M
SMA773C
Checking and adjusting plug gap is not required between

change intervals.
SMA806CA
INSTALLATION
EM-33
http://vnx.su
FUEL INJECTOR AND FUEL TUBE

[QR]

PFP:16600
EBS00KNH
PBIC2178E
1.
Fuel feed hose
2.
Quick connector cap (engine side)
3.
Quick connector cap (vehicle side)
4.
Centralized under-floor piping
5.
Sub-harness
6.
Fuel tube protector
7.
Fuel tube
8.
O-ring (black)
9.
Clip
10. Fuel injector
11. O-ring (green)
CAUTION:
Do not remove or disassemble parts unless instructed as shown in the figure.
REMOVAL
1.
2.
3.
Disconnect quick connectors at engine side and vehicle side as
follows, and remove fuel feed hose.
CAUTION:
Disconnect quick connector by using quick connector
release (special service tool), not by picking out retainer
tabs.
NOTE:
There is quick connector for the engine side and for the vehicle
side, and they have different shapes. But disconnection is same
procedure. The following procedure shows the engine side.
PBIC2175E
a.
Remove quick connector cap (engine side).
KBIA0701E
EM-34
http://vnx.su

[QR]
b.
c.
d.
With the sleeve side of quick connector release facing quick connector, install quick connector release
A
onto fuel tube.
Insert quick connector release into quick connector until sleeve
contacts and goes no further. Hold quick connector release on
that position.
EM
CAUTION:
Inserting quick connector release hard will not disconnect
quick connector. Hold quick connector release where it
C
contacts and goes no further.
Draw and pull out quick connector straight from fuel tube.
CAUTION:
D
Pull quick connector holding A position in the figure.
KBIA0702E
Do not pull with lateral force applied. O-ring inside quick
connector may be damaged.
E
Prepare container and cloth beforehand as fuel will leak out.
Avoid fire and sparks.
Keep parts away from heat source. Especially, be careful when welding is performed around
F
them.
Do not expose parts to battery electrolyte or other acids.
G
Do not bend or twist connection between quick connector and fuel feed hose during installation/removal.
To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with
H
plastic bags or something similar.
I
J
PBIC2205E
4.
5.
6.
7.
8.
9.
Remove PCV hose. Refer to EM-18, "Removal and Installation (QR20DE)" .

Disconnect harness connector from ignition coil.
Remove sub-harness for fuel injector.
Remove electric throttle control actuator and intake manifold support. Refer to EM-18, "Removal and
Loosen mounting bolts in reverse order as shown in the figure.
Remove fuel tube protector.
PBIC2180E
10. Pull out fuel tube and fuel injector assembly rearward of engine.
CAUTION:
When removing, be careful to avoid any interference with fuel injector.
Use a shop cloth to absorb any fuel leaks from fuel tube.
EM-35
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[QR]
11. Remove fuel injector from fuel tube with the following procedure:
a. Open and remove clip.
b. Remove fuel injector from fuel tube by pulling straight.
CAUTION:
Be careful with remaining fuel that may go out from fuel
tube.
Be careful not to damage fuel injector nozzle during
removal.
Do not bump or drop fuel injector.
Do not disassemble fuel injector.
SBIA0364E
INSTALLATION
1.
Note the following, and install O-rings to fuel injector.

CAUTION:
Upper and lower O-rings are different. Be careful not to confuse them.
Fuel tube side
Nozzle side
: Black
: Green
Handle O-ring with bare hands. Do not wear gloves.

Lubricate O-ring with new engine oil.
Do not clean O-ring with solvent.
Make sure that O-ring and its mating part are free of foreign material.
When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to
twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it
quickly into fuel tube.
Insert O-ring straight into fuel tube. Do not decenter or twist it.
EM-36
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[QR]
2.
a.
b.
c.
Install fuel injector to fuel tube with the following procedure:

Insert clip into clip mounting groove on fuel injector.
Insert clip so that lug A of fuel injector matches notch A of
clip.
CAUTION:
Do not reuse clip. Replace it with a new one.
Be careful to keep clip from interfering with O-ring. If
interference occurs, replace O-ring.
Insert fuel injector into fuel tube with clip attached.
Insert it while matching it to the axial center.
Insert fuel injector so that lug B of fuel tube matches notch
B of clip.
Make sure that fuel tube flange is securely fixed in flange fixing groove on clip.
Make sure that installation is complete by checking that fuel
injector does not rotate or come off.
EM
G
SBIA0439E
3.
4.
5.
From the engine rear side, set fuel tube and fuel injector assembly at its position for installation on intake
manifold.
CAUTION:
For installation, be careful not to interfere with fuel injector nozzle.
Set fuel tube protector onto fuel tube.
Tighten mounting bolts with the following procedure.
Tighten bolts evenly in two steps in numerical order as shown
in the figure.
1st step
: 10.1 Nm (1.0 kg-m, 7 ft-lb)
2nd step
: 23.6 Nm (2.4 kg-m, 17 ft-lb)
L
PBIC2180E
6.
7.
a.
b.
Connect sub-harness for fuel injector.

Note the following, and connect quick connectors at engine side and vehicle side to install fuel feed hose.
NOTE:
There is quick connector for the engine side and for the vehicle side, and they have different shapes. But
connection is same procedure. The following procedure shows the engine side.
Check the connection for foreign material and damage.
Align center to insert quick connector straightly into fuel tube.
Insert fuel tube into quick connector until the top spool on fuel
tube is inserted completely and the second level spool is positioned slightly below quick connector bottom end.
CAUTION:
Hold A position in the figure when inserting fuel tube
into quick connector.
Carefully align center to avoid inclined insertion to prevent damage to O-ring inside quick connector.
KBIA0272E
EM-37
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[QR]
Insert until you hear a click sound and actually feel the engagement.
To avoid misidentification of engagement with a similar sound, be sure to perform the next
step.
Before clamping fuel feed hose with hose clamps, pull quick connector hard by hand holding A position.
Make sure it is completely engaged (connected) so that it does not come out from fuel tube.
Install quick connector cap to quick connector connection. (On
both the engine side and the vehicle side)
Install so that the arrow mark on the side faces up.
CAUTION:
Make sure that quick connector and fuel tube are
securely fit into quick connector cap installation groove.
If quick connector cap cannot be installed smoothly,
quick connector may have not been installed correctly.
Check connection again.
NOTE:
PBIC2348E
There is quick connector cap for the engine side and for the
vehicle side, and they have different shapes. The figure shows engine side as an example.
Install fuel feed hose to hose clamp.
c.
d.
8.
9.

Check on Fuel Leaks
1.
2.
Apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then make sure
NOTE:
Start engine. With engine speed increased, make sure again there are no fuel leaks at connections.
CAUTION:
EM-38
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[QR]
EBS011SY
EM
F
PBIC2179E
1.
Fuel feed hose
2.
Quick connector cap (engine side)
3.
Quick connector cap (vehicle side)
4.
Centralized under-floor piping
5.
Sub-harness
6.
Fuel tube
7.
O-ring (black)
8.
Clip
9.
Fuel injector
10. O-ring (green)
11. Insulator
CAUTION:
Do not remove or disassemble parts unless instructed as shown in the figure.
REMOVAL
1.
2.
3.
"FUEL PRESSURE CHECK" (WITHOUT EURO-OBD).
Disconnect quick connectors at engine side and vehicle side as
follows, and remove fuel feed hose.
CAUTION:
Disconnect quick connector by using quick connector
release (special service tool), not by picking out retainer
tabs.
NOTE:
There is quick connector for the engine side and for the vehicle
side, and they have different shapes. But disconnection is same
procedure. The following procedure shows the engine side.
PBIC2175E
a.
Remove quick connector cap (engine side).
KBIA0701E
EM-39
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[QR]
b.
c.
d.
With the sleeve side of quick connector release facing quick connector, install quick connector release
onto fuel tube.
Insert quick connector release into quick connector until sleeve
contacts and goes no further. Hold quick connector release on
that position.
CAUTION:
Inserting quick connector release hard will not disconnect
quick connector. Hold quick connector release where it
contacts and goes no further.
Draw and pull out quick connector straight from fuel tube.
CAUTION:
Pull quick connector holding A position in the figure.
KBIA0702E
Do not pull with lateral force applied. O-ring inside quick
connector may be damaged.
Prepare container and cloth beforehand as fuel will leak out.
Avoid fire and sparks.
Keep parts away from heat source. Especially, be careful when welding is performed around
them.
Do not expose parts to battery electrolyte or other acids.
Do not bend or twist connection between quick connector and fuel feed hose during installation/removal.
PBIC2205E
4.
5.
6.
7.
Remove intake manifold collector. Refer to EM-21, "Removal and Installation (QR25DE)" .
Disconnect sub-harness for fuel injector.
Loosen mounting bolts in reverse order as shown in the figure.
Remove fuel tube and fuel injector assembly and insulators.
CAUTION:
When removing, be careful to avoid any interference with
fuel injector.
Use a shop cloth to absorb any fuel leaks from fuel tube.
KBIA0239E
EM-40
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[QR]
8.
a.
b.
Remove fuel injector from fuel tube with the following procedure:
Open and remove clip.
Remove fuel injector from fuel tube by pulling straight.
CAUTION:
Be careful with remaining fuel that may go out from fuel
tube.
Be careful not to damage fuel injector nozzle during
removal.
Do not bump or drop fuel injector.
EM
G
SBIA0364E
INSTALLATION
1.
Note the following, and install O-rings to fuel injector.

CAUTION:
Upper and lower O-rings are different. Be careful not to confuse them.
Fuel tube side
Nozzle side
: Black
: Green

Lubricate O-ring with new engine oil.
Do not clean O-ring with solvent.
Make sure that O-ring and its mating part are free of foreign material.
When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to
twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it
quickly into fuel tube.
Insert O-ring straight into fuel tube. Do not decenter or twist it.
EM-41
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[QR]
2.
a.
b.
c.
Install fuel injector to fuel tube with the following procedure:

Insert clip into clip mounting groove on fuel injector.
Insert clip so that lug A of fuel injector matches notch A of
clip.
CAUTION:
Do not reuse clip. Replace it with a new one.
Be careful to keep clip from interfering with O-ring. If
interference occurs, replace O-ring.
Insert fuel injector into fuel tube with clip attached.
Insert it while matching it to the axial center.
Insert fuel injector so that lug B of fuel tube matches notch
B of clip.
Make sure that fuel tube flange is securely fixed in flange fixing groove on clip.
Make sure that installation is complete by checking that fuel
injector does not rotate or come off.
SBIA0439E
3.
a.
b.
Install fuel tube and fuel injector assembly with the following procedure:
Insert the tip of each fuel injector into intake manifold.
Tighten mounting bolts evenly in two steps in numerical order as
shown in the figure.
1st step
: 10.1 Nm (1.0 kg-m, 7 ft-lb)
2nd step
: 23.6 Nm (2.4 kg-m, 17 ft-lb)
KBIA0239E
4.
5.
6.
a.
b.
Connect sub-harness for fuel injector.

Install intake manifold collector. Refer to EM-21, "Removal and Installation (QR25DE)" .
Note the following, and connect quick connectors at engine side and vehicle side to install fuel feed hose.
NOTE:
There is quick connector for the engine side and for the vehicle side, and they have different shapes. But
connection is same procedure. The following procedure shows the engine side.
Check the connection for foreign material and damage.
Align center to insert quick connector straightly into fuel tube.
NOTE:
The figure shows engine side as an example.
Insert fuel tube into quick connector until the top spool on fuel
tube is inserted completely and the second level spool is positioned slightly below quick connector bottom end.
CAUTION:
Hold A position in the figure when inserting fuel tube
into quick connector.
Carefully align center to avoid inclined insertion to preKBIA0272E
vent damage to O-ring inside quick connector.
Insert until you hear a click sound and actually feel the engagement.
EM-42
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[QR]
To avoid misidentification of engagement with a similar sound, be sure to perform the next
step.
A
Before clamping fuel feed hose with hose clamps, pull quick connector hard by hand holding A position.
Make sure it is completely engaged (connected) so that it does not come out from fuel feed tube.
Install quick connector cap to quick connector connection. (On
EM
both the engine side and the vehicle side)
Install so that the arrow mark on the side faces up.
C
CAUTION:
Make sure that quick connector and fuel tube are
securely fit into quick connector cap installation groove.
If quick connector cap cannot be installed smoothly,
D
quick connector may have not been installed correctly.
Check connection again.
NOTE:
E
PBIC2348E
There is quick connector cap for the engine side and for the
vehicle side, and they have different shapes. The figure shows engine side as an example.
Install fuel feed hose to hose clamp.
F
c.
d.
7.
8.

Check on Fuel Leaks
1.
2.
Apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then make sure
NOTE:
Start engine. With engine speed increased, make sure again there are no fuel leaks at connections.
CAUTION:
EM-43
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ROCKER COVER
[QR]
ROCKER COVER
PFP:13264
EBS00KNI
PBIC2349E
1.
PCV hose
2.
O-ring
3.
PCV valve
4.
Oil filler cap
5.
Rocker cover
6.
Rocker cover gasket
REMOVAL
1.
2.
3.
4.
5.
Disconnect PCV hose from rocker cover.

Remove ignition coil. Refer to EM-31, "IGNITION COIL" .
Remove PCV valve and O-ring from rocker cover, if necessary.
Remove oil filler cap from rocker cover, if necessary.
Loosen bolts in reverse order shown in the figure.
KBIA0242E
6.
7.
Remove rocker cover gasket from rocker cover.

Use scraper to remove all traces of liquid gasket from cylinder head and camshaft bracket (No. 1).
CAUTION:
Do not scratch or damage the mating surface when cleaning off old liquid gasket.
EM-44
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ROCKER COVER
[QR]
INSTALLATION
1.
a.
b.
Apply liquid gasket to the position shown in the figure with the
following procedure:
Refer to figure a to apply liquid gasket to joint part of camshaft
bracket (No. 1) and cylinder head.
Refer to figure b to apply liquid gasket in 90 degrees to figure
a.
EM
G
PBIC2635E
2.
3.
4.
Install rocker cover gasket to rocker cover.

Install rocker cover.
Check if rocker cover gasket is not dropped from the installation groove of rocker cover.
Tighten bolts in two steps separately in numerical order as

1st step
: 2.0 Nm (0.2 kg-m, 18 in-lb)
K
2nd step
: 8.3 Nm (0.85 kg-m, 73 in-lb)
L
KBIA0242E
5.
EM-45
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TIMING CHAIN
[QR]
TIMING CHAIN
PFP:13028
EBS00KNL
PBIC2181E
1.
O-ring
2.
Camshaft sprocket (INT)
3.
Camshaft sprocket (EXH)
4.
Chain tensioner
5.
Spring
6.
Chain tensioner plunger
7.
Timing chain slack guide
8.
Timing chain
9.
Front cover
11.
Intake valve timing control solenoid

valve
12. Intake valve timing control cover
10. Chain guide

13. RH engine mounting bracket
14. Crankshaft pulley bolt
15. Crankshaft pulley
16. Front oil seal
17. Balancer unit timing chain tensioner
18. Oil pump drive spacer
19. Crankshaft sprocket
20. Timing chain tension guide
21. Balancer unit timing chain
22. Balancer unit
23. Oil ring
REMOVAL
1.
Remove the following parts.
EM-46
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TIMING CHAIN
[QR]
Hood assembly; Refer to BL-12, "HOOD" .
A
RH and LH undercovers
PCV hose; Refer to EM-18, "INTAKE MANIFOLD" .
Ignition coil; Refer to EM-31, "IGNITION COIL" .
EM
Rocker cover; Refer to EM-44, "ROCKER COVER" .
Engine coolant reservoir tank; Refer to CO-12, "RADIATOR" .
Drive belt; Refer to EM-13, "REMOVAL" .
C
Alternator; Refer to SC-12, "CHARGING SYSTEM" .
Drive belt auto-tensioner; Refer to EM-14, "REMOVAL" .
Exhaust front tube; Refer to EX-2, "EXHAUST SYSTEM" .
D
Remove A/C compressor from engine. Temporarily secure A/C compressor to vehicle side with a rope to
avoid putting a load on them.
Remove bracket mounting bolts for fixing A/C piping on right strut housing and exhaust manifold cover. E
Doing so simplifies moving.
Remove power steering oil pump with piping connected, and secure it to vehicle side temporarily. Refer to
PS-37, "HYDRAULIC LINE" .
F
Remove power steering reservoir tank from bracket to move power steering piping. Refer to PS-37,
"HYDRAULIC LINE" .
CAUTION:
G
To avoid power steering fluid leakage, temporarily fix power steering reservoir tank vertically.
Install engine slingers into front left of cylinder head and rear
right of cylinder head.
H
Use alternator bracket mounting bolt holes for the front side.
2.
3.
4.
5.
6.
Slinger bolts:
Front
: 57.9 Nm (5.9 kg-m, 43 ft-lb)

Rear
: 28.0 Nm (2.9 kg-m, 21 ft-lb)

SBIA0271E
7.
Lift with hoist, and support the engine posture.
8.
9.
10.
11.
12.
Remove RH engine mounting insulator and bracket. Refer to EM-82, "ENGINE ASSEMBLY" .
Remove center member and rear engine mounting bracket. Refer to EM-82, "ENGINE ASSEMBLY" .
Drain engine oil. Refer to LU-8, "Changing Engine Oil" .
Remove oil pan (upper and lower), and oil strainer. Refer to EM-27, "OIL PAN AND OIL STRAINER" .
Remove intake valve timing control cover.
Use a seal cutter (special service tool: KV10111100) or equivalent tool to cut liquid gasket for removal.
CAUTION:
Be careful not to damage mounting surface.
KBIA0085E
13. Pull chain guide between camshaft sprockets out through front cover.
14. Set No. 1 cylinder at TDC on its compression stroke with the following procedure:
EM-47
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TIMING CHAIN
[QR]
a.
Rotate crankshaft pulley clockwise and align TDC mark to timing

indicator on front cover.
KBIA0190E
b.
At the same time, make sure that the mating marks on camshaft
sprockets are located as shown in the figure.
If not, rotate crankshaft pulley one more turn to align mating
marks to the positions in the figure.
PBIC2351E
15. Remove crankshaft pulley with the following procedure:

a. Fix crankshaft pulley with a pulley holder (commercial service
tool), loosen crankshaft pulley bolt, and locate bolt seating surface at 10 mm (0.39 in) from its original position.
PBIC2434E
b.
Attach a pulley puller (special service tool) in the M 6 thread hole

on crankshaft pulley, and remove crankshaft pulley.
PBIC2413E
16. Remove front cover with the following procedure:
EM-48
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TIMING CHAIN
[QR]
a.
b.

and remove them.
CAUTION:
Be careful not to damage mounting surface.
EM
G
KBIA0083E
17. If front oil seal needs to be replaced, lift it with a suitable tool, and remove it.
CAUTION:
Be careful not to damage front cover.
18. Remove timing chain and camshaft sprockets with the following procedure:
a. Push in chain tensioner plunger. Insert a stopper pin into hole on
chain tensioner body to secure chain tensioner plunger and
remove chain tensioner.
NOTE:
Use approx. 0.5 mm (0.02 in) dia. hard metal pin as a stopper
pin.
L
KBIA0048E
b.
Secure hexagonal part of camshaft with a wrench. Loosen camshaft sprocket mounting bolts and remove timing chain and
camshaft sprockets.
CAUTION:
Do not rotate crankshaft or camshaft while timing chain is
removed. It causes interference between valve and piston.
KBIA0049E
19. Remove timing chain slack guide, timing chain tension guide and oil pump drive spacer.
20. Remove balancer unit timing chain tensioner with the following procedure:
EM-49
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TIMING CHAIN
[QR]
a.
b.
c.
d.
Lift lever up, and release ratchet claw for return proof.
Push tensioner sleeve in, and hold it.
Matching the hole on lever with the one on body, insert a stopper
pin to secure tensioner sleeve.
NOTE:
Use approximately 1 mm (0.04 in) dia. hard metal pin as a stopper pin.
Remove balancer unit timing chain tensioner.
KBIA0121E
21. Remove balancer unit timing chain and crankshaft sprocket.

22. Loosen mounting bolts in reverse order as shown in the figure,
and remove balancer unit.
CAUTION:
Do not disassemble balancer unit.
NOTE:
Use TORX socket (size E14).
KBIA0122E

Timing Chain
Check timing chain for cracks and any excessive wear at the roller
links of timing chain. Replace timing chain if necessary.
PBIC0282E
Balancer Unit Mounting Bolt Outer Diameter
Measure the outer diameters (d1, d2) at two positions as

If reduction appears in A range, regard it as d2 .
Limit (d1 d2)
: 0.15 mm (0.0059 in)
If it exceeds the limit (large difference in dimensions), replace it

with a new one.
PBIC1137E
EM-50
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TIMING CHAIN
[QR]
INSTALLATION
A
NOTE:
The figure shows the relationship between the mating mark on each
timing chain and that on the corresponding sprocket, with the components installed.
1. Make sure that crankshaft key points straight up.
EM
PBIC2182E
2.
a.
b.
Tighten mounting bolts in numerical order as shown in figure

with the following procedure, and install balancer unit.
CAUTION:
If mounting bolts are re-used, check their outer diameter
before installation. Refer to EM-50, "INSPECTION AFTER
REMOVAL" .
Apply new engine oil to threads and seat surfaces of mounting
bolts.
Tighten all bolts.
: 48.1 Nm (4.9 kg-m, 35 ft-lb)
c.
d.
K
KBIA0122E
Turn all bolts 90 degrees clockwise (angle tightening).

Completely loosen.
: 0 Nm (0 kg-m, 0 ft-lb)
e.
CAUTION:
In this step, loosen bolts in reverse order as shown in the
figure.
Tighten all bolts.
: 48.1 Nm (4.9 kg-m, 35 ft-lb)
KBIA0080E
f.
Turn them another 90 degrees clockwise (angle tightening).

CAUTION:
Check tightening angle with an angle wrench (special service tool) or a protractor. Do not make
judgment by visual check alone.
EM-51
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TIMING CHAIN
[QR]
3.
Install crankshaft sprocket and balancer unit timing chain.

Make sure that crankshaft sprocket is positioned with mating
marks on cylinder block and crankshaft sprocket meeting at
the top.
Install it by aligning mating marks on each sprocket and balancer unit timing chain.
PBIC2183E
4.
5.
Install balancer unit timing chain tensioner.

NOTE:
Chain guide and tensioner move freely with the staking pin as
the axle. Therefore, bolt hole position of the three points could
be changed during removal. If points change, temporarily fix the
two mounting bolts on chain guide, and move tensioner to mate
the bolt holes.
Be careful not to let mating marks of each sprocket and timing
chain slip.
After installation, make sure the mating marks have not
slipped, then remove stopper pin and release tensioner
sleeve.
KBIA0124E
Install timing chain and related parts.

Install by aligning mating marks on each sprocket and timing
chain.
Before and after installing chain tensioner, check again to
make sure that mating marks have not slipped.
After installing chain tensioner, remove stopper pin, and make
sure that tensioner moves freely.
CAUTION:
For the following note, after the mating marks are
aligned, keep them aligned by holding them with a
hand.
To avoid skipped teeth, do not rotate crankshaft and
camshaft until front cover is installed.
NOTE:
Before installing chain tensioner, it is possible to change the
position of mating mark on timing chain for that on each
sprocket for alignment.
PBIC2182E
6.
7.
a.
Install front oil seal to front cover. Refer to EM-67, "Removal and Installation of Front Oil Seal" .
Install front cover with the following procedure:
Install O-rings to cylinder head and cylinder block.
EM-52
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TIMING CHAIN
[QR]
b.

(special service tool: WS39930000) to front cover as shown in
the figure.
NOTE:
Application instruction differs depending on the position.
Detail of A
Detail of B
Detail of C
EM
: Cross over the start of the application and the end.

: Apply liquid gasket outside of bolt
holes. (For all bolt holes other than
B, apply to the inside.)
: Between here only, apply 4.5 - 5.5
mm (0.177 - 0.217 in) dia.
G
SBIA0267E
c.
Make sure that mating marks of timing chain and each sprocket are still aligned. Then install front cover.
CAUTION:
Do not let A/C and power steering pipings interfere with upper part of front cover.
Be careful not to damage front oil seal by interference with front end of crankshaft.
d.
e.
Tighten mounting bolts in numerical order as shown in the figure.

After all bolts are tightened, retighten them to specified torque in
numerical order as shown in the figure.
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking to
surface for fitting oil pan.
KBIA0083E
8.
9.
a.
b.
c.
Install chain guide between camshaft sprockets.

Install intake valve timing control cover with the following procedure:
Install intake valve timing control solenoid valves to intake valve timing control cover if removed.
Install oil rings to the camshaft sprocket (INT) insertion points on backside of intake valve timing control
cover.
Install O-ring to front cover.
EM-53
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TIMING CHAIN
[QR]
d.

(special service tool: WS39930000) to intake valve timing control cover as shown in the figure.
SBIA0260E
e.
KBIA0085E
10. Insert crankshaft pulley by aligning with crankshaft key.

When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference).
CAUTION:
Install protecting front oil seal lip section from any damage.
11. Tighten crankshaft pulley bolt.
Secure crankshaft pulley with a pulley holder (commercial service tool), and tighten crankshaft pulley
bolt.
Perform angle tightening with the following procedure:
a. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.
b. Tighten crankshaft pulley bolt.
: 42.1 Nm (4.3 kg-m, 31 ft-lb)
c.
d.
Put a paint mark on crankshaft pulley, mating with any one of six
easy to recognize angle marks on bolt flange.
Turn another 60 degrees clockwise (angle tightening).
Check the tightening angle with movement of one angle mark.
SEM751G
12. Install all removed parts in the reverse order of removal.
EM-54
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TIMING CHAIN
[QR]
Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
EM
quantity, fill to the specified level. Refer to MA-17, "RECOMMENDED FLUIDS AND LUBRICANTS" .
Use procedure below to check for fuel leakage.
Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel
C
leakage at connection points.
Start engine. With engine speed increased, check again for fuel leakage at connection points.
Run engine to check for unusual noise and vibration.

D
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may
generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after
E
hydraulic pressure rises.
Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids
including engine oil and engine coolant.
F
Bleed air from lines and hoses of applicable lines, such as in cooling system.
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
G
Summary of the inspection items:
Item
Before starting engine
Engine running
After engine stopped
Engine coolant
Level
Leakage
Level
Engine oil
Level
Leakage
Level
Other oils and fluid*
Level
Leakage
Level
Leakage
Leakage
Leakage
Leakage
Fuel
Exhaust gases
* Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.
EM-55
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CAMSHAFT
[QR]
CAMSHAFT
PFP:13001
EBS00LS2
PBIC2184E
1.
Camshaft bracket (No. 2 to 5)
2.
Seal washer
3.
Camshaft bracket (No. 1)
4.
Front cover
5.
Chain guide
6.
Chain tensioner
7.
Spring
8.
Chain tensioner plunger
9.
O-ring
valve
10. Oil ring
11. O-ring
12.
13. Intake valve timing control cover
14. Camshaft sprocket (INT)
15. Camshaft sprocket (EXH)
16. O-ring
17. Valve lifter
18. Camshaft (INT)
19. Camshaft (EXH)
20. O-ring
21. Camshaft position sensor (PHASE)
NOTE:
This section describes removal/installation procedure of camshaft without removing front cover. If front cover
is removed or installed, removal of camshaft bracket (No. 1) is easier before step 8 and installation is easier
after step 3. Regarding removal and installation of front cover, refer to EM-46, "TIMING CHAIN" .
REMOVAL
1.
2.
3.
Ignition coil; Refer to EM-31, "IGNITION COIL" .
Rocker cover; Refer to EM-44, "ROCKER COVER" .
Remove power steering reservoir tank from bracket to move power steering piping. Refer to PS-37,
"HYDRAULIC LINE" .
EM-56
http://vnx.su
CAMSHAFT
[QR]
4.
a.
b.
c.
d.
e.
CAUTION:
To avoid power steering fluid leakage, temporarily fix power steering reservoir tank vertically.
Remove intake valve timing control cover with the following procedure:
Disconnect intake valve timing control solenoid valve harness connector.
Remove intake valve timing control solenoid valve, if necessary.
Disconnect ground cables.
EM
KBIA0085E
5.
6.
a.
b.
Pull chain guide between camshaft sprockets out through front cover.
Set No. 1 cylinder at TDC on its compression stroke with the following procedure:
Open splash guard on RH undercover.
Rotate crankshaft pulley clockwise and align TDC mark to timing
indicator on front cover.
J
KBIA0190E
c.
At the same time, make sure that the mating marks on camshaft
sprockets are located as shown in the figure.
If not, rotate crankshaft pulley one more turn to align mating
marks to the positions in the figure.
PBIC2351E
7.
a.
Remove camshaft sprockets with the following procedure:

Line up the mating marks on camshaft sprockets, and paint indelible mating marks on timing chain link
plate.
EM-57
http://vnx.su
CAMSHAFT
[QR]
b.
Push in chain tensioner plunger. Insert a stopper pin into hole on

chain tensioner body to secure chain tensioner plunger and
remove chain tensioner.
NOTE:
Use approximately 0.5 mm (0.02 in) dia. hard metal pin as a
stopper pin.
KBIA0048E
c.
Secure hexagonal part of camshaft with a wrench. Loosen camshaft sprocket mounting bolts and remove camshaft sprockets.
CAUTION:
Do not rotate crankshaft or camshaft while timing chain is
removed. It causes interference between valve and piston.
NOTE:
Chain tension holding work is not necessary. Crankshaft
sprocket and timing chain do not disconnect structurally while
front cover is attached.
KBIA0049E
8.
9.
Remove camshaft position sensor (PHASE) from cylinder head back side.
CAUTION:
Handle carefully to avoid dropping and shocks.
Do not disassemble.
Do not allow metal powder to adhere to magnetic part at sensor tip.
Do not place sensor in a location where it is exposed to magnetism.
and remove camshaft brackets and camshafts.
Remove camshaft bracket (No. 1) by slightly tapping it with a
plastic hammer.
SBIA0255E
10. Remove valve lifters.

Identify installation positions, and store them without mixing them up.

Camshaft Runout
1.
2.
3.
Put V-block on a precise flat table, and support No. 2 and 5 journal of camshaft.
CAUTION:
Do not support No. 1 journal (on the side of camshaft
sprocket) because it has a different diameter from the other
four locations.
Set dial indicator vertically to No. 3 journal.
Turn camshaft to one direction with hands, and measure the
camshaft runout on dial indicator. (Total indicator reading)
PBIC2499E
EM-58
http://vnx.su
CAMSHAFT
[QR]
Standard: Less than 0.02 mm (0.0008 in).
4.
If out of the standard, replace camshaft.
Camshaft Cam Height

1.
EM
Measure the camshaft cam height with a micrometer.

Standard:
Intake
QR20DE
QR25DE
Exhaust
QR20DE
QR25DE
: 45.015 - 45.205 mm (1.7722 - 1.7797 in)

: 45.665 - 45.855 mm (1.7978 - 1.8053 in)
: 42.825 - 43.015 mm (1.6860 - 1.6935 in)

: 43.975 - 44.165 mm (1.7313 - 1.7388 in)
E
PBIC0039E
2.
Camshaft Journal Oil Clearance
CAMSHAFT JOURNAL DIAMETER

Measure the outer diameter of camshaft journal with a micrometer.
Standard:
No. 1
: 27.935 - 27.955 mm (1.0998 - 1.1006 in)
No. 2, 3, 4, 5 : 23.435 - 23.455 mm (0.9226 - 0.9234 in)
I
PBIC0040E
CAMSHAFT BRACKET INNER DIAMETER
Tighten camshaft bracket bolts with specified torque. Refer to EM-61, "INSTALLATION" for the tightening
procedure.
Measure the inner diameter of camshaft bracket with an inside

micrometer.
Standard:
No. 1
No. 2, 3, 4, 5
: 28.000 - 28.021 mm (1.1024 - 1.1032 in)

: 23.500 - 23.521 mm (0.9252 - 0.9260 in)
M
PBIC0041E
CAMSHAFT JOURNAL OIL CLEARANCE

(Oil clearance) = (Camshaft bracket inner diameter) (Camshaft journal diameter)
Standard: 0.045 - 0.086 mm (0.0018 - 0.0034 in)
If out of the standard, replace either or both camshaft and cylinder head.
NOTE:
Camshaft bracket cannot be replaced as a single part, because it is machined together with cylinder head.
Replace whole cylinder head assembly.
Camshaft End Play

1.
Install camshaft in cylinder head. Refer to EM-61, "INSTALLATION" for tightening procedure.
EM-59
http://vnx.su
CAMSHAFT
[QR]
2.
Install dial indicator in thrust direction on front end of camshaft.

Read the end play of dial indicator when camshaft is moved forward/backward (in direction to axis).
Standard: 0.115 - 0.188 mm (0.0045 - 0.0074 in)
PBIC2446E
Measure the following parts if out of the standard.

Dimension A for camshaft No. 1 journal
Standard
Dimension B for cylinder head No. 1 journal

Standard
: 25.800 - 25.848 mm (1.0157 - 1.0176 in)
: 25.660 - 25.685 mm (1.0102 - 1.0112 in)
Refer to the standards above, and then replace camshaft and/

or cylinder head.
KBIA2426J
Camshaft Sprocket Runout

1.
2.
Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft.
CAUTION:
Do not support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter
from the other four locations.
Measure the camshaft sprocket runout with a dial indicator.
(Total indicator reading)
Limit
: 0.15 mm (0.0059 in)
If it exceeds the limit, replace camshaft sprocket.
PBIC0930E
Valve Lifter
Check if surface of valve lifter has any wear or cracks.
If anything above is found, replace valve lifter. Refer to EM-64,

"Valve Clearance" .
KBIA0182E
Valve Lifter Clearance

VALVE LIFTER OUTER DIAMETER
EM-60
http://vnx.su
CAMSHAFT
[QR]
Measure the outer diameter of valve lifter with a micrometer.

A
Standard: 33.965 - 33.980 mm (1.3372 - 1.3378 in)
EM
C
JEM798G
VALVE LIFTER HOLE DIAMETER

Measure the diameter of valve lifter hole of cylinder head with an
inside micrometer.
Standard: 34.000 - 34.021 mm (1.3386 - 1.3394 in)

VALVE LIFTER CLEARANCE
(Valve lifter clearance) = (Valve lifter hole diameter) (Valve

lifter outer diameter)
Standard: 0.020 - 0.056 mm (0.0008 - 0.0022 in)
If out of the standard, referring to the each standard of valve

lifter outer diameter and valve lifter hole diameter, replace either
or both valve lifter and cylinder head.
G
PBIC0043E
INSTALLATION
1.
2.
Install valve lifters.

Install them in the original positions.
Install camshafts.
Distinction between intake and exhaust camshafts is performed with the different shapes of rear end.
Intake
Exhaust
: Signal plate shape for camshaft position

sensor (PHASE)
: Cone end shape
L
KBIA0246E
Install camshafts so that camshaft dowel pins on the front side

are positioned as shown in the figure.
KBIA0051E
3.
a.
Install camshaft brackets with the following procedure:

Remove foreign material completely from camshaft bracket backside and from cylinder head installation
face.
EM-61
http://vnx.su
CAMSHAFT
[QR]
b.
Install camshaft brackets (No. 2 to 5) aligning the identification

marks on upper surface as shown in the figure.
NOTE:
Install so that identification mark can be correctly read when
viewed from the exhaust side.
SBIA0256E
c.
i.
Install camshaft bracket (No. 1) with the following procedure:

Apply liquid gasket to camshaft bracket (No. 1) as shown in the
figure.
CAUTION:
After installation, be sure to wipe off any excessive liquid
gasket leaking from part A.
PBIC2579E
ii.
Apply liquid gasket to camshaft bracket (No. 1) contact surface

on the front cover backside.
Apply liquid gasket to the outside of bolt hole on front cover.
SBIA0258E
iii. For camshaft bracket (No. 1) near installation position, and

install it without disturbing the liquid gasket applied to the surfaces.
PBIC2641E
EM-62
http://vnx.su
CAMSHAFT
[QR]
4.
a.
Tighten mounting bolts of camshaft brackets in the following

steps, in numerical order as shown in the figure.
Tighten No. 9 to 11 in numerical order.
: 2.0 Nm (0.2 kg-m, 1 ft-lb)

b.
EM
Tighten No. 1 to 8 in numerical order.

: 2.0 Nm (0.2 kg-m, 1 ft-lb)
c.
Tighten all bolts in numerical order.

: 5.9 Nm (0.6 kg-m, 4 ft-lb)
d.
SBIA0255E
Tighten all bolts in numerical order.

: 10.4 Nm (1.1 kg-m, 8 ft-lb)
5.
6.
7.
8.
9.
a.
b.
c.
d.
CAUTION:
After tightening mounting bolts of camshaft brackets, be sure to wipe off excessive liquid gasket
from the parts listed below.
Mating surface of rocker cover.
Mating surface of front cover. (When installed without front cover)
Install camshaft position sensor (PHASE).
Install camshaft sprockets.
Install them by aligning the mating marks on each camshaft
sprocket with the ones painted on timing chain link plate during removal.
CAUTION:
Aligned mating marks could slip. Therefore, after
matching them, hold the timing chain in place by hand.
Before and after installing chain tensioner, make sure
again that mating marks have not slipped.
NOTE:
Before installation of chain tensioner, it is possible to re-match
PBIC2351E
the marks on timing chain with the ones on each sprocket.
Install chain tensioner.
CAUTION:
After installation, pull the stopper pin off completely, and make sure that chain tensioner plunger
is released.
Install chain guide.
Install intake valve timing control cover with the following procedure:
Install intake valve timing control solenoid valve to intake valve timing control cover if removed.
Install oil rings to the camshaft sprocket (INT) insertion points on backside of intake valve timing control
cover.
Install O-ring to front cover.
Apply liquid gasket with a tube presser (special service tool:
WS39930000) to intake valve timing control cover as shown in
the figure.
SBIA0260E
EM-63
http://vnx.su
CAMSHAFT
[QR]
e.
KBIA0085E
10. Inspect and adjust valve clearance. Refer to EM-64, "Valve Clearance" .
11. Install in the reverse order of removal after this step.
Valve Clearance
EBS00LS3
INSPECTION
Perform inspection as follows after removal, installation or replacement of camshaft or valve-related parts, or if
there is unusual engine conditions regarding valve clearance.
1. Remove rocker cover. Refer to EM-44, "ROCKER COVER" .
2. Open splash guard on RH undercover.
3. Measure the valve clearance with the following procedure:
a. Set No. 1 cylinder at TDC of its compression stroke.
Rotate crankshaft pulley clockwise and align TDC mark to
timing indicator on front cover.
KBIA0190E
At the same time, make sure that both intake and exhaust
cam noses of No. 1 cylinder face outside as shown in the figure.
If they do not face outside, rotate crankshaft pulley once more
(360 degrees) and align as shown in the figure.
KBIA0400J
b.
Use a feeler gauge, measure the clearance between valve lifter

and camshaft.
SEM139D
EM-64
http://vnx.su
CAMSHAFT
[QR]
Valve clearance:
Unit: mm (in)
Cold
Hot * (reference data)
Intake
0.24 - 0.32 (0.009 - 0.013)
0.304 - 0.416 (0.012 - 0.016)
Exhaust
0.26 - 0.34 (0.010 - 0.013)
0.308 - 0.432 (0.012 - 0.017)
EM
*:Approximately 80C (176F)
By referring to the figure, measure the valve clearances at

locations marked as shown in the table below (locations
indicated with black arrow in the figure) with a feeler gauge.
No. 1 cylinder compression TDC
Measuring position
No. 1 cylinder at
compression TDC
No. 1 CYL.
INT
EXH
No. 2 CYL.
No. 3 CYL.
No. 4 CYL.
PBIC2624E
c.
Rotate crankshaft pulley one revolution (360 degrees) and align

TDC mark to timing indicator on front cover.
I
KBIA0190E
By referring to the figure, measure the valve clearance at

locations marked as shown in the table below (locations
indicated with black arrow in the figure) with a feeler gauge.
No. 4 cylinder compression TDC
Measuring position
No. 4 cylinder at
compression TDC
No. 1 CYL.
No. 2 CYL.
INT
EXH
No. 3 CYL.
No. 4 CYL.
M
PBIC2625E
4.
If out of standard, perform adjustment. Refer to EM-65, "ADJUSTMENT" .
ADJUSTMENT
1.
2.
Perform adjustment depending on selected head thickness of valve lifter.

Remove camshaft. Refer to EM-56, "REMOVAL" .
Remove valve lifters at the locations that are out of the standard.
EM-65
http://vnx.su
CAMSHAFT
[QR]
3.
Measure the center thickness of the removed valve lifters with a

micrometer.
KBIA0057E
4.
Use the equation below to calculate valve lifter thickness for replacement.
Valve lifter thickness calculation:
t = t1 + (C1 C2 )
t
= Valve lifter thickness to be replaced
= Removed valve lifter thickness
t1
C1 = Measured valve clearance
C2 = Standard valve clearance:
Intake
: 0.28 mm (0.011 in)
Exhaust
: 0.30 mm (0.012 in)
Thickness of new valve lifter can be identified by stamp mark

on the reverse side (inside the cylinder).
Stamp mark 696 indicates 6.96 mm (0.2740 in) in thickness.
KBIA0119E
NOTE:
Available thickness of valve lifter: 26 sizes range 6.96 to 7.46 mm (0.2740 to 0.2937 in) in steps of 0.02
mm (0.0008 in) (when manufactured at factory). Refer to EM-116, "Available Valve Lifter" .
5. Install the selected valve lifter.
6. Install camshaft. Refer to EM-61, "INSTALLATION" .
7. Manually rotate crankshaft pulley a few rotations.
8. Make sure that valve clearances for cold engine are within specifications by referring to the specified values. Refer to EM-64, "INSPECTION" .
9. Install all removed parts in the reverse order of removal. Refer to EM-61, "INSTALLATION" .
10. Warm up the engine, and check for unusual noise and vibration.
EM-66
http://vnx.su
OIL SEAL
[QR]
OIL SEAL
Removal and Installation of Valve Oil Seal
PFP:12279
A
EBS00KNM
REMOVAL
1.
2.
3.
4.
Remove camshafts. Refer to EM-56, "CAMSHAFT" .

EM
Remove valve lifters. Refer to EM-56, "CAMSHAFT" .
Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve
from dropping into cylinder.
C
CAUTION:
When rotating crankshaft, be careful to avoid scarring front cover with timing chain.
Remove valve collet.
D
Compress valve spring with valve spring compressor, attachment and adapter (special service tool). Remove valve collet
with a magnet hand.
E
CAUTION:
When working, be careful not to damage valve lifter holes.
F
G
PBIC1791E
5.
6.
Remove valve spring retainer and valve spring.

CAUTION:
Do not remove valve spring seat from valve spring.
Remove valve oil seal with a valve oil seal puller (special service
tool).
SEM093F
INSTALLATION
1.
2.
Apply new engine oil to valve oil seal joint surface and seal lip.
Press in valve oil seal to the height H shown in the figure with a
valve oil seal drift (special service tool).
NOTE:
Dimension H is height that measured before installing valve
spring (with valve spring seat).
Height H
: 11.8 - 12.4 mm (0.465 - 0.488 in)
KBIA1999J
3.
Removal and Installation of Front Oil Seal

REMOVAL
1.

RH undercover
EM-67
http://vnx.su
EBS00KNN
OIL SEAL
[QR]
Drive belt; Refer to EM-13, "DRIVE BELTS" .
Crankshaft pulley; Refer to EM-46, "TIMING CHAIN" .
Remove front oil seal with a suitable tool.
CAUTION:
Be careful not to damage front cover and crankshaft.
2.
SEM829E
INSTALLATION
1.
2.
Apply new engine oil to new front oil seal joint surface and seal lip.
Install front oil seal so that each seal lip is oriented as shown in
the figure.
SEM715A
Press-fit front oil seal until it is flush with front end surface of
front cover with a suitable tool.
CAUTION:
Be careful not to damage front cover and crankshaft.
Press-fit oil seal straight to avoid causing burrs or tilting.
SBIA0266E
3.
Removal and Installation of Rear Oil Seal
EBS00KNO
REMOVAL
1.
2.
3.
4.
Remove transaxle assembly. Refer to MT-17, "TRANSAXLE ASSEMBLY" (M/T models) or AT-413,
Remove clutch cover and clutch disk (M/T models). Refer to CL-16, "CLUTCH DISC, CLUTCH COVER
AND FLYWHEEL" .
Remove drive plate (A/T models) or flywheel (M/T models). Refer to EM-86, "CYLINDER BLOCK" .
Remove rear oil seal with a suitable tool.
CAUTION:
Be careful not to damage crankshaft and cylinder block.
INSTALLATION
1.
Apply new engine oil to new rear oil seal joint surface and seal lip.
EM-68
http://vnx.su
OIL SEAL
[QR]
2.
Install rear oil seal so that each seal lip is oriented as shown in
the figure.
EM
C
SEM715A
Press in rear oil seal to the position as shown in the figure.

E
G
SBIA0281E
Press-fit rear oil seal with a suitable drift [outside diameter

102 mm (4.02 in), inside diameter 86 mm (3.39 in)].
CAUTION:
Be careful not to damage crankshaft and cylinder
block.
Press-fit oil seal straight to avoid causing burrs or tilting.
Do not touch grease applied onto oil seal lip.
SBIA0280E
3.

L
EM-69
http://vnx.su
CYLINDER HEAD
[QR]
CYLINDER HEAD
On-Vehicle Service
PFP:11041
EBS00KNP
CHECKING COMPRESSION PRESSURE

1.
2.
3.
Warm up engine thoroughly. Then, stop it.

Disconnect fuel pump fuse to avoid fuel injection during measurement.
PBIB0508E
4.
5.
6.
Remove ignition coil and spark plug from each cylinder. Refer to EM-31, "IGNITION COIL" and EM-32,
"SPARK PLUG" .
Connect engine tachometer (not required in use of CONSULT-II).
Install compression tester with adapter onto spark plug hole.
KBIA0130E
Use the adapter whose picking up end inserted to spark plug

hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it
may be caught by cylinder head during removal.
SBIA0533E
7.
With accelerator pedal fully depressed, turn ignition switch to START for cranking. When the gauge
pointer stabilizes, read the compression pressure and engine rpm. Perform these steps to check each cylinder.
Compression pressure:
Unit: kPa (bar, kg/cm2 , psi) /rpm
Engine type
Standard
Minimum
QR20DE
1,190 (11.9, 12.1, 173) / 250
990 (9.9, 10.1, 144) / 250
QR25DE
1,250 (12.5, 12.8, 181) / 250
1,060 (10.6, 10.8, 154) / 250
CAUTION:
Always use a fully changed battery to obtain specified engine speed.
EM-70
http://vnx.su
Differential limit between cylinders

100 (1.0, 1.0, 14) / 250
CYLINDER HEAD
[QR]
If the engine speed is out of specified range, check battery liquid for proper gravity. Check engine
speed again with normal battery gravity.
A
If compression pressure is below minimum value, check valve clearances and parts associated with
combustion chamber (Valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head
gasket). After the checking, measure the compression pressure again.
EM
If some cylinder has low compression pressure, pour small amount of engine oil into the spark plug hole
of the cylinder to re-check it for compression.
If the added engine oil improves the compression, piston rings may be worn out or damaged. Check
C
piston rings and replace if necessary.
If the compression pressure remains at low level despite the addition of engine oil, valves may be malfunctioning. Check valves for damage. Replace valve or valve seat accordingly.
D
If two adjacent cylinders have respectively low compression pressure and their compression remains
low even after the addition of engine oil, gaskets are leaking. In such a case, replace cylinder head gaskets.
E
8. After inspection is completed, install removed parts.
9. Start engine, and confirm that engine runs smoothly.
10. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-72, "TROUBLE DIAGNOSIS" (WITH F
EURO-OBD) or EC-569, "TROUBLE DIAGNOSIS" (WITHOUT EURO-OBD).
EBS00KNQ
L
PBIC2185E
1.
Cylinder head assembly
2.
Cylinder head gasket
3.
Cylinder head bolt
REMOVAL
1.
2.
3.
Drain engine coolant and engine oil. Refer to CO-9, "Changing Engine Coolant" and LU-8, "Changing
Engine Oil" .
Remove the following components and related parts.
Exhaust manifold and three way catalyst assembly; Refer to EM-25, "EXHAUST MANIFOLD AND
THREE WAY CATALYST" .
Intake manifold and fuel tube assembly (QR20DE); Refer to EM-18, "Removal and Installation
(QR20DE)" .
Intake manifold collector, intake manifold and fuel tube assembly (QR25DE); Refer to EM-21, "Removal
and Installation (QR25DE)" .
Water control valve and water control valve housing (water outlet); Refer to CO-23, "THERMOSTAT
AND WATER CONTROL VALVE" .
EM-71
http://vnx.su
CYLINDER HEAD
[QR]
4.
5.
6.
7.
NOTE:
Can be removed and installed even when assembled with cylinder head.
Remove front cover and timing chain. Refer to EM-46, "TIMING CHAIN" .
Remove camshafts. Refer to EM-56, "CAMSHAFT" .
Securely support bottom of cylinder block with a jack or equivalent tool, and release the hoist that was
supporting it.
Remove cylinder head loosening bolts in reverse order as
Using the following tool, loosen cylinder head bolts.
Bolt with washer
: Hexagonal wrench [size 10 mm (0.39 in)]
Flange bolt
: TORX socket (size E20)
8.
NOTE:
There are two types of cylinder head bolt because of parallel
manufacture.
Remove cylinder head gasket.
KBIA0058E

Cylinder Head Bolts Outer Diameter
Cylinder head bolts are tightened by plastic zone tightening

method. Whenever the size difference between d1 and d2
exceeds the limit, replace them with a new one.
Limit (d1 d2): 0.23 mm (0.0091 in)
If reduction of outer diameter appears in a position other than

d2, use it as d2 point.
NOTE:
When replacing any cylinder head bolts, it is possible to use them
with mixing flange bolt and bolt with washer.
SBIA0269E
Cylinder Head Distortion

NOTE:
When performing this inspection, cylinder block distortion should be also checked. Refer to EM-107, "CYLINDER BLOCK DISTORTION" .
1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper.
CAUTION:
Use utmost care not to allow gasket debris to enter passages for engine oil or water.
2. At each of several locations on bottom surface of cylinder head,
measure the distortion in six directions.
Limit: 0.1 mm (0.004 in)
If it exceeds the limit, replace cylinder head.
PBIC0075E
EM-72
http://vnx.su
CYLINDER HEAD
[QR]
INSTALLATION
1.
2.
a.
b.
: 50 Nm (5.1 kg-m, 37 ft-lb)

c.
d.
Install cylinder head gasket.

Tighten cylinder head bolts in numerical order as shown in figure
with the following procedure, and install cylinder head.
CAUTION:
If cylinder head bolts are re-used, check their outer diameters before installation. Refer to EM-72, "Cylinder Head
Bolts Outer Diameter" .
Apply new engine oil to threads and seating surface of mounting
bolts.
Tighten all bolts.
EM
D
KBIA0058E

Completely loosen.
: 0 Nm (0 kg-m, 0 ft-lb)
e.
CAUTION:
In this step, loosen bolts in reverse order of that indicated in the figure.
Tighten all bolts.
: 39.2 Nm (4.0 kg-m, 29 ft-lb)

f.
g.

Turn all bolts 75 degrees clockwise again (angle tightening).
CAUTION:
Check and confirm the tightening angle by using an angle
wrench (special service tool) or protractor. Avoid judgment
by visual inspection without the tool.
KBIA0059E
3.

L

EM-73
http://vnx.su
CYLINDER HEAD
[QR]
Item
Engine running
Engine coolant
Level
Leakage
Level
Engine oil
Level
Leakage
Level
Level
Leakage
Level
Leakage
Leakage
Leakage
Leakage
Fuel
Exhaust gases
Disassembly and Assembly
EBS00KNR
PBIC2629E
1.
Valve collet
2.
Valve spring retainer
3.
Valve spring (with valve spring seat)
4.
Valve oil seal
5.
Valve guide
6.
Cylinder head
7.
Valve seat
8.
Valve (INT)
9.
Valve (EXH)
10. Spark plug tube
11. Spark plug
DISASSEMBLY
1.
2.
3.
4.
Remove spark plug with spark plug wrench (commercial service tool).
Remove spark plug tube, if necessary.
Using pliers, remove it from cylinder head.
CAUTION:
Be careful not to damage cylinder head.
Do not remove spark plug tube if not necessary. Once removed, spark plug tube cannot be
reused because of deformation.
Remove valve lifter.
EM-74
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CYLINDER HEAD
[QR]
Compress valve spring with valve spring compressor, attachment and adapter (special service tool). Remove valve collet
with a magnet hand.
CAUTION:
EM
C
PBIC1791E
5.
6.
7.
Remove valve spring retainer and valve spring (with valve spring seat).
CAUTION:
Push valve stem to combustion chamber side, and remove valve.
Remove valve oil seal with a valve oil seal puller (special service
tool).
SEM093F
8.
9.
When valve seat must be replaced, refer to EM-79, "VALVE SEAT REPLACEMENT" to removal.
When valve guide must be replaced, refer to EM-77, "VALVE GUIDE REPLACEMENT" to removal.
ASSEMBLY
1.
2.
3.
Install valve guide if removed. Refer to EM-77, "VALVE GUIDE REPLACEMENT" .

Install valve seat if removed. Refer to EM-79, "VALVE SEAT REPLACEMENT" .
Install valve oil seal.
Install with a valve oil seal drift (special service tool) to match
dimension in the figure.
NOTE:
Dimension H is height that measured before installing valve
spring (with valve spring seat).
Height H
: 11.8 - 12.4 mm (0.465 - 0.488 in)
KBIA1999J
4.
Install valve.
Install larger diameter to intake side.
EM-75
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CYLINDER HEAD
[QR]
5.
Install valve spring (with valve spring seat).

Install smaller pitch (valve spring seat side) to cylinder head
side.
Confirm identification color of valve spring.
Intake
Exhaust
: Blue
: Yellow
PBIC0525E
6.
7.
Install valve spring retainer.

Install valve collet.
Compress valve spring with a valve spring compressor,
attachment and adapter (special service tool). Install valve
collet with a magnet hand.
CAUTION:
When working, be careful not to damage valve lifter
holes.
Tap valve stem edge lightly with a plastic hammer after installation to check its installed condition.
PBIC1791E
8.
9.
a.
b.
c.
Install valve lifter.

Install spark plug tube if removed.
Press-fit it into cylinder head with the following procedure:
Remove old thread locking sealant from cylinder head side
installation hole.
Apply thread locking sealant all round on spark plug tube within
approximately 12 mm (0.47 in) width from edge of spark plug
tube on the press-fit side.
Use Genuine Thread Locking Sealant or equivalent.
Using a drift, press-fit spark plug tube so that height is as same
as H shown in figure.
PBIC2636E
Standard press-fit height H:

41.2 - 42.2 mm (1.622 - 1.661 in)
CAUTION:
When press-fitting, be careful not to deform spark plug tube.
After press-fitting, wipe off any protruding thread locking sealant on top surface of cylinder
head.
10. Install spark plug with spark plug wrench (commercial service tool).
EM-76
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CYLINDER HEAD
[QR]
Inspection After Disassembly
EBS00KNS
VALVE DIMENSIONS
Check dimensions of each valve. For dimensions, refer to EM115, "Valve Dimensions" .
If dimensions are out of the standard, replace valve.
EM
D
SEM188A
VALVE GUIDE CLEARANCE

Valve Stem Diameter
Measure the diameter of valve stem with a micrometer.

Standard
Intake
Exhaust
: 5.965 - 5.980 mm (0.2348 - 0.2354 in)

: 5.955 - 5.970 mm (0.2344 - 0.2350 in)
H
SEM938C
Valve Guide Inner Diameter

Measure the inner diameter of valve guide with a bore gauge.
Standard
Intake and Exhaust
: 6.000 - 6.018 mm (0.2362 - 0.2369 in)
Valve Guide Clearance

(Valve guide clearance) = (Valve guide inner diameter) (Valve stem diameter).
Valve guide clearance:
Standard
Intake
: 0.020 - 0.053 mm (0.0008 - 0.0021 in)
Exhaust : 0.030 - 0.063 mm (0.0012 - 0.0025 in)
Limit
Intake
: 0.08 mm (0.003 in)
Exhaust : 0.09 mm (0.004 in)
If it exceeds the limit, replace valve guide and/or valve.
VALVE GUIDE REPLACEMENT

When valve guide is removed, replace with oversized [0.2 mm (0.008 in)] valve guide.
EM-77
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CYLINDER HEAD
[QR]
1.
To remove valve guide, heat cylinder head to 110 to 130C (230

to 266F) by soaking in heated oil.
SEM008A
2.
Drive out valve guide with a press [under a 20 kN (2 ton, 2.2 US

ton, 2.0 lmp ton) pressure] or hammer and suitable tool.
CAUTION:
Cylinder head contains heat, when working, wear protective
equipment to avoid getting burned.
SEM931C
3.
Ream cylinder head valve guide hole with a valve guide reamer
(commercial service tool).
Valve guide hole diameter (for service parts):
Intake and exhaust
: 10.175 - 10.196 mm (0.4006 - 0.4014 in)
SEM932C
4.
Heat cylinder head to 110 to 130C (230 to 266F) by soaking in

heated oil.
SEM008A
EM-78
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CYLINDER HEAD
[QR]
5.
Press valve guide from camshaft side to dimensions as shown

in the figure.
Projection H:
Intake
Exhaust
: 10.1 - 10.3 mm (0.398 - 0.406 in)

: 10.0 - 10.4 mm (0.394 - 0.409 in)
EM
CAUTION:
C
PBIC2187E
6.
Apply reamer finish to valve guide with a valve guide reamer

E
Standard
Intake and exhaust:
6.000 - 6.018 mm (0.2362 - 0.2369 in)
G
SEM932C
VALVE SEAT CONTACT
After confirming that the dimensions of valve guides and valves

are within specifications, perform this procedure.
Apply prussian blue (or white lead) onto contacting surface of
valve seat to check the condition of the valve contact on the surface.
Check if the contact area band is continuous all around the circumference.
If not, grind to adjust valve fitting and check again. If the contacting surface still has NG conditions even after the re-check,
replace valve seat.
K
SBIA0322E
VALVE SEAT REPLACEMENT

When valve seat is removed, replace with oversized [0.5 mm (0.020 in)] valve seat.
1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess
in cylinder head. Set the machine depth stop to ensure this. Refer to EM-118, "Valve Seat" .
2. Ream cylinder head recess diameter for service valve seat.
Oversize [0.5 mm (0.020 in)]
Intake
: 37.000 - 37.016 mm (1.4567 - 1.4573 in)
Exhaust : 32.000 - 32.016 mm (1.2598 - 1.2605 in)
Be sure to ream in circles concentric to the valve guide center.

This will enable valve seat to fit correctly.
SEM795A
EM-79
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CYLINDER HEAD
[QR]
3.

heated oil.
SEM008A
4.
5.
Provide valve seats cooled well with dry ice. Press-fit valve seat into cylinder head.
CAUTION:
Avoid directly to touching cold valve seats.
Cylinder head contains heat, when working, wear protective equipment to avoid getting burned.
Using valve seat cutter set (commercial service tool) or valve
seat grinder, finish valve seat to the specified dimensions. For
dimensions, refer to EM-118, "Valve Seat" .
CAUTION:
When using valve seat cutter, firmly grip the cutter handle
with both hands. Then, press on the contacting surface all
around the circumference to cut in a single drive. Improper
pressure on with the cutter or cutting many different times
may result in stage valve seat.
SEM934C
6.
7.
Using compound, grind to adjust valve fitting.

Check again for normal contact. Refer to EM-79, "VALVE SEAT CONTACT" .
VALVE SPRING SQUARENESS
Set try square along the side of valve spring and rotate the
spring. Measure the maximum clearance between the top of
valve spring and try square.
CAUTION:
Limit: 1.9 mm (0.075 in)
If it exceeds the limit, replace valve spring (with valve spring

seat).
PBIC0080E
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD
Check valve spring pressure with valve spring seat installed at

the specified spring height.
CAUTION:
SEM113
EM-80
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CYLINDER HEAD
[QR]
Standard:
Items
Free height
Installation height
Installation load
Height during valve open
Load with valve open
Identification color
Intake
Exhaust
44.84 - 45.34 mm (1.7654 - 1.7850 in)
45.28 - 45.78 mm (1.7827 - 1.8024 in)
35.30 mm (1.390 in)
35.30 mm (1.390 in)
151 - 175 N (15.4 - 17.8 kg, 34 - 39 lb)
151 - 175 N (15.4 - 17.8 kg, 34 - 39 lb)
24.94 mm (0.9819 in)
26.39 mm (1.0390 in)
358 - 408 N (36.5 - 41.6 kg, 80 - 92 lb)
325 - 371 N (33.1 - 37.8 kg, 73 - 83 lb)
Blue
Yellow
If the installation load or load with valve open is out of the standard, replace valve spring (with valve spring
seat).
EM
EM-81
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ENGINE ASSEMBLY
[QR]
ENGINE ASSEMBLY
PFP:10001
EBS00KNT
PBIC2392E
1.
Rear engine mounting insulator
2.
Rear engine mounting bracket
3.
RH engine mounting insulator
4.
RH engine mounting bracket
5.
Front engine mounting bracket
6.
Front engine mounting insulator
7.
Center member
8.
LH engine mounting insulator
9.
LH engine mounting bracket
11.
Grommet
10. Stopper
WARNING:
Situate vehicle on a flat and solid surface.
Place chocks at front and back of rear wheels.
For engines not equipped with engine slingers, attach proper slingers and bolts described in
PARTS CATALOG.
CAUTION:
Always be careful to work safely, avoid forceful or uninstructed operations.
Do not start working until exhaust system and engine coolant are cool enough.
If items or work required are not covered by the engine section, refer to the applicable sections.
Always use the support point specified for lifting.
Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for
unavoidable reasons, support at the rear axle jacking point with transmission jack or similar tool
before starting work, in preparation for the backward shift of center of gravity.
For supporting points for lifting and jacking point at rear axle, refer to GI-36, "Garage Jack and
Safety Stand" .
REMOVAL
Outline
Remove engine, transaxle and transfer assembly with front suspension member from vehicle downward. Separate front suspension member, and then separate engine and transaxle.
EM-82
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ENGINE ASSEMBLY
[QR]
Preparation
1.
2.
3.
4.
5.
6.
A
Remove hood assembly. Refer to BL-12, "HOOD" .
EM
Drain engine coolant from radiator. Refer to CO-9, "DRAINING ENGINE COOLANT" .
LH and RH undercovers
C
Front road wheels and tyres
Battery; Refer to SC-3, "BATTERY" .
D
Air duct and air cleaner case assembly; Refer to EM-16, "AIR CLEANER AND AIR DUCT" .
Alternator; Refer to SC-12, "CHARGING SYSTEM" .
Radiator and radiator cooling fan assembly; Refer to CO-12, "RADIATOR" .
E
Disconnect engine room harness from the engine side and set it aside for easier work.
Disconnect all vacuum hoses and air hoses connected to vehicle side at engine side.
F
Engine Room LH
1.
2.
3.
4.
5.
Disconnect fuel feed hose, and plug it to prevent fuel from draining. Refer to EM-34, "FUEL INJECTOR
AND FUEL TUBE"
Disconnect heater hose, and install plug it to prevent engine coolant from draining.
Disconnect control cable from transaxle (A/T models). Refer to AT-404, "ON-VEHICLE SERVICE" .
Disconnect clutch operating cylinder from transaxle, and move it aside (M/T models). Refer to CL-12,
"OPERATING CYLINDER" .
Disconnect shift and select cable from transaxle (M/T models). Refer to MT-14, "CONTROL LINKAGE" .
Engine Room RH
1.
2.
Remove engine coolant reservoir tank. Refer to CO-12, "RADIATOR" .

Remove A/C compressor with piping connected from engine. Temporarily secure it on vehicle side with a
rope to avoid putting load on it. Refer to ATC-144, "Removal and Installation of Compressor" .
Vehicle Underbody
1.
2.
3.
4.
5.
6.
7.
8.
9.

Remove propeller shaft. Refer to PR-3, "REAR PROPELLER SHAFT" .
Remove steering lower joint from steering gear. Refer to PS-11, "STEERING COLUMN" .
Disconnect power steering fluid piping at a point between vehicle and engine. Refer to PS-37, "HYDRAULIC LINE" .
Remove rear plate cover from oil pan (upper). Then remove bolts fixing drive plate to torque converter
(A/T models). Refer to EM-27, "OIL PAN AND OIL STRAINER" and AT-413, "REMOVAL AND INSTALLATION" .
Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to MT-17, "TRANSAXLE ASSEMBLY" (M/T models) or AT-413, "REMOVAL AND INSTALLATION" (A/T models).
Remove front wheel sensor (LH and RH) for ABS from steering knuckle. Refer to BRC-45, "WHEEL SENSORS" (ABS) or BRC-114, "WHEEL SENSORS" (ESP/TCS/ABS).
Remove brake caliper assembly with piping connected from steering knuckle. Temporarily secure it on
vehicle side with a rope to avoid load on it. Refer to BR-27, "FRONT DISC BRAKE" .
Remove lower ends of left and right strut from steering knuckle. Refer to FSU-5, "FRONT SUSPENSION
ASSEMBLY" .
Removal
1.
Install engine slingers into front left of cylinder head and rear right of cylinder head.
EM-83
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ENGINE ASSEMBLY
[QR]
Use alternator bracket mounting bolt holes for the front side.
Slinger bolts:
Front
: 57.9 Nm (5.9 kg-m, 43 ft-lb)
Rear
: 28.0 Nm (2.9 kg-m, 21 ft-lb)
SBIA0271E
2.
3.
Lift with hoist and secure engine in position.

Use a manual lift table caddy (commercial service tool) or equivalently rigid tool such as a transmission jack. Securely support
bottom of engine and transaxle, and simultaneously adjust hoist
tension.
CAUTION:
Put a piece of wood or something similar as the supporting
surface, secure a completely stable condition.
KBIA0256E
4.
5.
Remove RH engine mounting insulator.

Pull LH engine mounting through-bolt out.
PBIC2188E
6.
7.
Remove mounting bolts at front end of center member.

Remove front suspension member mounting bolts and nuts.
Refer to FSU-5, "FRONT SUSPENSION ASSEMBLY" .
KBIA0270E
8.
Remove engine, transaxle and transfer assembly with front suspension member and center member from
vehicle downward by carefully operating supporting tools.
CAUTION:
During the operation, make sure that no part interferes with vehicle side.
Before and during this lifting, always check if any harnesses are left connected.
During the removal operation, always be careful to prevent vehicle from falling off the lift due to
changes in the center of gravity.
If necessary, support vehicle by setting a jack or equivalent tool at the rear.
EM-84
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ENGINE ASSEMBLY
[QR]
9.
Remove power steering oil pump with piping connected from engine. Move it aside on front suspension
member. Refer to PS-37, "HYDRAULIC LINE" .
A
10. Remove front engine mounting and rear engine mounting through-bolts to remove front suspension member and center member.
11. Remove starter motor. Refer to SC-22, "STARTING SYSTEM" .
EM
12. Separate engine and transaxle. Refer to MT-17, "TRANSAXLE ASSEMBLY" (M/T models) or AT-413,
C
INSTALLATION
Do not allow engine oil to get on mounting insulator. Be careful not to damage mounting insulator.
When installation directions are specified, install parts according to the direction marks on them referring
to figure of components. Refer to EM-82, "Removal and Installation" .
Make sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts.


Item
Engine running
Engine coolant
Level
Leakage
Level
Engine oil
Level
Leakage
Level
Level
Leakage
Level
Leakage
Leakage
Leakage
Leakage
Fuel
Exhaust gases
EM-85
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CYLINDER BLOCK
[QR]
CYLINDER BLOCK
PFP:11010
EBS00KNU
PBIC3599E
1.
Cylinder block
2.
O-ring
3.
Crankshaft position sensor (POS)
4.
Knock sensor
5.
Water drain plug
6.
Lower cylinder block
7.
Lower cylinder block mounting bolt
8.
Snap ring
9.
Connecting rod
10. Connecting rod bearing
11.
Connecting rod bearing cap
13. Piston
14. Oil ring
15. Second ring
16. Top ring
17. Piston pin
18. Thrust bearing
19. Main bearing upper
20. Crankshaft
21. Crankshaft key
22. Main bearing lower
23. Rear oil seal
24. Pilot converter (A/T models)
25. Signal plate
26. Drive plate (A/T models)
27. Reinforce plate (A/T models)
28. Flywheel (M/T models)
EM-86
http://vnx.su
12. Connecting rod bolt
CYLINDER BLOCK
[QR]
DISASSEMBLY
1.
2.
a.
b.
Remove engine, transaxle and transfer assembly from vehicle, and separate transaxle and transfer A
assembly from engine. Refer to EM-82, "ENGINE ASSEMBLY" .
Mount engine on an engine stand with the following procedure:
Remove oil cooler with oil cooler bracket on right side of cylinder block. Refer to LU-11, "OIL COOLER" . EM
Install engine sub-attachment (special service tool) to right side
of cylinder block.
C
Do not use bolt hole at the upper right looking from bolt insertion side as shown in the figure.
D
E
PBIC2190E
Machine a bolt hole at the lower right of the engine subattachment looking from bolt insertion side as shown in the
figure.
SBIA0272E
c.
Lift engine, and mount it onto the engine stand (special service
tool).
KBIA0140E
EM-87
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CYLINDER BLOCK
[QR]
A widely use engine stand can be used.

NOTE:
This example is an engine stand for holding at transaxle
mounting side with flywheel (M/T models) or drive plate (A/T
models) removed.
PBIC0085E
3.
4.

Drain engine coolant by removing water drain plug from inside of
engine.
PBIC2716E
5.
6.
7.
Remove cylinder head. Refer to EM-70, "CYLINDER HEAD" .

Remove knock sensor.
CAUTION:
Carefully handle knock sensor avoiding shocks.
Remove crankshaft position sensor (POS).
CAUTION:
Avoid impacts such as a dropping.
Do not disassemble.
Keep it away from metal particles.
Do not place sensor in a location where it is exposed to
magnetism.
PBIC2191E
8.
9.
Remove clutch cover and clutch disc (M/T models). Refer to CL-16, "CLUTCH DISC, CLUTCH COVER
AND FLYWHEEL" .
Remove flywheel (M/T models) or drive plate (A/T models).
Secure crankshaft with a stopper plate, and remove mounting
bolts.
Using the following TORX socket, loosen mounting bolts.
Flywheel (M/T models)
: size T55 (commercial service tool)
Drive plate (A/T models)
: size E20
CAUTION:
Be careful not to damage contact surface for clutch disc of
flywheel (M/T models).
EM-88
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PBIC2352E
CYLINDER BLOCK
[QR]
NOTE:
The flywheel, two block construction, allows movement in response to transaxle side pressure, or when
twisted in its rotational direction. Therefore, some amount of noise is normal.
10. Remove pilot converter using pilot bushing puller (special service tool) or suitable tool. (A/T models)
NOTE:
M/T models have no pilot bushing.
EM
SBIA0274E
11. Remove piston and connecting rod assembly with the following procedure:
Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer
to EM-104, "CONNECTING ROD SIDE CLEARANCE" .
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Remove connecting rod cap.
c. Using a hammer handle or similar tool, push piston and connecting rod assembly out to the cylinder head side.
CAUTION:
Be careful not to damage the cylinder wall, resulting from
an interference of the connecting rod big end.
J
PBIC0259E
12. Remove connecting rod bearings.

CAUTION:
When removing them, note the installation position. Keep them in the correct order.
13. Remove piston rings form piston.
Use a piston ring expander (commercial service tool).
CAUTION:
When removing piston rings, be careful not to damage
the piston.
Be careful not to damage piston rings by expanding
them excessively.
PBIC0087E
14. Remove piston from connecting rod with the following procedure:
EM-89
http://vnx.su
CYLINDER BLOCK
[QR]
a.
Using snap ring pliers, remove snap ring.
PBIC1638E
b.
Heat piston to 60 to 70C (140 to 158F) with a industrial use

drier or equivalent.
PBIC1639E
c.
Push out piston pin with stick of outer diameter approximately 19

mm (0.75 in).
PBIC0262E
15. Remove lower cylinder block mounting bolts.

Loosen them in reverse order as shown in the figure, and
remove them.
Use TORX socket (size E14) for bolts No. 1 to 10.
Before loosening lower cylinder block mounting bolts, measure crankshaft end play. Refer to EM-104, "CRANKSHAFT
END PLAY" .
KBIA0063E
16. Remove lower cylinder block.

CAUTION:
Be careful not to damage the mounting surface.
17. Remove crankshaft.
EM-90
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CYLINDER BLOCK
[QR]
CAUTION:
Be careful not damage or deform signal plate mounted on
A
crankshaft.
When setting crankshaft on a flat floor surface, use a
block of wood to avoid interference between signal plate
EM
and the floor surface.
Do not remove signal plate unless it is necessary to do
so.
C
NOTE:
When removing or installing signal plate, use TORX socket (size
T30).
D
SBIA0275E
18. Pull rear oil seal out from rear end of crankshaft.
NOTE:
When replacing rear oil seal without removing lower cylinder block, use a screwdriver to pull it out from
E
between crankshaft and cylinder block.
CAUTION:
F
19. Remove main bearings and thrust bearings from cylinder block and lower cylinder block.
CAUTION:
ASSEMBLY
1.
2.
Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to
remove any foreign material.
CAUTION:
Use a goggles to protect your eye.
Install each plug to cylinder block as shown in the figure.
Apply liquid gasket to the thread of water drain plug A.
NOTE:
Do not apply liquid gasket to the thread of plug B.
L
PBIC2770E
3.
a.
Tighten each plug as specified below.

Part
Washer
Tightening torque
No
9.8 Nm (1.0 kg-m, 87 in-lb)
Yes
53.9 Nm (5.5 kg-m, 40 ft-lb)
Install main bearings and thrust bearings with the following procedure:
Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block and lower cylinder
block.
EM-91
http://vnx.su
CYLINDER BLOCK
[QR]
b.
Install thrust bearings to the both sides of the No. 3 journal housing on cylinder block.
Install thrust bearings with the oil groove facing crankshaft
arm (outside).
PBIC0264E
c.
4.
a.
b.
5.
6.
a.
b.
i.
Install the main bearings paying attention to the direction.

Main bearing with an oil hole and groove goes on cylinder
block. The one without them goes on lower cylinder block.
Only main bearing (on cylinder block) for No. 3 journal has different specifications.
Before installing main bearings, apply new engine oil to the
bearing surface (inside). Do not apply new engine oil to the
back surface, but thoroughly clean it.
When installing, align main bearing stopper to the notch.
Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.
Install signal plate to crankshaft if removed.
Position crankshaft and signal plate using a dowel pin, and
tighten mounting bolts.
Remove dowel pin.
CAUTION:
Be sure to remove dowel pin.
NOTE:
Dowel pin of crankshaft and signal plate is provided as a set for
each. If dowel pin is not available (when reusing crankshaft and
signal), use M6 bolt [length 10 mm (0.39 in) or more] as a substitute.
Install crankshaft to cylinder block.
While turning crankshaft by hand, make sure that it turns smoothly.
Install lower cylinder block with the following procedure:
Apply liquid gasket with a tube presser (special service tool:
WS39930000) to lower cylinder block as shown in the figure.
CAUTION:
After liquid gasket is applied, rear oil seal installation must
be finished within 5 minutes. Therefore, the following procedure must be performed quickly.
NOTE:
Lower cylinder block cannot be replaced as a single part,
because it is machined together with cylinder block.
Tighten lower cylinder block mounting bolts with the following
procedure:
Apply new engine oil to threads and seat surfaces of mounting bolts.
EM-92
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PBIC2193E
SBIA0278E
SBIA0279E
CYLINDER BLOCK
[QR]
ii.
Tighten M8 bolts in numerical order from No. 11 to 22 in the figure.
: 25.1 Nm (2.6 kg-m, 19 ft-lb)

NOTE:
There are more processes to complete the tightening of mounting bolts. However stop procedure here to install rear oil seal.
EM
C
KBIA0063E
c.
d.
i.
Install rear oil seal. Refer to EM-68, "Removal and Installation of Rear Oil Seal" .
Restart tightening of lower cylinder block mounting bolts with the following procedure:
Tighten M10 bolts in numerical order from No. 1 to 10.
: 39.2 Nm (4.0 kg-m, 29 ft-lb)

F
KBIA0063E
ii.
Turn M10 bolts 60 degrees clockwise (angle tightening) in order

from No. 1 to 10 in the figure.
CAUTION:
wrench (special service tool) or protractor. Avoid judgment
by visual inspection without the tool.
K
KBIA0065E
7.
a.
b.
After installing mounting bolts, make sure that crankshaft can be rotated smoothly by hand.
Wipe off completely any protruding liquid gasket on front side of engine.
Check crankshaft end play. Refer to EM-104, "CRANKSHAFT END PLAY" .
Install piston to connecting rod with the following procedure:
Using snap ring pliers, install new snap ring to the groove of the piston rear side.
Insert it fully into groove to install.
Assemble piston to connecting rod.
Using an industrial use drier or similar tool, heat the piston until the piston pin can be pushed in by hand
without excess force [approx. 60 to 70 C (140 to 158 F)]. From the front to the rear, insert piston pin
into piston and connecting rod.
EM-93
http://vnx.su
CYLINDER BLOCK
[QR]
Assemble so that the front mark on the piston head and the oil
holes and the cylinder number on connecting rod are positioned as shown in the figure.
Install new snap ring to the groove of the piston front side.
Insert it fully into groove to install.
After installing, make sure that connecting rod moves
smoothly.
c.
PBIC2194E
8.
Using a piston ring expander (commercial service tool), install piston rings.
CAUTION:
Be careful not to damage piston.
Position each ring with the gap as shown in the figure referring to the piston front mark.
Install second ring with the stamped surface facing upward.
Stamped mark:
Top ring
Second ring
:
: 2F
NOTE:
If there is no stamped mark on piston ring, no specific orientation is required for installation.
PBIC2195E
9.
Install connecting rod bearings to connecting rod and connecting rod cap.
When installing connecting rod bearings, apply new engine oil to the bearing surface (inside). Do not
apply new engine oil to the back surface, but thoroughly clean it.
When installing, align the connecting rod bearing stopper protrusion with the cutout of connecting rod and connecting rod
cap to install.
Ensure the oil hole on connecting rod and that on the corresponding bearing are aligned.
PBIC0266E
10. Install piston and connecting rod assembly to crankshaft.

Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin.
Match the cylinder position with the cylinder number on connecting rod to install.
EM-94
http://vnx.su
CYLINDER BLOCK
[QR]
Using a piston ring compressor (special service tool) or suitable tool, install piston with the front mark on the piston head
facing the front of the engine.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod
big end.
EM
C
PBIC1619E
11. Install connecting rod cap.

Match the stamped cylinder number marks on connecting rod
with those on connecting rod cap to install.
G
PBIC2196E
12. Tighten connecting rod bolt with the following procedure:

a. Apply new engine oil to the threads and seats of connecting rod bolts.
b. Tighten bolts.
: 19.6 Nm (2.0 kg-m, 14 ft-lb)

c.
Then turn all bolts 90 degrees clockwise (Angle tightening).

CAUTION:
wrench (special service tool) or protractor. Avoid judgement by visual inspection without the tool.
KBIA0068E
After tightening connecting rod bolt, make sure that crankshaft rotates smoothly.
Check the connecting rod side clearance. Refer to EM-104, "CONNECTING ROD SIDE CLEARANCE" .
13. Install flywheel (M/T models) or drive plate (A/T models).

CAUTION:
Make sure that dowel pin is installed at the rear end of crankshaft.
When installing flywheel (M/T models) or drive plate (A/T models) to crankshaft, make sure that align
crankshaft side dowel pin with flywheel/drive-plate side dowel pin hole correctly.
CAUTION:
If these are not aligned correctly, engine runs roughly and MI turns on.
Secure crankshaft with a stopper plate, and tighten mounting bolts crosswise over several times.
EM-95
http://vnx.su
CYLINDER BLOCK
[QR]
Install drive plate, reinforcement plate and pilot converter as

shown in figure (A/T models).
Using a drift of 33 mm (1.30 in) in diameter, press-fit pilot converter into the end of crankshaft until it stops (A/T models).
KBIA0075E
14. Install knock sensor.

Install knock sensor with connector facing lower left by 45
degrees as shown in the figure.
CAUTION:
Do not tighten mounting bolts while holding the connector.
If any impact by dropping is applied to knock sensor,
replace it with a new one.
NOTE:
Make sure that there is no foreign material on the cylinder
block mating surface and the back surface of knock sensor.
Make sure that knock sensor does not interfere with other
parts.
15. Install crankshaft position sensor (POS).
16. Assemble in the reverse order of disassembly after this step.
KBIA0069E
How to Select Piston and Bearing
EBS00KNV
DESCRIPTION
Selection points
Between cylinder block and

crankshaft
Selection parts
Selection items
Main bearing
Selection methods
Main bearing grade (bearing

thickness)
Determined by match of cylinder block bearing housing

grade (inner diameter of housing) and crankshaft journal
grade (outer diameter of journal)
Between crankshaft and connecting rod
Connecting rod bearing
Connecting rod bearing grade

(bearing thickness)
Combining service grades for

connecting rod big end diameter and crankshaft pin outer
diameter determine connecting
rod bearing selection.
Between cylinder block and piston
Piston and piston pin assembly

(piston is available together
with piston pin as an assembly.)
Piston grade (piston outer

diameter)
Piston grade = cylinder bore

grade (inner diameter of bore)
Between piston and connecting

rod*
*For the service parts, the grade for fitting cannot be selected between piston pin and connecting rod. (Only grade 0 is available.) The
information at the shipment from the plant is described as a reference.
The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.
EM-96
http://vnx.su
CYLINDER BLOCK
[QR]
HOW TO SELECT PISTON
When New Cylinder Block is Used
Check the cylinder bore grade on rear left side of cylinder block,
and select piston of the same grade.
If there is a corrected stamp mark on the cylinder block, use it as
a correct reference.
EM
D
SBIA0283E
When Cylinder Block is Reused

1.
2.
3.
Measure the cylinder bore inner diameter. Refer to EM-108, "Cylinder Bore Inner Diameter" .
Determine the bore grade by comparing the measurement with the values under the cylinder bore inner
diameter of the Piston Selection Table.
Select piston of the same grade.
Piston Selection Table

Unit: mm (in)
Grade number (Mark)
2 (or no mark)
Cylinder bore Inner diameter
89.010 - 89.020 (3.5043 - 3.5047)
89.020 - 89.030 (3.5047 - 3.5051)
Piston skirt diameter
88.990 - 89.000 (3.5035 - 3.5039)
89.000 - 89.010 (3.5039 - 3.5043)
NOTE:
There is no piston grade 1.
Piston is available together with piston pin as an assembly.
The piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts,
no grades can be selected. (Only grade 0 is available.)
HOW TO SELECT CONNECTING ROD BEARING

When New Connecting Rod and Crankshaft are Used
1.
Apply connecting rod big end diameter grade stamped on connecting rod side face to the row in the Connecting Rod Bearing
Selection Table.
PBIC2196E
2.
Apply crankshaft pin journal diameter grade stamped on crankshaft front side to the column in the Connecting Rod Bearing
Selection Table.
PBIC2198E
EM-97
http://vnx.su
CYLINDER BLOCK
[QR]
3.
4.
Read the symbol at the cross point of selected row and column in the Connecting Rod Bearing Selection
Table.
Apply the symbol obtained to the Connecting Rod Bearing Grade Table to select connecting rod bearing.
When Crankshaft and Connecting Rod are Reused

1.
2.
3.
4.
Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter individually. Refer to EM-106, "CONNECTING ROD BIG END DIAMETER" and EM-110, "CRANKSHAFT
PIN JOURNAL DIAMETER" .
Apply the measured dimension to the Connecting Rod Bearing Selection Table.
Read the symbol at the cross point of selected row and column in the Connecting Rod Bearing Selection
Table.
Apply the symbol obtained to the Connecting Rod Bearing Grade Table to select connecting rod bearing.
Connecting Rod Bearing Selection Table
PBIC2199E
EM-98
http://vnx.su
CYLINDER BLOCK
[QR]
Connecting Rod Bearing Grade Table
Unit: mm (in)
Grade number
Thickness
1.495 - 1.499
(0.0589 - 0.0590)
1.499 - 1.503
(0.0590 - 0.0592)
1.503 - 1.507
(0.0592 - 0.0593)
1.507 - 1.511
(0.0593 - 0.0595)
Black
Brown
Green
Yellow
Undersize Bearings Usage Guide
EM
When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod
bearings, use undersize (US) bearings.
When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing
installed, and grind the crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard.
CAUTION:
In grinding crankshaft pin to use undersize bearings, keep the
fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)].
H
PBIC2200E
Bearing undersize table

Unit: mm (in)
Size
Thickness
US 0.25 (0.0098)
1.624 - 1.632 (0.0639 - 0.0643)
HOW TO SELECT MAIN BEARING

When New Cylinder Block and Crankshaft are Used
1.
Main Bearing Selection Table rows correspond to main bearing

housing grade on rear left side of cylinder block.
If there is a corrected stamp mark on cylinder block, use it as
a correct reference.
SBIA0283E
2.
Apply main journal diameter grade stamped on crankshaft front

side to column in the Main Bearing Selection Table.
PBIC2198E
EM-99
http://vnx.su
CYLINDER BLOCK
[QR]
3.
4.
Read the symbol at the cross point of selected row and column in the Main Bearing Selection Table.
CAUTION:
There are two main bearing selection tables. One is for odd-numbered journals (No. 1, 3 and 5) and
the other is for even-numbered journals (No. 2 and 4). Make certain to use the appropriate table.
This is due to differences in the specified clearances.
Apply the symbol obtained to the Main Bearing Grade Table to select main bearing.
NOTE:
Service part is available as a set of both upper and lower.
When Cylinder Block and Crankshaft are Reused

1.
2.
3.
4.
Measure the dimensions of the cylinder block main bearing housing inner diameter and crankshaft main
journal diameter individually. Refer to EM-108, "MAIN BEARING HOUSING INNER DIAMETER" and EM109, "CRANKSHAFT MAIN JOURNAL DIAMETER" .
Apply the measured dimension to the Main Bearing Selection Table.
Read the symbol at the cross point of selected row and column in the Main Bearing Selection Table.
CAUTION:
There are two main bearing selection tables. One is for odd-numbered journals (No. 1, 3 and 5) and
the other is for even-numbered journals (No. 2 and 4). Make certain to use the appropriate table.
This is due to differences in the specified clearances.
Apply the symbol obtained to the Main Bearing Grade Table to select main bearing.
NOTE:
Service part is available as a set of both upper and lower.
EM-100
http://vnx.su
CYLINDER BLOCK
[QR]
Main Bearing Selection Table (No. 1, 3 and 5 journals)
A
EM
L
PBIC2201E
EM-101
http://vnx.su
CYLINDER BLOCK
[QR]
Main Bearing Selection Table (No. 2 and 4 journals)
PBIC2202E
EM-102
http://vnx.su
CYLINDER BLOCK
[QR]
Main Bearing Grade Table (All Journals)
Unit: mm (in)
Grade number
Thickness
1.973 - 1.976 (0.0777 - 0.0778)
Black
1.976 - 1.979 (0.0778 - 0.0779)
Brown
1.979 - 1.982 (0.0779- 0.0780)
Green
1.982 - 1.985 (0.0780 - 0.0781)
Yellow
1.985 - 1.988 (0.0781 - 0.0783)
Blue
1.988 - 1.991 (0.0783 - 0.0784)
Pink
1.991 - 1.994 (0.0784 - 0.0785)
Purple
1.994 - 1.997 (0.0785 - 0.0786)
White
UPR
1.973 - 1.976 (0.0777 - 0.0778)
Black
LWR
1.976 - 1.979 (0.0778 - 0.0779)
Brown
UPR
1.976 - 1.979 (0.0778 - 0.0779)
Brown
LWR
1.979 - 1.982 (0.0779 - 0.0780)
Green
UPR
1.979 - 1.982 (0.0779- 0.0780)
Green
LWR
1.982 - 1.985 (0.0780 - 0.0781)
Yellow
UPR
1.982 - 1.985 (0.0780 - 0.0781)
Yellow
LWR
1.985 - 1.988 (0.0781 - 0.0783)
Blue
UPR
1.985 - 1.988 (0.0781 - 0.0783)
Blue
LWR
1.988 - 1.991 (0.0783 - 0.0784)
Pink
UPR
1.988 - 1.991 (0.0783 - 0.0784)
Pink
LWR
1.991 - 1.994 (0.0784 - 0.0785)
Purple
UPR
1.991 - 1.994 (0.0784 - 0.0785)
Purple
LWR
1.994 - 1.997 (0.0785 - 0.0786)
White
01
12
23
34
45
56
67
Remarks
EM
Grade and color are the same

for upper and lower bearings.
Grade and color are different

Use Undersize Bearing Usage Guide

When the specified main bearing oil clearance is not obtained with standard size main bearings, use
undersize (US) bearing.
When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and
grind main journal so that the main bearing oil clearance satisfies the standard.
CAUTION:
In grinding crankshaft main journal to use undersize bearings,
keep fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)].
PBIC2200E
Bearing undersize table

Unit: mm (in)
Size
Thickness
US 0.25 (0.0098)
2.106 - 2.114 (0.0829 - 0.0832)
EM-103
http://vnx.su
CYLINDER BLOCK
[QR]
EBS00KNW
CRANKSHAFT END PLAY
Measure the clearance between thrust bearings and crankshaft

arm when crankshaft is moved fully forward or backward with a
dial indicator.
Standard
Limit
: 0.10 - 0.26 mm (0.0039 - 0.0102 in)

: 0.30 mm (0.0118 in)
If the measured value exceeds the limit, replace thrust bearings,

and measure again. If it still exceeds the limit, replace crankshaft also.
PBIC2377E
CONNECTING ROD SIDE CLEARANCE
Measure the side clearance between connecting rod and crankshaft arm with a feeler gauge.
Standard
Limit
: 0.20 - 0.35 mm (0.0079 - 0.0138 in)

: 0.50 mm (0.0197 in)
If the measured value exceeds the limit, replace connecting rod,

and measure again. If it still exceeds the limit, replace crankshaft also.
KBIA0071E
PISTON TO PISTON PIN OIL CLEARANCE

Piston Pin Hole Diameter
Measure the inner diameter of piston pin hole with an inside
micrometer.
Standard: 19.993 - 20.005 mm (0.7871 - 0.7876 in)
PBIC0116E
Piston Pin Outer Diameter

Measure the outer diameter of piston pin with a micrometer.
Standard: 19.989 - 20.001 mm (0.7870 - 0.7874 in)
PBIC0117E
Piston to Piston Pin Oil Clearance

(Piston to piston pin oil clearance) = (Piston pin hole diameter) (Piston pin outer diameter)
Standard: 0.002 - 0.006 mm (0.0001 - 0.0002 in)
If oil clearance is out of the standard, replace piston and piston pin assembly.
EM-104
http://vnx.su
CYLINDER BLOCK
[QR]
When replacing piston and piston pin assembly, refer to EM-108, "PISTON TO CYLINDER BORE
CLEARANCE" .
A
NOTE:
Piston is available together with piston pin as assembly.
Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, EM
no grades can be selected. (Only grade 0 is available.)
PISTON RING SIDE CLEARANCE
Measure the side clearance of piston ring and piston ring groove
with a feeler gauge.
Standard:
Top ring
2nd ring
Oil ring
: 0.045 - 0.080 mm (0.0018 - 0.0031 in)

: 0.030 - 0.070 mm (0.0012 - 0.0028 in)
: 0.065 - 0.135 mm (0.0026 - 0.0053 in)
Limit:
Top ring
2nd ring
: 0.11 mm (0.0043 in)

: 0.10 mm (0.0039 in)
SEM024AA
If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit,
replace piston also.
PISTON RING END GAP
Make sure that cylinder bore inner diameter is within specification. Refer to EM-108, "Cylinder Bore Inner Diameter" .
Lubricate with new engine oil to piston and piston ring, and then
insert piston ring until middle of cylinder with piston, and measure piston ring end gap with a feeler gauge.
Standard:
Top ring
2nd ring
Oil ring
(rail ring)
: 0.21 - 0.31 mm (0.0083 - 0.0122 in)

: 0.32 - 0.47 mm (0.0126 - 0.0185 in)
: 0.20 - 0.60 mm (0.0079 - 0.0236 in)
Limit:
Top ring
2nd ring
Oil ring
(rail ring)
: 0.54 mm (0.0213 in)

: 0.67 mm (0.0264 in)
: 0.95 mm (0.0374 in)
SEM822B
If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit,
re-bore cylinder and use oversized piston and piston rings.
EM-105
http://vnx.su
CYLINDER BLOCK
[QR]
CONNECTING ROD BEND AND TORSION
Check with a connecting rod aligner.

Bend:
Limit: 0.15 mm (0.0059 in) per 100 mm (3.94 in) length
Torsion:
Limit: 0.30 mm (0.0118 in) per 100 mm (3.94 in) length
If it exceeds the limit, replace connecting rod assembly.
PBIC2077E
CONNECTING ROD BIG END DIAMETER
Install connecting rod cap without connecting rod bearing installed, and tightening connecting rod bolts to
the specified torque. Refer to EM-91, "ASSEMBLY" for the tightening procedure.
Measure the inner diameter of connecting rod big end with an
inside micrometer.
Standard: 48.000 - 48.013 mm (1.8898 - 1.8903 in)
If out of the standard, replace connecting rod assembly.
PBIC1641E
CONNECTING ROD BUSHING OIL CLEARANCE

Connecting Rod Bushing Inner Diameter
Measure the inner diameter of connecting rod bushing with an inside
micrometer.
Standard: 20.000 - 20.012 mm (0.7874 - 0.7879 in)
PBIC0120E
EM-106
http://vnx.su
CYLINDER BLOCK
[QR]
A
Measure the outer diameter of piston pin with a micrometer.

Standard: 19.989 - 20.001 mm (0.7870 - 0.7874 in)
EM
PBIC0117E
Connecting Rod Bushing Oil Clearance

(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) (Piston pin outer diameter)
Standard: 0.005 - 0.017 mm (0.0002 - 0.0007 in)
If the measured value is out of the standard, replace connecting rod assembly and/or piston and piston pin
assembly.
If replacing piston and piston pin assembly, refer to EM-108, "PISTON TO CYLINDER BORE CLEARANCE" .
If replacing connecting rod assembly, refer to EM-110, "CONNECTING ROD BEARING OIL CLEARANCE" to select connecting rod bearing.
J
PBIC2196E
Factory installed parts grading:
Service parts apply only to grade 0.

Unit: mm (in)
Grade
Connecting rod bushing
20.000 - 20.006
(0.7874 - 0.7876)
20.006 - 20.012
(0.7876 - 0.7879)
Piston pin hole diameter
19.993 - 19.999
(0.7871 - 0.7874)
19.999 - 20. 005

(0.7874 - 0.7876)
Piston pin outer diameter
19.989 - 19.995
(0.7870 - 0.7872)
19.995 - 20.001
(0.7872 - 0.7874)
inner diameter*
*: After installing in connecting rod.
PBIC2197E
CYLINDER BLOCK DISTORTION
Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon,
or other contamination.
CAUTION:
Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.
EM-107
http://vnx.su
CYLINDER BLOCK
[QR]
Measure the distortion on the cylinder block upper face at some

different points in six directions with a straight edge and feeler
gauge.
Limit: 0.1 mm (0.004 in)
If it exceeds the limit, replace cylinder block.
PBIC0121E
MAIN BEARING HOUSING INNER DIAMETER
Install lower cylinder block without main bearings installed, and

tighten lower cylinder block mounting bolts to the specified
torque. Refer to EM-91, "ASSEMBLY" for the tightening procedure.
Measure the inner diameter of main bearing housing with a bore
gauge.
Standard: 58.944 - 58.968 mm (2.3206 - 2.3216 in)
If out of the standard, replace cylinder block and lower cylinder

block assembly.
NOTE:
Cylinder block cannot be replaced as a single, because it is
machined together with lower cylinder block.
PBIC2012E
PISTON TO CYLINDER BORE CLEARANCE

Cylinder Bore Inner Diameter
Using a bore gauge, measure the cylinder bore for wear, out-ofround and taper at six different points on each cylinder. (X and
Y directions at A, B and C) (Y is in longitudinal direction
of engine)
NOTE:
When determining cylinder bore grade, measure the cylinder
bore at B position.
Standard inner diameter:
89.010 - 89.030 mm (3.5043 - 3.5051 in)
Wear limit:
0.2 mm (0.008 in)
Out-of-round (Difference between X and Y):
0.015 mm (0.0006 in)
Taper limit (Difference between A and C):
0.01 mm (0.0004 in)
SBIA0284E
If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall,
hone or re-bore the cylinder inner wall.
Oversize piston is provided. When using oversize piston, re-bore the cylinder so that the clearance of the
piston to cylinder bore satisfies the standard.
CAUTION:
When using oversize piston, use it for all cylinders with oversize piston rings.
Oversize (OS): 0.2 mm (0.008 in)
EM-108
http://vnx.su
CYLINDER BLOCK
[QR]
Piston Skirt Diameter
A
Measure the outer diameter of piston skirt with a micrometer.

Measure point
: Distance from the top 42.0 mm (1.654 in)
Standard
: 88.990 - 89.010 mm (3.5035 - 3.5043 in)
EM
PBIC0125E
Piston to Cylinder Bore Clearance

E
Calculate by piston skirt diameter and cylinder bore inner diameter (direction X, position B).
(Clearance) = (Cylinder bore inner diameter) (Piston skirt diameter)
Standard
Limit
: 0.010 - 0.030 mm (0.0004 - 0.0012 in)

: 0.08 mm (0.0031 in)
If it exceeds the limit, replace piston and piston pin assembly. Refer to EM-97, "HOW TO SELECT PISTON" .
Re-boring Cylinder Bore

1.
Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter.
H
Re-bored size calculation: D = A + B - C

where,
D: Bored diameter
A: Piston diameter as measured
B: Piston - to - cylinder bore clearance (standard value)
C: Honing allowance 0.02 mm (0.0008 in)
2.
3.
4.
5.
Install lower cylinder block, and tighten mounting bolts to the specified torque. Otherwise, cylinder bores
may be distorted in final assembly. Refer to EM-91, "ASSEMBLY" for the tightening procedure.
Cut cylinder bores.
NOTE:
When any cylinder needs boring, all other cylinders must also be bored.
Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a
time.
Hone cylinders to obtain specified piston to cylinder bore clearance.
Measure the finished cylinder bore for out-of-round and taper.
NOTE:
Measurement should be done after cylinder bore cools down.
CRANKSHAFT MAIN JOURNAL DIAMETER
Measure the outer diameter of crankshaft main journals with a

micrometer.
Standard: 54.955 - 54.979 mm (2.1636 - 2.1645 in) dia.
If out of the standard, measure the main bearing oil clearance.

Then use undersize bearing. Refer to EM-111, "MAIN BEARING
OIL CLEARANCE" .
PBIC0270E
EM-109
http://vnx.su
CYLINDER BLOCK
[QR]
CRANKSHAFT PIN JOURNAL DIAMETER
Measure the outer diameter of crankshaft pin journal with a micrometer.

Standard: 44.956 - 44.974 mm (1.7699-1.7706 in) dia.
If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing.
Refer to EM-110, "CONNECTING ROD BEARING OIL CLEARANCE" .
OUT-OF-ROUND AND TAPER OF CRANKSHAFT
Measure the dimensions at four different points as shown in the

figure on each main journal and pin journal with a micrometer.
Out-of-round is indicated by the difference in dimensions
between X and Y at A and B.
Taper is indicated by the difference in dimension between A
and B at X and Y.
Limit:
Out-of-round (Difference between X and Y)
: 0.005 mm (0.0002 in)
Taper (Difference between A and B)
: 0.005 mm (0.0002 in)
PBIC2203E
If the measured value exceeds the limit, correct or replace crankshaft.

If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then
select main bearing and/or connecting rod bearing. Refer to EM-111, "MAIN BEARING OIL CLEARANCE"
and/or EM-110, "CONNECTING ROD BEARING OIL CLEARANCE" .
CRANKSHAFT RUNOUT
Place a V-block on a precise flat table to support the journals on

the both end of the crankshaft.
Place a dial indicator straight up on the No. 3 journal.
While rotating crankshaft, read the movement of the pointer on
the dial indicator. (Total indicator reading)
Limit:
QR20DE: 0.03 mm (0.0012 in)
QR25DE: 0.05 mm (0.0020 in)
If it exceeds the limit, replace crankshaft.
PBIC2541E
CONNECTING ROD BEARING OIL CLEARANCE

Method by Calculation
Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified torque. Refer to EM-91, "ASSEMBLY" for tightening procedure.
Measure the inner diameter of connecting rod bearing with an
inside micrometer.
(Bearing oil clearance) = (Connecting rod bearing inner diameter) (Crankshaft pin journal diameter)
Standard
Limit
: 0.028 - 0.045 mm (0.0011 - 0.0018 in)

: 0.10 mm (0.0039 in)
If clearance exceeds the limit, select proper connecting rod

bearing according to connecting rod big end diameter and
crankshaft pin journal diameter to obtain specified bearing oil
clearance. Refer to EM-97, "HOW TO SELECT CONNECTING
ROD BEARING" .
Method of Using Plastigage
Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely.
EM-110
http://vnx.su
PBIC1642E
CYLINDER BLOCK
[QR]
Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding
oil holes.
A
Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified torque. Refer to EM-91, "ASSEMBLY" for the tightening procedure.
CAUTION:
EM
Do not rotate crankshaft.
Remove connecting rod cap and bearing, and using the scale on
the plastigage bag, measure the plastigage width.
C
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the Method by Calculation.
D
E
PBIC1149E
MAIN BEARING OIL CLEARANCE

Method by Calculation
Install main bearings to cylinder block and lower cylinder block, and tighten lower cylinder block mounting
bolts to the specified torque. Refer to EM-91, "ASSEMBLY" for the tightening procedure.
Measure the inner diameter of main bearing with a bore gauge.

(Bearing oil clearance) = (Main bearing inner diameter) (Crankshaft main journal diameter)
Standard:
No. 1, 3 and 5 journals
: 0.012 - 0.022 mm (0.0005 - 0.0009 in)
No. 2 and 4 journals
: 0.018 - 0.028 mm (0.0007 - 0.0011 in)
Limit : 0.1 mm (0.004 in)
J
PBIC2204E
If clearance exceeds the limit, select proper main bearing

according to main bearing inner diameter and crankshaft main journal diameter to obtain specified bearing
oil clearance. Refer to EM-99, "HOW TO SELECT MAIN BEARING" .
Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely.
Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding
oil holes.
Install main bearings to cylinder block and lower cylinder block, and tighten lower cylinder block mounting
bolts to the specified torque. Refer to EM-91, "ASSEMBLY" for the tightening procedure.
CAUTION:
Remove lower cylinder block and bearings, and using the scale
on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the Method by Calculation.
PBIC1149E
EM-111
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CYLINDER BLOCK
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MAIN BEARING CRUSH HEIGHT
When lower cylinder block is removed after being tightened to

the specified torque with main bearings installed, the tip end of
bearing must protrude. Refer to EM-91, "ASSEMBLY" for the
tightening procedure.
Standard: There must be crush height.
If the standard is not met, replace main bearings.
SEM502G
CONNECTING ROD BEARING CRUSH HEIGHT
When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings
installed, the tip end of bearing must protrude. Refer to EM-91,
"ASSEMBLY" for the tightening procedure.
Standard
: There must be crush height.
If the standard is not met, replace connecting rod bearings.
PBIC1646E
LOWER CYLINDER BLOCK MOUNTING BOLT OUTER DIAMETER
Perform only with M10 bolts.

Measure the outer diameters (d1 , d2 ) at two positions as
If reduction appears in A range, regard it as d2 .
Limit (d1 d2 ): 0.13 mm (0.0051 in)
If it exceeds the limit (a large difference in dimensions), replace

lower cylinder block mounting bolt with a new one.
PBIC0911E
CONNECTING ROD BOLT OUTER DIAMETER
Measure the outer diameter d at position as shown in the figure.

If reduction appears in a position other than d, regard it as d.
Limit: 7.75 mm (0.3051 in)
When d exceeds the limit (when it becomes thinner), replace

connecting rod bolt with a new one.
PBIC0912E
EM-112
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CYLINDER BLOCK
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FLYWHEEL DEFLECTION (M/T MODELS)
Measure the deflection of flywheel contact surface to clutch with

a dial indicator.
Measure the deflection at 210 mm (8.27 in) dia.
Standard
EM
: 0.45 mm (0.0177 in) or less.
If measured value is out of the standard, replace flywheel.

CAUTION:
When measuring, keep magnetic fields (such as dial indicator
stand) away from signal plate of the rear end of crankshaft.
PBIC2168E
MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS)

CAUTION:
Do not disassemble double mass flywheel.
Movement Amount of Thrust (Fore-and-Aft) Direction
Measure the movement amount of thrust (fore-and-aft) direction when 100 N (10.2 kg, 22 lb) force is
added at the portion of 125 mm (4.92 in) radius from the center of flywheel.
Standard
: 1.3 mm (0.051 in) or less
Movement Amount in Radial (Rotation) Direction

Check the movement amount of radial (rotation) direction with the following procedure:
1. Install a bolt to clutch cover mounting hole, and place a torque wrench on the extended line of the flywheel
center line.
Tighten bolt at a force of 9.8 Nm (1.0 kg-m, 87 in-lb) to keep it from loosening.
2. Put a mating mark on circumferences of the two flywheel
masses without applying any load (Measurement standard
points).
3. Apply a force of 9.8 Nm (1.0 kg-m, 87 in-lb) in each direction,
and mark the movement amount on the mass on the transaxle
side.
4. Measure the dimensions of movement amounts A and B on
circumference of the flywheel on the transaxle side.
Standard: 28.3 mm (1.114 in) or less.
PBIC1263E
EM-113
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SERVICE DATA AND SPECIFICATIONS (SDS)

[QR]

Standard and Limit
PFP:00030
EBS00KNX
GENERAL SPECIFICATIONS
Engine type
QR20DE
QR25DE
Cylinder arrangement
In-line 4
Displacement
cm
Bore and stroke
(cu in)
mm (in)
1,998 (121.92)
2,488 (151.82)
89.0 x 80.3 (3.504 x 3.161)
89.0 x 100.0 (3.504 x 3.937)
Valve arrangement
DOHC
Firing order
1-3-4-2
Number of piston rings
Compression
Oil
Compression ratio
Compression pressure
kPa (bar, kg/cm2 , psi) / 250 rpm
9.0
9.5
Standard
1,190 (11.9, 12.1, 173)
1,250 (12.5, 12.8, 181)
Minimum
990 (9.9, 10.1, 144)
1,060 (10.6, 10.8, 154)
100 (1.0, 1.0, 14)
DRIVE BELT
Tension of drive belt
Auto adjustment by auto-tensioner
INTAKE MANIFOLD AND EXHAUST MANIFOLD

Unit: mm (in)
Items
Surface distortion
Limit
Intake manifold collector (QR25DE)
0.1 (0.004)
Intake manifold (QR25DE)
0.1 (0.004)
Exhaust manifold and three way catalyst assembly
0.3 (0.012)
SPARK PLUG
Unit: mm (in)
Destination
Except Russia
For Russia
Make
NGK
Standard type
LFR5A-11
PLFR5A-11
Hot type
LFR4A-11
PLFR4A-11
Cold type
LFR6A-11
PLFR6A-11
Standard: 1.0 - 1.1 (0.039 - 0.043)
Nominal: 1.1 (0.043)
Spark plug gap
CYLINDER HEAD
Unit: mm (in)
Items
Limit
Head surface distortion
0.1 (0.004)
PBIC0283E
EM-114
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VALVE
Valve Timing
A
Unit: degree
EM
C
Valve timing
PBIC0187E
Engine type
QR20DE
212
236
-4 (26)
60 (30)
QR25DE
224
244
0 (30)
64 (27)
E
e
f
29
41
): Valve timing control ON
Valve Dimensions
Unit: mm (in)
J
SEM188A
Valve head diameter D
Valve length L
Valve stem diameter d
Intake
35.5 - 35.8 (1.398 - 1.409)
Exhaust
30.5 - 30.8 (1.201 - 1.213)
Intake
97.16 (3.8252)
Exhaust
98.82 (3.8905)
Intake
5.965 - 5.980 (0.2348 - 0.2354)
Exhaust
5.955 - 5.970 (0.2344 - 0.2350)
Intake
Valve seat angle
Valve margin T
4515 - 4545
Exhaust
Intake
1.1 (0.043)
Exhaust
1.3 (0.051)
Valve Clearance
Unit: mm (in)
Items
Cold
Hot* (reference data)
Intake
0.24 - 0.32 (0.009 - 0.013)
0.304 - 0.416 (0.012 - 0.016)
Exhaust
0.26 - 0.34 (0.010 - 0.013)
0.308 - 0.432 (0.012 - 0.017)
*: Approximately 80C (176F)
EM-115
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Available Valve Lifter
Thickness
mm (in)
Identification mark
KBIA0119E
6.96 (0.2740)
696
6.98 (0.2748)
698
7.00 (0.2756)
700
7.02 (0.2764)
702
7.04 (0.2772)
704
7.06 (0.2780)
706
7.08 (0.2787)
708
7.10 (0.2795)
710
7.12 (0.2803)
712
7.14 (0.2811)
714
7.16 (0.2819)
716
7.18 (0.2827)
718
7.20 (0.2835)
720
7.22 (0.2843)
722
7.24 (0.2850)
724
7.26 (0.2858)
726
7.28 (0.2866)
728
7.30 (0.2874)
730
7.32 (0.2882)
732
7.34 (0.2890)
734
7.36 (0.2898)
736
7.38 (0.2906)
738
7.40 (0.2913)
740
7.42 (0.2921)
742
744 (0.2929)
744
7.46 (0.2937)
746
Valve Spring
Free height
mm (in)
Pressure
N (kg, lb) at height mm (in)
Squareness
mm (in)
Standard
Standard
Intake
44.84 - 45.34 (1.7654 - 1.7850)
Exhaust
45.28 - 45.78 (1.7827 - 1.8024)
Intake and exhaust
Limit
151 - 175 (15.4 - 17.8, 34 - 39) at 35.30 (1.390)

1.9 (0.075)
EM-116
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Valve Lifter
Unit: mm (in)
Items
Standard
Valve lifter outer diameter
33.965 - 33.980 (1.3372 - 1.3378)
Valve lifter hole diameter
34.000 - 34.021 (1.3386 - 1.3394)
Valve lifter clearance
EM
0.020 - 0.056 (0.0008 - 0.0022)
Valve Guide
C
Unit: mm (in)
PBIC0184E
Items
Outer diameter
Valve guide
Standard part
Service part
10.023 - 10.034 (0.3946 - 0.3950)
10.223 - 10.234 (0.4025 - 0.4029)
Inner diameter (Finished size)
Cylinder head valve guide hole diameter

Interference fit of valve guide
Projection length L
10.175 - 10.196 (0.4006 - 0.4014)
0.027 - 0.059 (0.0011 - 0.0023)
Items
Valve guide clearance
6.000 - 6.018 (0.2362 - 0.2369)

9.975 - 9.996 (0.3927 - 0.3935)
Standard
Limit
Intake
0.020 - 0.053 (0.0008 - 0.0021)
0.08 (0.003)
Exhaust
0.030 - 0.063 (0.0012 - 0.0025)
0.09 (0.004)
Intake
10.1 - 10.3 (0.398 - 0.406)
Exhaust
10.0 - 10.4 (0.394 - 0.409)
EM-117
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Valve Seat
Unit: mm (in)
PBIC2397E
Items
Cylinder head seat recess diameter D
Valve seat outer diameter d
Standard
Oversize [0.5 (0.02)] (Service)
Intake
36.500 - 36.516 (1.4370 - 1.4376)
37.000 - 37.016 (1.4567 - 1.4573)
Exhaust
31.500 - 31.516 (1.2402 - 1.2408)
32.000 - 32.016(1.2598 - 1.2605)
Intake
36.597 - 36.613 (1.4408 - 1.4415)
37.097 - 37.113 (1.4605 - 1.4611)
Exhaust
31.600 - 31.616 (1.2441 - 1.2447)
32.100 - 32.116 (1.2638 - 1.2644)
Intake
Valve seat interference fit
0.081 - 0.113 (0.0032 - 0.0044)
Exhaust
Items
Height h
0.084 - 0.116 (0.0033 - 0.0046)

Standard
Service
Intake
5.9 - 6.0 (0.232 - 0.236)
5.0 - 5.1 (0.197 - 0.201)
Exhaust
5.9 - 6.0 (0.232 - 0.236)
4.91 - 5.01 (0.1933 - 0.1972)
Depth H
6.0 (0.236)
CAMSHAFT AND CAMSHAFT BEARING

Unit: mm (in)
Items
Camshaft runout [TIR*]
Standard
Limit
Less than 0.02 (0.0008)
SEM671
Intake
Camshaft journal oil clearance
QR25DE
45.665 - 45.855 (1.7978 - 1.8053)
42.825 - 43.015 (1.6860 - 1.6935)
QR25DE
43.975 - 44.165 (1.7313 - 1.7388)
No. 1
27.935 - 27.955 (1.0998 - 1.1006)
No. 2, 3, 4, 5
23.435 - 23.455 (0.9226 - 0.9234)
No. 1
28.000 - 28.021 (1.1024 - 1.1032)
No. 2, 3, 4, 5
23.500 - 23.521 (0.9252 - 0.9260)
0.045 - 0.086 (0.0018 - 0.0034)
Exhaust
Camshaft bracket inner diameter
45.015 - 45.205 (1.7722 - 1.7797)
QR20DE
Camshaft cam height A
Camshaft journal outer diameter
QR20DE
EM-118
http://vnx.su

[QR]
Items
Camshaft end play
Standard
Limit
0.115 - 0.188 (0.0045 - 0.0074)
0.15 (0.0059)
Camshaft sprocket runout [TIR*]
*: Total indicator reading
EM
CYLINDER BLOCK
Unit: mm (in)
F
PBIC0281E
Surface distortion
Cylinder bore
Limit
Inner diameter
Standard
0.1 (0.004)
Grade No. 2
89.010 - 89.020 (3.5043 - 3.5047)
Grade No. 3
89.020 - 89.030 (3.5047 - 3.5051)
Wear limit
0.2 (0.008)

Taper (Difference between A and C)
0.015 (0.0006)
Limit
Difference in inner diameter between cylinders
0.01 (0.0004)
Grade No. A
Grade No. B
Grade No. C
Grade No. D
Grade No. E
Grade No. F
Grade No. G
Grade No. H
Grade No. J
Grade No. K
Grade No. L
Grade No. M
Grade No. N
Grade No. P
Grade No. R
Grade No. S
Grade No. T
Grade No. U
Grade No. V
Grade No. W
Grade No. X
Grade No. Y
Grade No. 4
Grade No. 7
Main bearing housing inner diameter grade
Standard
58.944 - 58.945 (2.3206 - 2.3207)

58.945 - 58.946 (2.3207 - 2.3207)
58.946 - 58.947 (2.3207 - 2.3207)
58.947 - 58.948 (2.3207 - 2.3208)
58.948 - 58.949 (2.3208 - 2.3208)
58.949 - 58.950 (2.3208 - 2.3209)
58.950 - 58.951 (2.3209 - 2.3209)
58.951 - 58.952 (2.3209 - 2.3209)
58.952 - 58.953 (2.3209 - 2.3210)
58.953 - 58.954 (2.3210 - 2.3210)
58.954 - 58.955 (2.3210 - 2.3211)
58.955 - 58.956 (2.3211 - 2.3211)
58.956 - 58.957 (2.3211 - 2.3211)
58.957 - 58.958 (2.3211 - 2.3212)
58.958 - 58.959 (2.3212 - 2.3212)
58.959 - 58.960 (2.3212 - 2.3213)
58.960 - 58.961 (2.3213 - 2.3213)
58.961 - 58.962 (2.3213 - 2.3213)
58.962 - 58.963 (2.3213 - 2.3214)
58.963 - 58.964 (2.3214 - 2.3214)
58.964 - 58.965 (2.3214 - 2.3215)
58.965 - 58.966 (2.3215 - 2.3215)
58.966 - 58.967 (2.3215 - 2.3215)
58.967 - 58.968 (2.3215 - 2.3216)
Less than 0.03 (0.0012)
EM-119
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PISTON, PISTON RING AND PISTON PIN
Available Piston
Unit: mm (in)
PBIC0188E
Piston skirt diameter A
Standard
Grade No. 2
88.990 - 89.000 (3.5035 - 3.5039)
Grade No. 3
89.000 - 89.010 (3.5039 - 3.5043)
0.20 (0.008) oversize (Service)
89.180 - 89.210 (3.5110 - 3.5122)
Grade No. 0
19.993 - 19.999 (0.7871 - 0.7874)
Grade No. 1
19.999 - 20.005 (0.7874 - 0.7876)
Piston height H dimension

Piston pin hole diameter
Piston to cylinder bore clearance
42.0 (1.654)
Standard
0.010 - 0.030 (0.0004 - 0.0012)
Limit
0.08 (0.0031)
Piston Ring
Unit: mm (in)
Items
Side clearance
End gap
Standard
Limit
Top
0.045 - 0.080 (0.0018 - 0.0031)
0.11 (0.0043)
2nd
0.030 - 0.070 (0.0012 - 0.0028)
0.10 (0.0039)
Oil ring
0.065 - 0.135 (0.0026 - 0.0053)
Top
0.21- 0.31 (0.0083 - 0.0122)
0.54 (0.0213)
2nd
0.32 - 0.47 (0.0126 - 0.0185)
0.67 (0.0264)
Oil (rail ring)
0.20 - 0.60 (0.0079 - 0.0236)
0.95 (0.0374)
Piston Pin
Unit: mm (in)
Grade No. 0
19.989 - 19.995 (0.7870 - 0.7872)
Grade No. 1
19.995 - 20.001 (0.7872 - 0.7874)
Piston to piston pin oil clearance
Standard
0.002 - 0.006 (0.0001 - 0.0002)
Standard
0.005 - 0.017 (0.0002 - 0.0007)
EM-120
http://vnx.su

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CONNECTING ROD
Unit: mm (in)
Center distance
QR20DE
152.85 - 152.95 (6.018 - 6.022)
QR25DE
143.00 - 143.10 (5.630 - 5.634)
Bend [per 100 (3.94)]
Limit
0.15 (0.0059)
Torsion [per 100 (3.94)]
Limit
0.30 (0.0118)
Connecting rod bushing inner diameter*
Connecting rod big end diameter
EM
Grade No. 0
20.000 - 20.006 (0.7874 - 0.7876)
Grade No. 1
20.006 - 20.012 (0.7876 - 0.7879)
Standard
Side clearance
0.20 - 0.35 (0.0079 - 0.0138)
Limit
0.50 (0.0197)
Grade No. 0
Grade No. 1
Grade No. 2
Grade No. 3
Grade No. 4
Grade No. 5
Grade No. 6
Grade No. 7
Grade No. 8
Grade No. 9
Grade No. A
Grade No. B
Grade No. C
48.000 - 48.001 (1.8898 - 1.8898)

48.001 - 48.002 (1.8898 - 1.8898)
48.002 - 48.003 (1.8898 - 1.8899)
48.003 - 48.004 (1.8899 - 1.8899)
48.004 - 48.005 (1.8899 - 1.8900)
48.005 - 48.006 (1.8900 - 1.8900)
48.006 - 48.007 (1.8900 - 1.8900)
48.007 - 48.008 (1.8900 - 1.8901)
48.008 - 48.009 (1.8901- 1.8901)
48.009 - 48.010 (1.8901- 1.8902)
48.010 - 48.011 (1.8902 - 1.8902)
48.011 - 48.012 (1.8902 - 1.8902)
48.012 - 48.013 (1.8902 - 1.8903)
*: After installing in connecting rod
CRANKSHAFT
Unit: mm (in)
L
SBIA0535E
SEM645
Center distance r
QR20DE
40.11 - 40.19 (1.5791 - 1.5823)
QR25DE
49.96 - 50.04 (1.9669 - 1.9701)
Limit
Limit
Runout [TIR*]
Limit
0.005 (0.0002)
0.005 (0.0002)
QR20DE
0.03 (0.0012)
QR25DE
0.05 (0.0020)
Standard
Crankshaft end play
0.10 - 0.26 (0.0039 - 0.0102)
Limit
0.30 (0.0118)
EM-121
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Pin journal diameter grade. DP
Grade No. A
Grade No. B
Grade No. C
Grade No. D
Grade No. E
Grade No. F
Grade No. G
Grade No. H
Grade No. J
Grade No. K
Grade No. L
Grade No. M
Grade No. N
Grade No. P
Grade No. R
Grade No. S
Grade No. T
Grade No. U
44.974 - 44.973 (1.7706 - 1.7706)

44.973 - 44.972 (1.7706 - 1.7705)
44.972 - 44.971 (1.7705 - 1.7705)
44.971 - 44.970 (1.7705 - 1.7705)
44.970 - 44.969 (1.7705 - 1.7704)
44.969 - 44.968 (1.7704 - 1.7704)
44.968 - 44.967 (1.7704 - 1.7704)
44.967 - 44.966 (1.7704 - 1.7703)
44.966 - 44.965 (1.7703 - 1.7703)
44.965 - 44.964 (1.7703 - 1.7702)
44.964 - 44.963 (1.7702 - 1.7702)
44.963 - 44.962 (1.7702 - 1.7702)
44.962 - 44.961 (1.7702 - 1.7701)
44.961 - 44.960 (1.7701 - 1.7701)
44.960 - 44.959 (1.7701 - 1.7700)
44.959 - 44.958 (1.7700 - 1.7700)
44.958 - 44.957 (1.7700 - 1.7700)
44.957 - 44.956 (1.7700 - 1.7699)
Main journal diameter grade. Dm
Grade No. A
Grade No. B
Grade No. C
Grade No. D
Grade No. E
Grade No. F
Grade No. G
Grade No. H
Grade No. J
Grade No. K
Grade No. L
Grade No. M
Grade No. N
Grade No. P
Grade No. R
Grade No. S
Grade No. T
Grade No. U
Grade No. V
Grade No. W
Grade No. X
Grade No. Y
Grade No. 4
Grade No. 7
54.979 - 54.978 (2.1645 - 2.1645)

54.978 - 54.977 (2.1645 - 2.1644)
54.977 - 54.976 (2.1644 - 2.1644)
54.976 - 54.975 (2.1644 - 2.1644)
54.975 - 54.974 (2.1644 - 2.1643)
54.974 - 54.973 (2.1643 - 2.1643)
54.973 - 54.972 (2.1643 - 2.1642)
54.972 - 54.971 (2.1642 - 2.1642)
54.971 - 54.970 (2.1642 - 2.1642)
54.970 - 54.969 (2.1642 - 2.1641)
54.969 - 54.968 (2.1641 - 2.1641)
54.968 - 54.967 (2.1641 - 2.1641)
54.967 - 54.966 (2.1641 - 2.1640)
54.966 - 54.965 (2.1640 - 2.1640)
54.965 - 54.964 (2.1640 - 2.1639)
54.964 - 54.963 (2.1639 - 2.1639)
54.963 - 54.962 (2.1639 - 2.1639)
54.962 - 54.961 (2.1639 - 2.1638)
54.961 - 54.960 (2.1638 - 2.1638)
54.960 - 54.959 (2.1638 - 2.1637)
54.959 - 54.958 (2.1637 - 2.1637)
54.958 - 54.957 (2.1637 - 2.1637)
54.957 - 54.956 (2.1637 - 2.1636)
54.956 - 54.955 (2.1636 - 2.1636)
EM-122
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MAIN BEARING
Unit: mm (in)
EM
D
SEM685D
Grade number
Thickness
1.973 - 1.976 (0.0777 - 0.0778)
Black
1.976 - 1.979 (0.0778 - 0.0779)
Brown
1.979 - 1.982 (0.0779 - 0.0780)
Green
1.982 - 1.985 (0.0780 - 0.0781)
Yellow
1.985 - 1.988 (0.0781 - 0.0783)
Blue
1.988 - 1.991 (0.0783 - 0.0784)
Pink
1.991 - 1.994 (0.0784 - 0.0785)
Purple
1.994 - 1.997 (0.0785 - 0.0786)
White
UPR
1.973 - 1.976 (0.0777 - 0.0778)
Black
LWR
1.976 - 1.979 (0.0778 - 0.0779)
Brown
UPR
1.976 - 1.979 (0.0778 - 0.0779)
Brown
LWR
1.979 - 1.982 (0.0779 - 0.0780)
Green
01
12
23
34
45
56
67
UPR
1.979 - 1.982 (0.0779 - 0.0780)
Green
LWR
1.982 - 1.985 (0.0780 - 0.0781)
Yellow
UPR
1.982 - 1.985 (0.0780 - 0.0781)
Yellow
LWR
1.985 - 1.988 (0.0781 - 0.0783)
Blue
UPR
1.985 - 1.988 (0.0781 - 0.0783)
Blue
LWR
1.988 - 1.991 (0.0783 - 0.0784)
Pink
UPR
1.988 - 1.991 (0.0783 - 0.0784)
Pink
LWR
1.991 - 1.994 (0.0784 - 0.0785)
Purple
UPR
1.991 - 1.994 (0.0784 - 0.0785)
Purple
LWR
1.994 - 1.997 (0.0785 - 0.0786)
White
Remarks
F
Grade and color are the same
J
Grade and color are different
Unit: mm (in)
Item
Thickness
Main journal diameter
US 0.25 (0.0098)
2.106 - 2.114 (0.0829 - 0.0832)
Grind so that bearing clearance is the specified value.
Bearing Oil Clearance

Unit: mm (in)
No. 1, 3 and 5
0.012 - 0.022 (0.0005 - 0.0009)
No. 2 and 4
0.018 - 0.028 (0.0007 - 0.0011)
Limit
0.1 (0.004)
EM-123
http://vnx.su
Undersize
Standard

[QR]
CONNECTING ROD BEARING
Grade number
Thickness
mm (in)
1.495 - 1.499 (0.0589 - 0.0590)
Black
1.499 - 1.503 (0.0590 - 0.0592)
Brown
1.503 - 1.507 (0.0592 - 0.0593)
Green
1.507 - 1.511(0.0593 - 0.0595)
Yellow
Undersize
Unit: mm (in)
Item
Thickness
Crank pin journal diameter
US 0.25 (0.0098)
1.624 - 1.632 (0.0639 - 0.0643)
Grind so that bearing clearance is the specified value.

Unit: mm (in)
Standard
0.028 - 0.045 (0.0011 - 0.0018)
Connecting rod bearing oil clearance

Limit
0.10 (0.0039)
Tightening Torque
EBS00KNY
Unit: Nm (kg-m, ft-lb)

Unit: Nm (kg-m, in-lb)*2
*1: Parts to be tightened in particular orders.
1)-: Order of tightening when tightening two or more times separately.
*1
Drive belt auto-tensioner
21.6 (2.2, 16)
3.8 (0.39, 34) *2
Resonator
3.8 (0.39, 34)*2
Air cleaner case lower
3.8 (0.39, 34)*2
Intake manifold
19.6 (2.0, 14)
Intake manifold collector (QR25DE)
19.6 (2.0, 14)
Intake manifold support (QR20DE)
19.6 (2.0, 14)
Intake manifold support (QR25DE)
*1
*1
*1
M6 bolt
8.83 (0.90, 78) *2
M10 bolt
46.6 (4.8, 34)
Intake manifold rear support (QR25DE)
19.6 (2.0, 14)
8.43 (0.86, 75) *2
EVAP canister purge volume control solenoid valve
5.1 (0.52, 45) *2
Exhaust manifold and three way catalyst assembly
41.7 (4.3, 31)
Exhaust manifold covers (upper and lower)
5.8 (0.59, 51) *2
Three way catalyst cover
5.8 (0.59, 51) *2
45 (4.6, 33)
45 (4.6, 33)
Oil pan upper
M6 bolt
8.8 (0.90, 78) *2
M8 bolt
21.6 (2.2, 16)
Oil pan upper to transaxle joint bolts
42.7 (4.4, 31)
Oil pan lower
6.9 (0.70, 61) *2
Oil pan drain plug
34.3 (3.5, 25)
Rear plate cover
6.9 (0.70, 61) *2
21.6 (2.2, 16)
EM-124
http://vnx.su

[QR]
Oil strainer
*1
*1
*1
*1
M6 bolt
8.8 (0.90, 78) *2
M8 bolt
21.6 (2.2, 16)
Ignition coil
6.4 (0.65, 57) *2
Spark plug
24.5 (2.5, 18)
Fuel tube
Rocker cover
*1
*1
2)
23.6 (2.4, 17)
1)
2.0 (0.20, 18) *2
2)
8.3 (0.85, 73) *2

2.5 (0.26, 22) *2
Intake valve timing control solenoid valve
6.4 (0.65, 57) *2
Intake valve timing control cover
12.8 (1.3, 9)
Camshaft position sensor (PHASE)
6.4 (0.65, 57) *2
Camshaft sprockets (Intake and Exhaust)
142 (14, 105)
Chain tensioner
7.0 (0.71, 62) *2
Camshaft bracket
1)
2.0 (0.2, 1)
2)
5.9 (0.6, 4)
3)
10.4 (1.1, 8)
1)
42.1 (4.3, 31)
2)
60 (Angle tightening)
Front cover
12.8 (1.3, 9)
Timing chain slack guide
16.7 (1.7, 12)
Timing chain tension guide
16.7 (1.7, 12)
Balancer unit timing chain tensioner
7.0 (0.71, 62) *2
Balancer unit
Cylinder head
1)
48.1 (4.9, 35)
2)
3)
0 (0, 0)
4)
48.1 (4.9, 35)
5)
1)
50 (5.1, 37)
2)
3)
0 (0.0, 0)
3)
39.2 (4.0, 29)
4)
5)
Flywheel (M/T)
108 (11, 80)
Drive plate (A/T)
108 (11, 80)
Connecting rod bearing cap
*1
10.1 (1.0, 7)
PCV valve
Crankshaft pulley
*1
1)
Lower cylinder block
1)
19.6 (2.0, 14)
2)
M8 bolt
1)
25.1 (2.6, 19)
M10 bolt
2)
39.2 (4.0, 29)
M10 bolt
3)
Signal plate
18.5 (1.9, 14)
Water drain plug
9.8 (1.0, 87) *2
EM-125
http://vnx.su
EM

[QR]
Knock sensor
21.1 (2.2, 16)
6.4 (0.65, 57) *2
EM-126
http://vnx.su
PRECAUTIONS
[YD22DDTi]
PRECAUTIONS
Precautions for Draining Engine Coolant
[YD22DDTi]
PFP:00001
A
EBS00LQZ
Drain engine coolant when engine is cooled.
Precautions for Disconnecting Fuel Piping
Before starting work, make sure no fire or spark producing items are in the work area.
After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and Disassembly
EM
EBS00LR0
C
EBS00LR1
When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.
Exercise maximum care to avoid damage to mating or sliding surfaces.
Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Precautions for Inspection, Repair and Replacement
EBS00LR4
Use an angle wrench (special service tool: KV10112100) for the final tightening of the following engine
parts:
Cylinder head bolts
Main bearing cap bolts
Connecting rod cap nuts
Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angle
tightening)
Do not use a torque value for final tightening.
The torque value for these parts are for a preliminary step.
Ensure thread and seat surfaces are clean and coated with engine oil.
EM-127
http://vnx.su
EBS00LR3
Use torque wrench to tighten bolts or nuts to specification.

When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly as specified.
Replace with new liquid gasket, packing, oil seal or O-ring.
Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,
make sure that dowel pins are installed in the original position.
Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage.
Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, engine oil sliding surfaces well.
Release air within route when refilling after draining coolant.
After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust systems for leakage.
Parts Requiring Angle Tightening
EBS00LR2
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precautions for Assembly and Installation
PRECAUTIONS
[YD22DDTi]
Precautions For Liquid Gasket
EBS00ODW
REMOVAL OF LIQUID GASKET
After removing the mounting bolts and nuts, separate the mating
surface using the seal cutter (special service tool) and remove
the old liquid gasket sealing.
CAUTION:
Be careful not to damage the mating surfaces.
Tap seal cutter to insert it (1), and then slide it (2) by tapping on
the side as shown in the figure.
In areas where seal cutter is difficult to use, use plastic hammer
to lightly tap the areas where the liquid gasket is applied.
CAUTION:
If for some unavoidable reason tool such as screwdriver is
used, be careful not to damage the mating surfaces.
PBIC0275E

1.
2.
Using a scraper, remove the old liquid gasket adhering to the liquid gasket application surface and the mating surface.
Remove the liquid gasket completely from the groove of the
liquid gasket application surface, mounting bolts and bolt
holes.
Wipe the liquid gasket application surface and the mating surface with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
PBIC0003E
3.
4.
Attach the liquid gasket tube to the tube presser (special service
tool).
Apply the liquid gasket without breaks to the specified location
with the specified dimensions.
If there is a groove for the liquid gasket application, apply the
liquid gasket to the groove.
PBIC2160E
As for the bolt holes, normally apply the liquid gasket inside
the holes. If specified, it should be applied outside the holes.
Make sure to read the instruction in this manual.
Do not retighten after the installation.
After 30 minutes or more have passed from the installation, fill
the engine oil and engine coolant.
CAUTION:
If there are instructions in this manual, observe them.
EM-128
http://vnx.su
SEM159F
PREPARATION
[YD22DDTi]
PREPARATION
PFP:00002
A
EBS00LR6
Tool number
Tool name
Description
ST0501S000
Engine stand assembly
1. ST05011000
Engine stand
2. ST05012000
Base
EM
Disassembling and assembling
D
NT042
KV10106500
Engine stand shaft
F
NT028
KV11105900
Engine sub-attachment
Used with KV10106500
H
NT799
KV10115600
Valve oil seal drift
NT603
KV10107902
Valve oil seal puller
1. KV10116100
Valve oil seal puller adapter
Installing valve oil seal

Use side A.
Side A
a: 20 (0.79) dia.
b: 13 (0.51) dia.
c: 10.3 (0.406) dia.
d: 8 (0.31) dia.
e: 10.7 (0.421)
f: 5 (0.20)
Unit: mm (in)
Removing valve oil seal
M
S-NT605
KV11103000
Pulley puller
Removing crankshaft pulley
NT676
ED19600610
Compression gauge adapter
Checking compression pressure
ZZA1188D
EM-129
http://vnx.su
PREPARATION
[YD22DDTi]
Tool number
Tool name
Description
KV101056S0
Ring gear stopper
1. KV10105630
Adapter
2. KV10105610
Plate
NT617
KV101151S0
Lifter stopper set
1. KV10115110
Camshaft pliers
2. KV10115120
Lifter stopper
Preventing crankshaft from rotating

a: 3 (0.12)
b: 6.4 (0.252)
c: 2.8 (0.110)
d: 6.6 (0.260)
e: 107 (4.21)
f: 14 (0.55)
g: 20 (0.79)
h: 14 (0.55) dia.
Unit: mm (in)
Changing adjusting shim
NT041
KV10116200
Valve spring compressor
1. KV10115900
Attachment
2. KV10109220
Adapter
Disassembling and assembling valve

mechanism
Part (1) is a component of KV10116200, but
Part (2) is not so.
PBIC1650E
ST16610001
Pilot bushing puller
Removing crankshaft pilot bush
NT045
KV10111100
Seal cutter
Removing steel oil pan and rear chain case,

etc.
NT046
WS39930000
Tube presser
NT052
KV10112100
Angle wrench
Tightening bolts for bearing cap, cylinder

head, etc.
NT014
EM-130
http://vnx.su
PREPARATION
[YD22DDTi]
Tool number
Tool name
Description
EM03470000
Piston ring compressor
Installing piston assembly into cylinder bore
EM
C
NT044
KV10109300
Pulley holder
Fixing crankshaft pulley

a: 68 mm (2.68 in)
b: 8 mm (0.31 in) dia.
E
NT628
KV11106010
Hexagon wrench
Removing and installing chain tensioner

a: 5 mm (0.20 in) (Face to face)
b: 20 mm (0.79 in)
NT801
KV11106020
Hexagon wrench
Removing and installing slack guide

b: 20 mm (0.79 in)
NT803
KV11106030
Positioning stopper pin
Fixing fuel pump sprocket

a: 6 mm (0.24 in) dia.
b: 80 mm (3.15 in)
L
NT804
KV11106040
TORX wrench
Removing and installing fuel pump sprocket

nut
a: T70
b: 26 mm (1.02 in)
NT805
EM-131
http://vnx.su
PREPARATION
[YD22DDTi]
Tool number
Tool name
Description
KV11106050
Hexagonal wrench
Removing and installing fuel pump sprocket

b: 42 mm (1.65 in)
SBIA0224E
KV11106060
Sprocket holder
Holding fuel pump sprocket
SBIA0225E
EM-132
http://vnx.su
PREPARATION
[YD22DDTi]
EBS00LR7
A
Tool name
Description
Valve seat cutter set
Finishing valve seat dimensions
EM
C
NT048
Piston ring expander
Removing and installing piston ring
NT030
Manual lift table caddy
Removing and installing engine
ZZA1210D
Valve guide reamer
Reaming valve guide with (1) or hole for

oversize valve guide with (2)
Intake and Exhaust:
d1 = 6.0 mm (0.236 in) dia.
d2 = 10.2 mm (0.402 in) dia.
J
NT016
Valve guide drift
Removing and installing valve guide

Intake and Exhaust:
a = 9.5 mm (0.374 in) dia.
b = 5.5 mm (0.217 in) dia.
L
NT015
TORX socket
Removing and installing flywheel

Size: T55
PBIC1113E
EM-133
http://vnx.su
PREPARATION
[YD22DDTi]
Tool name
Description
Cylinder head bolt wrench
Loosening and tightening cylinder head bolt,

and used with angle wrench [SST:
KV10112100]
a: 13 (0.51) dia.
b: 12 (0.47)
c: 10 (0.39)
Unit: mm (in)
NT583
TORX socket
Loosening and tightening main bearing cap

bolt
Size: E14
NT807
EM-134
http://vnx.su

[YD22DDTi]

NVH Troubleshooting Engine Noise
PFP:00003
A
EBS00LR8
EM
PBIC2311E
EM-135
http://vnx.su

[YD22DDTi]
Use the Chart Below to Help You Find the Cause of the Symptom.
EBS00LR9
1. Locate the area where noise occurs.

2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
Operating condition of engine
Location
of noise
Top of
engine
Rocker
cover
Cylinder
head
Type of
noise
Front of
engine
Timing
chain
case
Front of
engine
Reference page
After
warmup
When
starting
When
idling
When
racing
While
driving
Ticking or
clicking
Tappet
noise
Valve clearance
EM-182
Rattle
Camshaft
bearing
noise
Camshaft oil clearance

Camshaft runout
EM-179
EM-178
Piston pin
noise
Piston to piston pin

clearance
EM-239
EM-241
Piston
slap noise
Piston to cylinder bore

clearance
Piston ring side clearance
Piston ring end gap
Connecting rod bend
and torsion
EM-243
EM-240
EM-240
EM-241

Connecting rod bearing oil clearance (Big
end)
EM-241
EM-245
Slap or
knock
Crankshaft pulley
Cylinder
block
(Side of
engine)
Oil pan
Source of
noise
Before
warmup
Slap or
rap
Check item
Knock
Connecting rod
bearing
noise
Knock
Main
bearing
noise

Crankshaft runout
EM-246
EM-245
Timing
chain and
chain tensioner
noise
Timing chain cracks

and wear
Timing chain tensioner
operation
EM-190
EM-195
Drive belts
(Sticking
or slipping)
Drive belts deflection
Tapping or
ticking
Squeaking or fizzing
Creaking
Drive belts
(Slipping)
Idler pulley bearing

operation
Squall
Creak
Water
pump
noise
Water pump operation
A: Closely related
B: Related
C: Sometimes related
: Not related
EM-136
http://vnx.su
EM-137
CO-43,
"WATER
PUMP"
DRIVE BELTS
[YD22DDTi]
DRIVE BELTS
Checking Drive Belts
PFP:02117
A
EBS00LRA
Before inspecting engine, make sure engine has cooled down;

wait approximately 30 minutes after engine has been stopped.
Visually inspect all belts for wear, damage or cracks on contacting surfaces and edge areas.
When measuring deflection, apply 98 N (10 kg, 22 lb) at the
marked point ( ).
CAUTION:
When checking belt deflection immediately after installation, first adjust it to the specified value. Then, after turning crankshaft two turns or more, re-adjust to the
specified value to avoid variation in deflection between
pulleys.
Tighten idler pulley lock nut by hand and measure deflection without looseness.
EM
D
PBIC1251E
Belt Deflection:
F
Belt deflection with 98 N (10 kg, 22 lb) force applied* mm (in)
Applied belt
A/C compressor belt
Alternator and water pump belt
New
Adjusted
Limit for re-adjusting
4 - 5 (0.16 - 0.20)
6 - 7 (0.24 - 0.28)
8.5 (0.335)
9.0 - 10.5 (0.354 - 0.413)
11.0 - 12.5 (0.433 - 0.492)
16.5 (0.650)
*: When engine is cold.
Tension Adjustment
EBS00LRB
Adjust belts with the parts shown below.
Applied belt
Belt adjustment method
A/C compressor belt
Adjusting bolt on idler pulley
Adjusting bolt on alternator
CAUTION:
When a new belt is installed as a replacement, adjust it to the specified value under New value
because of insufficient adaptability with pulley grooves.
If the belt deflection of the current belt is out of the Limit for re-adjusting, adjust to the
Adjusted value.
When checking belt deflection immediately after installation, first adjust it to the specified value.
Then, after turning crankshaft two turns or more, re-adjust it to the specified value to avoid variation in deflection between pulleys.
Make sure the belts are fully fitted into the pulley grooves during installation.
Handle with care to avoid smearing the belts with engine oil or engine coolant.
Do not twist or bend the belts with strong force.
EM-137
http://vnx.su
DRIVE BELTS
[YD22DDTi]
A/C COMPRESSOR BELT
1.
2.
3.
4.
Remove RH engine undercover.

Loosen idler pulley lock nut (A).
Turn adjusting bolt (B) to adjust. Refer to EM-137, "Checking
Drive Belts" .
Tighten lock nut (A).
Nut A:
: 35 Nm (3.6 kg-m, 26 ft-lb)
PBIC1252E
ALTERNATOR AND WATER PUMP BELT

1.
2.
3.
4.
Loosen adjusting lock nut (C).

Loosen alternator fixing bolts (D) (each on front and rear).
Turn adjusting bolt (E) to adjust. Refer to EM-137, "Tension Adjustment" .
Tighten nut (C) and bolt (D) in this order.
Nut C:
: 21.5 Nm (2.2 kg-m, 16 ft-lb)
Bolt D:
: 50.5 Nm (5.2 kg-m, 37 ft-lb)
EBS00LRC
REMOVAL
1.
2.
3.
Loosen each belt. Refer to EM-137, "Tension Adjustment" .

Remove A/C compressor belt. Refer to EM-138, "A/C COMPRESSOR BELT" .
Remove alternator and water pump belt. Refer to EM-138, "ALTERNATOR AND WATER PUMP BELT" .
INSTALLATION
1.
2.
3.
4.
Install each belt on pulley in the reverse order of removal.

Adjust belt tension. Refer to EM-137, "Tension Adjustment" .
Tighten nuts and bolts provided for adjustment to the specified torque.
Make sure again that each belt tension is as specified.
EM-138
http://vnx.su

[YD22DDTi]

PFP:16500
A
EBS00LRD
EM
PBIC3612E
1.
Air cleaner case (upper)
2.
4.
7.
Collar
10. Clip
Clamp
3.
Air duct
5.
Grommet
6.
Air duct side
8.
Mounting rubber
9.
Air cleaner case (lower)
11.
Air cleaner filter
REMOVAL
1.
2.
3.
4.
5.
Remove mass air flow sensor harness clamp.

Disconnect harness connector from mass air flow sensor.
Remove air duct, air cleaner case (upper)/ mass air flow sensor.
Remove mass air flow sensor from air cleaner case (upper).
CAUTION:
Handle mass air flow sensor with following cares.
Do not shock it.
Do not disassemble it.
Do not touch its sensor.
Remove air cleaner case (lower) and air duct side.
INSTALLATION
EM-139
http://vnx.su

[YD22DDTi]
CHANGING AIR CLEANER FILTER
Removal
1.
2.
Unfasten clips and lift up air cleaner case (upper).

Remove air cleaner filter.
Installation
EM-140
http://vnx.su
CHARGE AIR COOLER

[YD22DDTi]
CHARGE AIR COOLER

PFP:14461
A
EBS00LRE
EM
I
PBIC2580E
1.
Charge air cooler cover
2.
Charge air cooler
3.
Gasket
4.
Air inlet tube
5.
Clamp
6.
Air inlet hose
7.
Bottom bracket
8.
Turbocharger boost control solenoid

valve
REMOVAL
1.
2.
3.
Remove charge air cooler cover.

Disconnect harness connector from turbocharger boost control solenoid valve.
Remove air inlet tube and air inlet hose.
4. Remove charge air cooler.
5. Remove air inlet tube from charge air cooler.
6. Remove turbocharger boost control solenoid valve if necessary.
CAUTION:
When removing charge air cooler, close opening on turbocharger and on intake manifold with shop
cloth or other suitable material.

Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace
charge air cooler if necessary.
Be careful not to deform core fins.
For cleaning procedure of charge air cooler core, refer to CO-36, "Checking Radiator".
INSTALLATION
Pay attention to identification mark color and direction when installing air inlet hose.
EM-141
http://vnx.su
CHARGE AIR COOLER

[YD22DDTi]
EM-142
http://vnx.su
INTAKE MANIFOLD
[YD22DDTi]
INTAKE MANIFOLD
PFP:14003
A
EBS00LRF
EM
PBIC3616E
1.
Fuel gallery
2.
Air relief plug
3.
Washer
4.
Gasket
7.
Heater hose
5.
EGR passage
6.
EGR volume control valve
8.
Water hose
9.
Water pipe
10. EGR volume control valve bracket
11. Washer
12. O-ring
13. EGR cooler
14. Exhaust manifold
15. Bracket
16. Intake manifold
17. Cylinder head
18. Spill hose
19. Fuel hose
REMOVAL
WARNING:
To avoid the danger of being scalded, do not drain engine coolant when engine is hot.
1. Drain engine coolant. Refer to CO-32, "Changing Engine Coolant" .
2. Remove air duct. Refer to EM-139, "Removal and Installation" .
3. Remove charge air cooler. Refer to EM-141, "Removal and Installation" .
4. Remove air inlet pipes. Refer to EM-148, "Removal and Installation" .
EM-143
http://vnx.su
INTAKE MANIFOLD
[YD22DDTi]
5.
6.
7.
8.
9.
Remove exhaust manifold insulator. Refer to EM-148, "EXHAUST MANIFOLD AND TURBOCHARGER" .
Disconnect harness connector from EGR volume control valve and water hoses.
Disconnect heater hose.
Remove EGR cooler.
Remove injection tube center. Refer to EM-164, "Removal and Installation" .
CAUTION:
Be careful not to spill fuel in the engine component.
10. Remove water pipe.
11. Remove fuel hoses and fuel gallery.
To prevent fuel from flowing out, plug the opening of the hose with plug after disconnection.
CAUTION:
12. Loosen bolts and nuts in reverse order of that shown in the figure, and remove intake manifold.
CAUTION:
PBIC0676E
13. Remove EGR volume control valve from intake manifold.

Surface Distortion
Check distortion on the mounting surface with a straightedge

and feeler gauge.
Limit
: 0.1 mm (0.004 in)
If it exceeds the limit, replace intake manifold.
PBIC0677E
INSTALLATION
Following instructions below, install in the reverse order of removal.
1. Install EGR volume control valve.
Handle with care avoiding any shocks.
Do not disassemble.
2. Install intake manifold.
Tighten fixing bolts and nuts in numerical order as shown in
the figure.
When stud bolts come off, install with the following torque.
: 10.5 Nm (1.1 kg-m, 8 ft-lb)
PBIC0676E
EM-144
http://vnx.su
INTAKE MANIFOLD
[YD22DDTi]
3.
Install water hose.

Install water hose by referring to identification marks avoiding
twisting.
When an insert stopper is not provided with the pipe, insert
the hose to the length below.
EM
: 25 - 30 mm (0.984 - 1.181 in)
When an insert stopper is provided on the pipe side, insert the

hose until it reaches the bulge.
G
PBIC2021E
4.
5.
Install remaining parts in the reverse order of removal.

Before starting engine, bleed air from fuel piping. Refer to FL-18, "Air Bleeding" .

Start engine and increase engine speed to check for fuel leak.
CAUTION:
Do not touch the engine immediately after stopped as engine becomes extremely hot.
NOTE:
Use mirrors for checking at points out of clear sight.
EM-145
http://vnx.su
CATALYST
[YD22DDTi]
CATALYST
PFP:20905
EBS00LRG
PBIC2670E
1.
Catalyst insulator
2.
Gasket
3.
Catalyst
4.
Locking pin
5.
Gusset
6.
Gasket cap
7.
Catalyst rear diffuser
8.
Turbocharger insulator
REMOVAL
1.
2.
3.
4.
5.
6.
7.
8.
9.
Remove engine undercover.

Drain engine coolant. Refer to CO-32, "Changing Engine Coolant" .
Remove radiator hose (upper and lower). Refer to CO-35, "RADIATOR" .
Remove cooling fan assembly. Refer to CO-37, "DISASSEMBLY AND ASSEMBLY" .
Remove radiator mounting bracket and radiator. Refer to CO-35, "Removal and Installation" .
Remove water inlet pipe. Refer to CO-45, "THERMOSTAT AND WATER PIPING" .
Remove catalyst insulators.
Remove catalyst.
CAUTION:
Do not disassemble.
NOTE:
Install two locking pins into both sides of the catalyst. Be careful not to confuse locking pins with insulator
mounting bolts.
Catalyst locking pin
: Flange bolt (black)
EM-146
http://vnx.su
CATALYST
[YD22DDTi]
INSTALLATION
A
Pushing gussets against the oil pan and the catalyst, temporarily tighten the mounting bolt. And then
tighten it to the specified torque.
EM
Assemble catalyst insulator with making clearance from catalyst.
EM-147
http://vnx.su
EXHAUST MANIFOLD AND TURBOCHARGER

[YD22DDTi]

PFP:14004
EBS00LRH
PBIC3614E
1.
2.
Gasket
3.
EGR cooler
4.
Air inlet pipe
5.
Exhaust manifold and turbocharger

assembly
6.
Oil feed tube
7.
Oil return hose
8.
Washer
9.
Eye-bolt
10. Turbocharger insulator
11. Exhaust manifold insulator
12. Air inlet pipe
REMOVAL
1.

CAUTION:
Perform this step when engine is cold.
Do not spill engine coolant on drive belts.
3. Remove air duct. Refer to EM-139, "Removal and Installation" .
4. Remove air inlet pipe.
5. Remove engine undercover.
6. Remove radiator hose (upper and lower). Refer to CO-35, "RADIATOR" .
7. Remove cooling fan assembly. Refer to CO-37, "DISASSEMBLY AND ASSEMBLY" .
8. Remove radiator mounting bracket and radiator. Refer to CO-35, "Removal and Installation" .
9. Remove water inlet pipe. Refer to CO-45, "THERMOSTAT AND WATER PIPING" .
10. Remove catalyst. Refer to EM-146, "Removal and Installation" .
11. Remove exhaust manifold insulator.
EM-148
http://vnx.su

[YD22DDTi]
12. Remove turbocharger insulator.
13. Remove oil feed tube.
14. Loosen exhaust manifold mounting nuts in reverse order in the
figure.
EM
D
JEM266G
15. Rotate exhaust manifold and turbocharger assembly so that the rear side (EGR cooler mounting side)
faces upward. And then pull out the assembly from between the engine and the A/C piping.
CAUTION:
Be careful not to deform each turbocharger piping when pulling out the assembly.
16. Remove exhaust manifold gasket.
CAUTION:
INSTALLATION
When a stud bolt is pulled out, tighten it to the following torque:
: 14.7 Nm (1.5 kg-m, 11ft-lb)
1.
2.
3.
Tighten the exhaust manifold mounting nuts in the following procedure:

Install gasket so that the alignment protrusion faces the No. 4 port. Refer to EM-148, "Removal and Installation" .
Tighten the nuts in order specified in the figure.
Re-tighten the nuts 1 to 4.
JEM266G
4.
Install in the reverse order of removal.

Start engine and raise engine speed to check no exhaust gas and engine oil leaks.
EM-149
http://vnx.su

[YD22DDTi]
EBS00LRI
PBIC3613E
1.
Exhaust manifold
2.
Gasket
3.
Oil feed tube
4.
Turbocharger
5.
Washer
6.
Eye- bolt
DISASSEMBLY
After applying penetrative lubricant to the mounting nuts, check for the penetration of the lubricant, and
then loosen the nuts to remove.
CAUTION:
Do not disassemble or adjust the turbocharger body.
ASSEMBLY
When a stud bolt is pulled out, tighten it to the following torque:

Catalyst side
: 25.5 Nm (2.6 kg-m, 19 ft-lb)
Air inlet side
: 11.3 Nm (1.2 kg-m, 8 ft-lb)
INSPECTION AFTER DISASSEMBLY

Surface Distortion
Check the distortion on the mounting surface in the six directions

using a straightedge and a feeler gauge.
Limit
: 0.3 mm (0.012 in)
If it exceeds the limit, replace exhaust manifold.
JEM267G
EM-150
http://vnx.su

[YD22DDTi]
Turbocharger
EBS00LRJ
EM
F
PBIC2532E
CAUTION:
When the compressor wheel turbine, wheel or rotor shaft is damaged, remove all the fragments and
foreign matter left in the following passages in order to prevent a secondary malfunction:
Suction side
Exhaust side
: Between turbocharger and air cleaner

: Between turbocharger and catalyst
ROTOR SHAFT CLEARANCE
Make sure that the rotor shaft rotates smoothly without any
resistance when it is rotated by your fingertips.
Make sure that the rotor shaft is not loose when it is moved vertically or horizontally.
Measure looseness with a dial indicator inserting its measuring
rod through oil drain hole of turbocharger.
Standard
: 0.086 - 0.117 mm (0.0034 - 0.0046 in)
Replace turbocharger if out of standard.
L
PBIC0727E
ROTOR SHAFT END PLAY
Standard
Place a dial indicator at the rotor shaft end in the axial direction
to measure the end play.
: 0.036 - 0.090 mm (0.0014 - 0.0035 in)
PBIC2643E
EM-151
http://vnx.su

[YD22DDTi]
TURBINE WHEEL
Make sure that there is no engine oil adhesion.

Make sure that there is no carbon accumulation.
Make sure that blades of turbine wheel are not bent or broken.
Make sure that turbine wheel does not interfere with turbine
housing.
If anything above is found, replace turbocharger.
PBIC0729E
COMPRESSOR WHEEL
Make sure that there is no engine oil adhesion inside the air
inlet.
Make sure that compressor wheel does not interfere with compressor housing.
Make sure that compressor wheel is not bent or broken.
If anything above is found, replace turbocharger.
PBIC0730E
TURBOCHARGER BOOST CONTROL ACTUATOR
Connect the handy vacuum pump to the actuator, and make

sure that the rod strokes smoothly in compliance with the following pressure.
Pressure to be applied at actuator part to move rod end as follows:
Standard (Pressure/rod stroke amount):
: 52.0 to 54.6 kPa ( 520 to 546 mbar, 390 to 410
mmHg, 15.4 to 16.1 inHg)/0.2 mm (0.0079 in)
: 32.0 to 40.0 kPa ( 320 to 400 mbar, 240 to
300 mmHg, 9.45 to 11.8 inHg)/5.0 mm (0.197 in)
EM-152
http://vnx.su
PBIC0941E

[YD22DDTi]
TROUBLE DIAGNOSIS OF TURBOCHARGER
A
Preliminary check:
Make sure that the engine oil level is between MIN and MAX of the oil level gauge. (When engine oil
amount is more than MAX, engine oil flows into the inlet duct through blow-by gas passage, and turboEM
charger is misjudged malfunction.)
Ask the customer if he/she always runs the vehicle in idle engine speed to cool the engine oil down after
driving.
Replace the turbocharger assembly when any malfunction is found after unit inspections specified in the C
table below.
If no malfunction is found after the unit inspections, judge that the turbocharger body has no malfunction.
Check the other parts again.
D
Inspection item
Turbine wheel
Compressor wheel
After checking both turbine and

compressor, inspect rotor shaft
end play.
Oil return port
Inspection result
Symptom
(when each inspection item meets each inspection result)
Engine oil
leakage
Smoke
Noise
Insufficient power/acceleration malfunction
Engine oil leaks
Carbon is accumulated
Friction with housing
Blades are bent or broken
Inside the air inlet is seriously contaminated by engine oil.
Friction with housing
Blades are bent or broken
There is resistance when the rotor

shaft is rotated by your fingertips.
The rotor shaft sometimes does not

rotate by your fingertips.
There is too much play in the bearing.
Carbon or sludge is accumulated in

the waste oil hole.
A: Large possibility
B: Medium possibility
C: Small possibility
EM-153
http://vnx.su

[YD22DDTi]

PFP:11110
EBS00LRK
PBIC2313E
1.
Rear plate cover
2.
Oil pan upper
3.
Gasket
4.
Oil strainer
5.
Oil pan drain plug
6.
Drain plug washer
7.
Oil pan lower
8.
Crankshaft position sensor
REMOVAL
WARNING:
To avoid the danger of being scalded, do not drain engine oil when engine is hot.
1. Remove engine undercover.
2. Drain engine oil. Refer to LU-21, "Changing Engine Oil" .
3. Remove oil pan lower as follows:
a. Loosen bolts in reverse order of that shown in the figure to
remove.
SBIA0161E
EM-154
http://vnx.su

[YD22DDTi]
b.
Insert the seal cutter (special service tool) between oil pan upper
and oil pan lower.
CAUTION:
Be careful not to damage aluminum mating surface.
Do not insert screwdriver, or oil pan flange will be
deformed.
EM
C
SEM544G
c.
d.
Slide the seal cutter by tapping on the side of the seal cutter with
a hammer.
Remove oil pan lower.
G
SEM545G
4.
5.
6.
7.
Remove A/C compressor belt. Refer to EM-137, "Tension Adjustment" .

Remove A/C compressor and bracket. Refer to ATC-144, "Removal and Installation of Compressor" .
Remove front exhaust tube and its support. Refer to EX-2, "EXHAUST SYSTEM" .
Remove crankshaft position sensor from transaxle.
CAUTION:
Avoid impacts such as a dropping.
Do not disassemble.
Keep it away from metal particles.
Do not place sensor close to magnetic materials.
PBIC2277E
Set a suitable transmission jack under transaxle and hoist

engine with engine slinger. Refer to EM-219, "Removal and
Installation" .
9. Remove center member. Refer to EM-219, "ENGINE ASSEMBLY" .
10. Remove rear plate cover and transaxle joint bolts.
11. Remove catalyst and catalyst rear diffuser. Refer to EM-146,
8.
JEM553G
12. Remove oil strainer.

13. Remove oil pan upper as follows:
EM-155
http://vnx.su

[YD22DDTi]
a.
Loosen bolts in reverse order of illustration to remove oil pan

upper.
SBIA0162E
b.
Insert the Seal cutter (special service tool) between oil pan
upper and cylinder block. Slide the Seal cutter by tapping on the
side of the Seal cutter with a hammer.
CAUTION:
Be careful not damage aluminum mating surface.
Do not insert screwdriver, or oil pan flange will be
deformed.
SEM365EA
c.
Remove oil pan upper.

Clean oil strainer if any object attached.
INSTALLATION
1.
a.
Install oil pan upper as follows:

Use the scraper to remove old liquid gasket from mating surfaces.
CAUTION:
pan upper.
Remove old liquid gasket from bolt hole and thread.
JEM117G
b.
c.
Apply a continuous bead of liquid gasket with the tube presser

(special service tool: WS39930000) to areas shown in the figure.
CAUTION:
At the 8 bolt holes marked
, liquid gasket should be
applied outside holes.
Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
or 4.5 to 5.5 mm (0.177 to 0.217 in) wide. (Be careful that
the diameter of the silicon bead is different around the
front.)
Attaching should be done within 5 minutes after coating.
Install oil pan upper.
EM-156
http://vnx.su
PBIC2314E

[YD22DDTi]
Tighten bolts in numerical order to the specified torque.

Bolt dimensions vary depending on the installation location.
Refer to the following and use appropriate bolts.
M6 x 30 mm (1.18 in)
M8 x 25 mm (0.98 in)
M8 x 60 mm (2.36 in)
: Bolt No. 15, 16

: Bolt No. 3, 4, 9, 10
: Bolt No. 1, 2, 5, 6, 7, 8,
11, 12, 13, 14
The shank length under the bolt neck above is the length of
the threaded part (pilot portion not included).
Install oil strainer.
Tighten transaxle joint bolts.
Install rear plate cover.
Install center member. Refer to EM-219, "ENGINE ASSEMBLY" .
Install crankshaft position sensor.
EM
2.
3.
4.
5.
6.
SBIA0162E
H
PBIC2277E
7.
a.
Install oil pan lower as follows:

CAUTION:
pan upper.
Remove old liquid gasket from bolt hole and thread.
L
SBIA0163E
b.

Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
wide.
SBIA0164E
EM-157
http://vnx.su

[YD22DDTi]
c.
Install oil pan lower.

SBIA0161E
8.
9.
Install oil pan drain plug.

Refer to figure in EM-154, "Removal and Installation" .
NOTE:
Pour engine oil or start engine at least 30 minutes after oil pan is installed.

1.
2.
3.
4.
Check engine oil level and adjust engine oil. Refer to LU-20, "ENGINE OIL" .
Check for leakage of engine oil when engine is warmed.
Check engine oil level again. Refer to LU-20, "ENGINE OIL" .
EM-158
http://vnx.su
GLOW PLUG
[YD22DDTi]
GLOW PLUG
PFP:22401
A
EBS00LRL
EM
I
PBIC2436E
1.
Glow plate
2.
Glow harness
4.
Cap
5.
Glow plug
3.
Glow nut
REMOVAL
CAUTION:
Remove glow plug only if necessary. If carbon adheres, it may be stuck and broken.
2. Remove glow harness from glow plate.
3. Remove glow nut to remove glow plate.
4. Remove glow plug.
CAUTION:
When removing or installing, do not use such tools as an air impact wrench.
Handle it carefully without giving any impact, even after removal. [As a guide, if it drops from
height of 10 cm (3.94 in) or higher, always replace it.]
INSTALLATION
1.
2.
3.
Remove adhered carbon from glow plug installation hole with a reamer.
Install glow plug.
EM-159
http://vnx.su
VACUUM PUMP
[YD22DDTi]
VACUUM PUMP
PFP:41920
EBS00LRM
PBIC3638E
1.
Vacuum pump and cylinder head rear cover

assembly
4.
Camshaft position sensor
2.
O-ring
3.
Cylinder head rear cover plate
INSPECTION BEFORE REMOVAL

1.
2.
Disconnect vacuum hose, and connect a vacuum gauge via 3-way connector.
Disconnect point where vacuum from vacuum pump can be measured directly and install 3-way connector.
Start engine and measure generated vacuum at idle speed.
Standard:
86.6 to 101.3 kPa ( 866 to 1,013 mbar, 650 to 760 mmHg, 25.59 to 29.92 inHg)
If out of standard, check for air suction in vacuum route, and measure again.
If still outside of standard, replace vacuum pump.
REMOVAL
1.
2.
3.
4.
5.
6.
7.
8.
9.

Remove air duct and air cleaner case (upper). Refer to EM-139, "Removal and Installation" .
Remove charge air cooler. Refer to EM-141, "Removal and Installation" .
Disconnect harness connector from fuel injector.
Remove injection tubes. Refer to EM-164, "Removal and Installation" .
Remove rocker cover. Refer to EM-175, "Removal and Installation" .
Remove spill tube. Refer to EM-164, "Removal and Installation" .
Remove nozzle support from No. 2 cylinder and No. 2 fuel injector. Refer to EM-164, "Removal and Installation" . (To fix the hexagonal portion of the camshaft.)
Remove air inlet pipes. Refer to EM-148, "Removal and Installation" .
EM-160
http://vnx.su
VACUUM PUMP
[YD22DDTi]
10.
11.
12.
13.
14.
15.
16.
Remove exhaust manifold cover. Refer to EM-148, "Removal and Installation" .

A
Disconnect heater hose. Refer to EM-143, "INTAKE MANIFOLD" .
Remove EGR cooler. Refer to EM-143, "INTAKE MANIFOLD" .
Disconnect vacuum hose from vacuum pump side.
EM
Remove camshaft position sensor.
Remove cylinder head rear cover plate.
Loosen and remove the mounting bolts in rear camshaft sprocket. Refer to EM-162, "Disassembly and C
Assembly" .
Loosen rear camshaft sprocket mounting bolt by fixing the hexagonal portion of camshaft.
17. Remove vacuum pump and cylinder head rear cover assembly.
D
Remove and install vacuum pump, sprocket, drive chain and chain guide as an assembly.
Loosen mounting bolts in reverse order shown in figure.
Do not remove any bolts not shown in figure. (Especially
E
never remove M6 bolts on vacuum pump.)
Use the seal cutter (special service tool: KV10111100) or
other suitable tool to remove.
F
G
SBIA0167E
INSTALLATION
1.
Install vacuum pump and cylinder head rear cover assembly

onto cylinder head. Refer to EM-163, "ASSEMBLY" .
(special service tool: WS39930000) to area shown in the figure.
K
PBIC1141E
2.
Tighten mounting bolts in order shown in the figure.
SBIA0167E
3.
4.
Install rear camshaft sprocket mounting bolts by fixing the hexagonal portion of camshaft.
Tighten rear camshaft sprocket mounting bolts.
EM-161
http://vnx.su
VACUUM PUMP
[YD22DDTi]
5.
Install cylinder head rear cover plate.

(special service tool: WS39930000) to area shown in the figure.
SBIA0169E
6.
Install in reverse order of removal.

When vacuum hose is connected, insert it securely by at least 15 mm (0.59 in).
CAUTION:
Do not start engine with vacuum circuit being open. If engine is started and vehicle is running while
vacuum pump is open (with vacuum hose disconnected), blow-by flow rate will increase and engine
may be damaged.
7. Before starting engine, bleed air from fuel piping. Refer to FL-18, "Air Bleeding" .

Check generated vacuum satisfies the specification at idle speed. Refer to EM-160, "INSPECTION BEFORE
REMOVAL" .
EBS00LRN
PBIC3639E
1.
Rear camshaft sprocket
2.
Drive chain
3.
Chain guide
4.
Cylinder head rear cover
5.
Vacuum pump
6.
O-ring
DISASSEMBLY
1.
Push on chain guide lightly so that clearance between drive chain and chain guide part reaches 0 mm (0
in). Then loosen chain guide mounting bolts.
EM-162
http://vnx.su
VACUUM PUMP
[YD22DDTi]
2.
3.
4.
Remove drive chain from rear camshaft sprocket and vacuum pump sprocket.
Remove rear camshaft sprocket.
Remove vacuum pump.
CAUTION:
Do not disassemble vacuum pump.
EM
ASSEMBLY
Follow procedure below to install each part onto cylinder head rear cover.
1. Install vacuum pump.
2. Temporarily fit chain guide.
F
SBIA0171E
3.
4.
5.
Install rear camshaft sprocket.

Fit drive chain onto rear camshaft sprocket and vacuum pump
sprocket.
Push on chain guide lightly so that clearance between drive
chain and chain guide sliding part reaches 0 mm (0 in). Then
tighten chain guide mounting bolts.
J
SBIA0172E
EM-163
http://vnx.su
INJECTION TUBE AND FUEL INJECTOR

[YD22DDTi]

PFP:00018
EBS00LRO
PBIC2584E
1.
Spill tube
2.
Eye-bolt
3.
Spill tube gasket
4.
Nozzle support
5.
Pin
6.
Fuel injector
7.
O-ring
8.
Nozzle gasket
9.
Washer
10. Nozzle oil seal
11. Rocker cover
12. Injection tube No. 1
16. Insert rubber
17. Injection tube center
18. Clip
19. Washer
20. Spring washer
21. Fuel rail
22. Fuel rail gasket
23. Fuel hose
REMOVAL
1.
2.
3.
4.
a.

Disconnect harness connector from fuel injector.
Remove spill hose. Refer to EM-143, "INTAKE MANIFOLD" .
Remove injection tubes as follows:
Put a paint mark or tag on injection tubes to identify each cylinder.
Use a fuel-resistant method.
EM-164
http://vnx.su

[YD22DDTi]
b.
Remove injection tubes in order of 2-1-4-3 individually.

CAUTION:
Be careful not to allow leaked fuel to contaminate engine
room. Especially, ensure to keep engine mounting insulator
clear of fuel.
EM
C
SBIA0203E
5.
Remove nozzle oil seal.

Using the flat-bladed screwdriver, pry flange to remove oil
seal.
NOTE:
Nozzle oil seal seals between fuel injector and rocker cover. If
only injection tube shall be removed and installed, nozzle oil
seal replacement is not required.
G
PBIC0944E
6.
7.
Remove spill tube mounting bolts and nut.

Loosen bolts and nut to the reverse order in the figure and
remove them.
CAUTION:
When loosening nut, fix spill tube retaining bolt with spanner.
PBIC3606E
EM-165
http://vnx.su

[YD22DDTi]
8.
a.
b.
c.
d.
Remove fuel injector as follows:

Remove nozzle support.
Remove fuel injector. While rotating it to left and right, raise it to
remove.
CAUTION:
Handle fuel injector carefully without giving any impact.
If nozzle gasket remains in cylinder head, hook it with tip of a
flat-bladed screwdriver and pull it out.
Remove O-ring from fuel injector.
PBIC0759E
INSTALLATION
1.
a.
b.
c.
d.
e.
2.
Install fuel injector as follows:

Install O-ring and nozzle gasket to fuel injector, and insert them into cylinder head.
Tighten injection tubes temporarily in the order of 3-4-1-2.
Be sure to fit nozzle support without looseness.
Tighten nozzle support bolts.
Apply engine oil onto threaded parts of bolts and seating areas.
Remove injection tubes.
Connect spill tube.
Tighten fixing bolts and nut in numerical order shown in the
figure.
CAUTION:
When tightening nut, fix spill tube retaining bolt with
spanner.
NOTE:
Connection of spill tube gasket may be broken, even if it is
tighten to the specified torque. It does not affect performance.
PBIC3606E
3.
Perform air tightness test for spill tube.

Connect a handy vacuum pump to spill connector. Make sure
that vacuum is retained while applying following vacuum.
Standard:
53.3 to 66.7 kPa ( 533 to 667 mbar, 400 to
500 mmHg, 15.75 to 19.69 inHg)
If outside of standard, reconnect spill tube. (Replace gasket in
this case.)
Install rocker cover. Refer to EM-175, "Removal and Installation"
.
Install nozzle oil seal.
Insert it straight until its flange fully contacts rocker cover.
4.
5.
EM-166
http://vnx.su
JEF250Z

[YD22DDTi]
6.
CAUTION:
Check gutter spring in nozzle oil seal on fuel injector for missing.
Connect injection tubes individually to each cylinder in order of
3-4-1-2.
EM
D
SBIA0203E
7.
8.
9.
Connect spill hose. Refer to EM-143, "INTAKE MANIFOLD" .

CAUTION:
NOTE:
EM-167
http://vnx.su
FUEL PUMP
[YD22DDTi]
FUEL PUMP
PFP:17042
EBS00LRP
CAUTION:
Before removing and installing fuel pump, be sure to remove sprocket. Do not loosen or remove
installation nut in the center of fuel pump. If loosened or removed, replace fuel pump.
After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike
piston heads.
When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting
surfaces with new engine oil.
PBIC2639E
1.
Washer
2.
Fuel pump sprocket
3.
Seal washer
4.
O-ring
5.
Adjust shim
6.
Sprocket nut
7.
Coupling
8.
Oil seal
9.
Key
10. Fuel hose
11. Fuel pump
12. Spacer
REMOVAL
1.
2.
3.
4.
5.

Remove RH engine mounting insulator and bracket. Refer to EM-219, "Removal and Installation" .
Pull power steering reservoir tank out of brackets to move power steering piping. Refer to PS-37,
"HYDRAULIC LINE" .
CAUTION:
To avoid removing power steering reservoir tank out of brackets, move it with power steering piping aside.
Remove RH front wheel.
EM-168
http://vnx.su
FUEL PUMP
[YD22DDTi]
6.
7.
8.

A
Remove front exhaust tube. Refer to EX-2, "EXHAUST SYSTEM" .
Remove fuel hoses from fuel pump.
CAUTION:
EM
While hoses are disconnected, plug them to prevent fuel from draining.
9. Disconnect harness connector from fuel pump.
C
10. Remove injection tube center, clip and insert rubber. Refer to EM-164, "INJECTION TUBE AND FUEL
INJECTOR" .
CAUTION:
D
11. Remove secondary timing chain. Refer to EM-190, "Removal and Installation" .
12. Hold fuel pump sprocket and remove bolt.
a. Insert the positioning stopper pin (special service tool) into the
hole 6 mm (0.24 in) in the diameter on the fuel pump sprocket.
b. Using the TORX wrench (special service tool), turn pump shaft
little by little to adjust the position of fuel pump sprocket so that
the holes align.
c. Push the positioning stopper pin (special service tool) through
fuel pump sprocket to fuel pump body to hold fuel pump
sprocket.
MBIA0049E
Insert the positioning stopper pin until its flange contacts the fuel
pump sprocket.
K
PBIC2535E
13. Using the hexagon wrench (special service tool) remove tightening bolts of fuel pump sprocket.
PBIC2404E
EM-169
http://vnx.su
FUEL PUMP
[YD22DDTi]
MBIA0074E
14. Using the sprocket holder (special service tool), hold fuel pump
sprocket to prevent falling.
For sprocket holder, use KV11106060 machined as shown in
the figure, because the previous bore is not fitting.
SBIA0217E
When the sprocket holder is installed, if the positioning stopper pin (special service tool) interferes, pull out the positioning
stopper pin approximately 10 mm (0.39 in), then install it.
After the sprocket holder is installed temporarily, tighten the
sprocket holder after making extension bar and TORX socket
(size: E10) insert into the machined bore.
The length of the sprocket holder mounting bolts should be
approximately 15 mm (0.59 in) (M6 thread length).
Make sure that the a- and b-faces of the sprocket holder contact the bottom side of the sprocket (small diameter side).
CAUTION:
Do not remove the sprocket holder (special service tool) until fuel pump is installed.
After the sprocket holder is installed, pull out the positioning
stopper pin from fuel pump sprocket.
PBIC2534E
MBIA0075E
EM-170
http://vnx.su
FUEL PUMP
[YD22DDTi]
15. Using the extension bar and the TORX socket (size: E10),
remove the tightening bolts.
EM
C
PBIC2405E
16. Remove the fuel pump toward the rear of engine.

CAUTION:
For removal, be careful not to drop the seal washer into the engine.
Do not disassemble or adjust fuel pump.
NOTE:
The seal washer of the tightening bolts cannot be reused.
17. Remove adjust shim.
18. Attach a suitable tool in the M8 bolt hole on coupling.
19. Loosen sprocket nut with the TORX wrench (special service
tool).
MBIA0013E
20. Remove coupling with a suitable puller.

K
M
MBIA0014E
21. Remove spacer from fuel pump.

22. Remove oil seal from spacer.
EM-171
http://vnx.su
FUEL PUMP
[YD22DDTi]
Timing Chain
Check for cracks and excessive wear at roller links. Replace
timing chain if necessary.
SEM984C
INSTALLATION
1.
Install new oil seal to spacer.
MBIA0045E
2.
Install spacer to fuel pump.
3.
Install coupling to fuel pump of spacer.

Using the TORX wrench (special service tool), tighten the
sprocket nut to fix the coupling.
MBIA0013E
4.
Install adjust shim.

For shim adjustment, measure dimension L [Distance
between front surface of coupling and the fuel pump flange
(spacer)] at two opposing points near the coupling bolt center.
Use the average of these two measurements to select the
shim grade that marked on adjust shim.
The shim adjustment is required only when the fuel pump is
replaced.
MBIA0077E
EM-172
http://vnx.su
FUEL PUMP
[YD22DDTi]
Part No. of adjusting shim
5.
Grade number
Measuring dimension L mm (in)
16614 8H800
0.5 t
39.23 - 39.77 (1.5445 - 1.5657)
16614 8H810
1.0 t
38.76 - 39.23 (1.5260 - 1.5445)
16614 8H860
1.2 t
38.57 - 38.76 (1.5185 - 1.5260)
16614 8H820
1.6 t
38.18 - 38.57 (1.5031 - 1.5185)
EM
Before fuel pump is installed, make sure that spacer and the 6
mm (0.24 in) dia. hole on coupling are aligned.
MBIA0016E
6.
Insert fuel pump to the mounting position from the rear side of
the engine, and install the tightening bolts with seal washer.
CAUTION:
Be careful not to drop the seal washer into engine.
I
PBIC2438E
7.
8.
Using the extension bar and the TORX socket (size: E10),
tighten the tightening bolts of fuel pump.
Remove the sprocket holder (special service tool).
M
PBIC2405E
9.
Using the TORX wrench (special service tool), turn the pump
shaft gradually to adjust the position of fuel pump sprocket.
Then, insert the positioning stopper pin (special service tool) to
the 6 mm (0.24 in) dia. hole of the fuel pump sprocket through
the pump body.
10. Remove the TORX wrench (special service tool).
MBIA0049E
EM-173
http://vnx.su
FUEL PUMP
[YD22DDTi]
11. Using the hexagon wrench (special service tool), tighten the
sprocket tightening bolt.
When the washer of the fuel pump sprocket is removed,
install it with the marking F (front) facing the front of the
engine.
12. Pull out the positioning stopper pin (special service tool).
PBIC2404E
13.
14.
a.
b.
c.
d.
e.
15.
16.
17.
18.
Install secondary timing chain. Refer to EM-190, "Removal and Installation" .

Install injection tube center as follows: Refer to EM-164, "INJECTION TUBE AND FUEL INJECTOR" .
Pre-set clip and insert rubber to injection tube center.
Pre-tight nut of injection tube center to fuel pump and fuel rail by hand. (until seal surface touched)
Adjust clip dimension and tight bolt for clip to intake manifold by tool.
Tight nut of injection tube center to fuel pump by tool.
Tight nut of injection tube center to fuel rail by tool.
Connect the harness connector to fuel pump.
Install fuel hoses.
Hereafter, install in the reverse order of removal.
EM-174
http://vnx.su
ROCKER COVER
[YD22DDTi]
ROCKER COVER
PFP:13264
A
EBS00LRQ
EM
I
PBIC2318E
1.
Nozzle oil seal
2.
Oil filler cap
4.
Rocker cover
5.
Washer
3.
Gasket
REMOVAL
1.
2.
3.
a.
b.
4.

Disconnect harness connector from fuel injector. Refer to EM-164, "INJECTION TUBE AND FUEL INJECTOR" .
Remove injection tube as follows: Refer to EM-164, "INJECTION TUBE AND FUEL INJECTOR" .
Put a paint mark or tag on injection tubes to identify each cylinder.
Use a fuel-resistant method.
Remove injection tubes in order of 2-1-4-3 individually.
CAUTION:
Be careful not to allow leaked fuel to contaminate engine room. Especially, ensure to keep engine
mounting insulator clear of fuel.
Remove injection nozzle oil seal.
Using the flat-bladed screwdriver, pry flange to remove nozzle
oil seal.
PBIC0944E
EM-175
http://vnx.su
ROCKER COVER
[YD22DDTi]
5.
Remove rocker cover.

Loosen holding bolts in reverse order of that shown in the figure and remove.
SBIA0175E
6.
Remove rocker cover gasket.
INSTALLATION
1.
Apply 3.0 mm (0.118 in) dia. on locations shown in the figure.

JEM248G
2.
3.
Install rocker cover gasket to rocker cover.

Tighten holding bolts in numerical order shown in the figure.
: 7.8 Nm (0.8 kg-m, 69 in-lb)
Re-tighten to the same torque in the same order as above.
SBIA0175E
4.
5.
6.
Install nozzle oil seal.

Insert it straight until flange fully contacts rocker cover.

CAUTION:
Do not touch the engine immediately after stopped as engine becomes extremely hot.
NOTE:
EM-176
http://vnx.su
CAMSHAFT
[YD22DDTi]
CAMSHAFT
PFP:13001
A
EBS00LRR
EM
I
PBIC2319E
1.
Camshaft bracket
2.
Camshaft (right side)
3.
Camshaft (left side)
4.
Camshaft sprocket (right side)
5.
Camshaft sprocket (left side)
6.
Adjusting shim
7.
Valve lifter
8.
Cylinder head
CAUTION:
This engine will have a different valve arrangement from

normal DOHC 4-valve type engines. As both camshafts on
this engine have intake and exhaust camshafts, in this
chapter they are named as follows:
Camshaft (right side)
Camshaft (left side)
: Intake manifold side

: Exhaust manifold side
Refer to the figure for intake and exhaust valve arrangement.

(The camshafts have, alternately, either intake valve or an
exhaust valve.)
REMOVAL
1.
2.
3.
4.
5.
6.
7.
8.
9.

Remove air duct. Refer to EM-139, "Removal and Installation" .
Remove air inlet pipe. Refer to EM-148, "EXHAUST MANIFOLD AND TURBOCHARGER" .
Remove vacuum pump. Refer to EM-160, "Removal and Installation" .
Remove fuel injector. Refer to EM-164, "Removal and Installation" .
Remove secondary timing chain. Refer to EM-190, "Removal and Installation" .
Remove camshaft sprockets.
EM-177
http://vnx.su
SBIA0178E
CAMSHAFT
[YD22DDTi]
Loosen the camshaft sprocket mounting bolt by fixing the hexagonal portion of camshaft.
JEM159G
10. Loosen and remove the camshaft sprocket bolts in reverse order
JEM160G
11. Remove camshaft.

Place distinguishing marks on the right and left sides with paint.
12. Remove adjusting shim and valve lifter.
Remove by taking notice of the installation position, and place outside engine in order to prevent confusion.

Visual Check of Camshaft
Check the camshaft for one sided wear or scratches.

Replace the camshaft if there are abnormalities.
Camshaft Runout
Prepare V-block on a flat surface and secure camshaft journals

No. 2 and No. 5.
Set the dial indicator vertically on journal No. 3.
Rotate camshaft in one direction by hand, then read needle
movement on dial indicator (total indicator reading).
Limit
: 0.02 mm (0.0008 in)
If it exceeds the limit, replace camshaft.

PBIC2499E
EM-178
http://vnx.su
CAMSHAFT
[YD22DDTi]
Camshaft Cam Height
Standard:
Intake
Exhaust
Measure the height of camshaft cam using the micrometer.

: 39.505 - 39.695 mm (1.5553 - 1.5628 in)
: 39.905 - 40.095 mm (1.5711 - 1.5785 in)
EM
SEM549A
Camshaft Journal Oil Clearance

CAMSHAFT JOURNAL DIAMETER
Measure outer diameter of camshaft journal with micrometer.

Standard:
No. 1
No. 2, 3, 4, 5
: 30.435 - 30.455 mm
(1.1982 - 1.1990 in)
: 23.935 - 23.955 mm
(0.9423 - 0.9431 in)
H
SEM012A
CAMSHAFT BRACKET INNER DIAMETER
Install camshaft bracket and tighten bolts to the specified torque. Refer to EM-181, "INSTALLATION" for
the tightening procedure.
Measure inner diameter of camshaft bracket using the inside

micrometer.
Standard:
No. 1
No. 2, 3, 4, 5
CAMSHAFT OIL CLEARANCE CALCULATIONS

(Oil clearance) = (Camshaft bracket inner diameter) (Camshaft journal diameter)
: 0.045 - 0.086 mm (0.0018 - 0.0034 in)
If out of standard, refer to the standard value of each unit, then replace the camshaft and/or cylinder head.
NOTE:
As the camshaft bracket is manufactured with the cylinder head, it is impossible to replace only the camshaft bracket.
EM-179
http://vnx.su
: 30.500 - 30.521 mm
(1.2008 - 1.2016 in)
: 24.000 - 24.021 mm
(0.9449 - 0.9457 in)
JEM162G
Standard
CAMSHAFT
[YD22DDTi]
Camshaft End Play
Install dial indicator in thrust direction on front end of camshaft.

Measure end play of dial indicator when camshaft is moved forward/backward (in direction to axis).
Standard
Limit
: 0.070 - 0.148 mm (0.0028 - 0.0058 in)

: 0.24 mm (0.0094 in)
PBIC2446E
Measure the following parts if out of the standard.

Dimension A for camshaft
Standard
Dimension B for cylinder head

Standard
: 6.882 - 6.930 mm (0.2709 - 0.2728 in)
: 7.000 - 7.030 mm (0.2755 - 0.2767 in)
Refer to the standards above, and then replace camshaft and/or

cylinder head.
PBIC2320E
Camshaft Sprocket Runout

1.
2.
3.
Install camshaft in cylinder head. Refer to EM-181, "INSTALLATION" for the tightening procedure.
Install sprocket on camshaft. Refer to EM-181, "INSTALLATION" .
Measure camshaft sprocket runout (total indicator reading).
Limit
: 0.15 mm (0.0059 in)
If it exceeds the limit, replace camshaft sprocket.
PBIC2644E
Valve Lifter and Adjusting Shim

Check if surface of valve lifter and adjusting shim has any wear or
cracks.
If anything above is found, replace valve lifter or adjusting shim.
SEM160D
EM-180
http://vnx.su
CAMSHAFT
[YD22DDTi]
Valve Lifter Clearance
A
VALVE LIFTER OUTER DIAMETER
Measure the outer diameter of the valve lifter with the micrometer.
Standard
EM
: 29.960 - 29.975 mm (1.1795 - 1.1801 in)
D
SEM961E
VALVE LIFTER HOLE DIAMETER
Measure the hole diameter of the cylinder head valve lifter with
the inside micrometer.
Standard
: 30.000 - 30.021 mm (1.1811 - 1.1819 in)
H
PBIC0367E
VALVE LIFTER CLEARANCE CALCULATIONS
(Valve lifter clearance) = (Valve lifter hole diameter) (Valve lifter outer diameter)
Standard
: 0.025 - 0.061 mm (0.0010 - 0.0024 in)
If out of standard, refer to the outer diameter and hole diameter standard values and replace valve lifter
and/or cylinder head.
K
INSTALLATION
1.
Install valve lifter and adjusting shim.

Make sure that these are installed in the same position as before the removal process.
Install camshaft.
Identify camshafts by the paint position and screw hole at the
rear end.
2.
Camshaft (right side) Intake manifold side:

Paint is at position A (Brown) without screw hole.
Camshaft (left side) Exhaust manifold side:
Paint is at position B (Pink) with screw hole.
PBIC2496E
EM-181
http://vnx.su
CAMSHAFT
[YD22DDTi]
Install so that knock pins are positioned in the directions

NOTE:
Though camshaft does not stop at the location as shown in
the figure, for the placement of cam nose, it is generally
accepted that camshaft is placed at the same direction as
PBIC2026E
3.
Install camshaft brackets.

Completely remove any foreign material on back surfaces of camshaft brackets and top surface of cylinder head.
Install correctly, identifying brackets by the journal No. and
front mark on top surface.
JEM175G
4.
a.
Tighten bolts in the order shown in the figure according to the

following procedure:
Tighten all bolts.
: 2 Nm (0.2 kg-m, 1 ft-lb)
Make sure camshaft thrusting parts (on rear side) securely fit
in their mating parts on the cylinder head.
Tighten all bolts.
b.
: 6 Nm (0.6 kg-m, 4 ft-lb)

JEM160G
c.
Tighten all bolts.

: 12.5 Nm (1.3 kg-m, 9 ft-lb)
5.
6.
7.
8.
Install camshaft sprockets.

Camshaft sprockets are commonly used for right side and left side.
Align camshaft sprocket and knock pin on camshaft, and install.
Holding the hexagonal part of camshaft with a wrench, tighten bolt securing camshaft sprocket.
Before installing spill tube after installing secondary timing chain, check and adjust valve clearance. Refer
to EM-182, "Valve Clearance" .
Valve Clearance
EBS00LRS
INSPECTION
When the camshaft or parts in connection with valves are removed or replaced, and a malfunction has
occurred (poor starting, idling, or other malfunction) due to the misadjustment of the valve clearance,
inspect as follows.
Inspect and adjust when the engine is cool (at normal temperature).
EM-182
http://vnx.su
CAMSHAFT
[YD22DDTi]
Be careful of the intake and exhaust valve arrangement. The
valve arrangement is different from that in a normal engine.
NOTE:
The camshafts have, alternately, either intake valve or exhaust
valve. (Refer to figure.)
EM
C
SBIA0178E
1.
2.
3.
4.
5.

Remove air duct. Refer to EM-139, "Removal and Installation" .
Remove fuel injector. Refer to EM-164, "Removal and Installation" .
Set the No. 1 piston to TDC on its compression stroke.
Turn crankshaft pulley clockwise so that the knock pin on
camshaft left side faces straight above. (No position indicator,
etc. is provided on the crankshaft pulley.)
I
PBIC2533E
6.
Put an alignment mark with paint, etc. on crankshaft pulley and

on oil pump housing as an angle indicator.
JEM177G
7.
While referring to the figure, measure the valve clearance

marked in the table below.
No. 1
Measuring point
When the No. 1

cylinder is in the
TDC
No. 2
INT
EXH
INT
EXH
No. 3
INT
No. 4
EXH
INT
EXH
NOTE:
The injection order is 1-3-4-2.
SBIA0180E
EM-183
http://vnx.su
CAMSHAFT
[YD22DDTi]
Measure the valve clearance using the feeler gauge when

engine is cool (at normal temperature).
SBIA0181E
Valve clearance:
Unit: mm (in)
Item
Cold
Hot* (Reference data)
Intake
0.24 -0.32 (0.0094 - 0.0126)
0.274 - 0.386 (0.0108 - 0.0152)
Exhaust
0.26 - 0.34 (0.0102 - 0.0134)
0.308 - 0.432 (0.0121 - 0.0170)
*: Reference data approximately 80C (176F)

8.
9.
Set the No. 4 cylinder at TDC by rotating the crankshaft clockwise once. (360 degrees)
While referring to the figure, measure the valve clearance
marked in the table below.
Measuring point
No. 1
INT
When the No. 4

cylinder is in the
TDC
EXH
No. 2
INT
No. 3
EXH
INT
EXH
No. 4
INT
EXH
SBIA0182E
10. If the valve clearance is outside the specification, adjust as follows.
ADJUSTMENTS
1.
2.
Remove adjusting shim for parts which are outside the specified valve clearance.
Extract engine oil on the upper side of the cylinder head (for the air blowing in step 6).
Rotate crankshaft to face the camshaft for adjusting shims that
are to be removed upward.
SBIA0183E
EM-184
http://vnx.su
CAMSHAFT
[YD22DDTi]
3.
Grip camshaft with the camshaft pliers (special service tool),

then using camshaft as a support point, push adjusting shim
downward to compress valve spring.
CAUTION:
Do not damage camshaft, cylinder head and the outer circumference of valve lifter.
EM
C
PBIC2321E
4.
With valve spring in a compressed state, remove the camshaft

pliers (special service tool) by securely setting the outer circumference of the valve lifter with the end of the lifter stopper (special service tool).
Hold the lifter stopper by hand until the shim is removed.
CAUTION:
Do not retrieve the camshaft pliers forcefully, as camshaft will be damaged.
G
PBIC2322E
5.
6.
7.
Move the round hole of adjusting shim to the front with the very
thin screwdriver or like that.
When adjusting shim on valve lifter will not rotate smoothly,
restart from step 3 to release the end of the lifter stopper (special service tool) from touching adjusting shim.
Remove adjusting shim from valve lifter by blowing air through
the round hole of the adjusting shim with the air gun.
CAUTION:
To prevent any remaining engine oil from being blown
around, thoroughly wipe the area clean and wear protective
goggles.
Remove adjusting shim by using the magnet hand.
PBIC2323E
PBIC2324E
8.
Measure the thickness of adjusting shim using the micrometer.

Measure near the center of the shim (the part that touches
camshaft).
FEM032
EM-185
http://vnx.su
CAMSHAFT
[YD22DDTi]
9.
Select the new adjusting shim from the following methods.

Calculation method of the adjusting shim thickness:
R = Thickness of removed shim
N = Thickness of new shim
M = Measured valve clearance
Intake
N = R + [M - 0.28 mm (0.0010 in)]
Exhaust
N = R + [M - 0.30 mm (0.0118 in)]
New adjusting shims have the thickness stamped on the rear

side.
Stamped mark
2.10
2.12
2.74
Shim thickness mm (in)

2.10 (0.0827)
2.12 (0.0835)
2.74 (0.1079)
Shims are available in 33 size from 2.10 mm (0.0827 in) to

2.74 mm (0.1079 in), in steps of 0.02 mm (0.0008 in).
10. Fit the selected adjusting shim to valve lifter.
CAUTION:
Place the stamped side of adjusting shim to valve lifter.
JEM184G
PBIC2325E
11. Compress valve spring using the camshaft pliers (special service tool: KV10115110) and remove the lifter
stopper (special service tool).
12. Rotate crankshaft 2 to 3 turns by hand.
13. Confirm that the valve clearance is within the specification. Refer to EM-182, "INSPECTION" .
14. Install remaining parts in the reverse order of removal. Refer to EM-181, "INSTALLATION" .
15. Warm up the engine, and check for unusual noise and vibration.
EM-186
http://vnx.su
OIL SEAL
[YD22DDTi]
OIL SEAL
Removal and Installation of Valve Oil Seal
PFP:12279
A
EBS01FBM
REMOVAL
1.
2.
3.
4.
Remove camshafts. Refer toEM-177, "Removal and Installation" .

EM
Remove adjusting shims and valve lifters. Refer to EM-177, "Removal and Installation" .
Check the installation positions, and keep them to avoid being confused.
Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve C
from dropping into cylinder.
Compress the valve spring with valve spring compressor,
D
attachment and adapter (special service tool). Remove valve
collet with a magnet hand.
CAUTION:
E
F
PBIC2388E
5.
6.
Remove valve spring retainer and valve spring.

Remove valve oil seal with the valve oil seal puller (special service tool).
JEM153G
INSTALLATION
1.
2.
Apply new engine oil to valve oil seal joint surface and seal lip.
Using the valve oil seal drift (special service tool), install valve oil
seals referring to the dimension shown in the figure.
JEM165G
3.
EM-187
http://vnx.su
OIL SEAL
[YD22DDTi]
Removal and Installation of Front Oil Seal
EBS01FBN
REMOVAL
1.
2.

RH engine undercover
Crankshaft pulley; Refer to EM-195, "PRIMARY TIMING CHAIN" .
Remove front oil seal with a suitable tool.
CAUTION:
Be careful not to damage oil pump housing and crankshaft.
AEM385
INSTALLATION
1.
2.
Apply new engine oil to new front oil seal joint surface and seal lip.
Install front oil seal so that each seal lip is oriented as shown in
the figure.
SEM715A
Using the suitable drift [62 mm (2.44 in) dia.], force fit the seal
until it hits the bottom.
CAUTION:
Do not touch lips of oil seal. Make sure seal surfaces are
free of foreign materials.
JEM142G
3.
EM-188
http://vnx.su
OIL SEAL
[YD22DDTi]
Removal and Installation of Rear Oil Seal
EBS01FBO
A
Remove transaxle and transfer assembly. Refer to MT-17, "Removal and Installation" and TF-57,
"Removal and Installation"
EM
Remove clutch cover and disk. Refer to CL-16, "CLUTCH DISC, CLUTCH COVER AND FLYWHEEL" .
Remove flywheel. Refer to EM-224, "DISASSEMBLY" .
Remove rear oil seal with a suitable tool.
C
CAUTION:
REMOVAL
1.
2.
3.
4.
INSTALLATION
1.
2.
Apply new engine oil to new rear oil seal joint surface and seal lip.
Install rear oil seal so that each seal lip is oriented as shown in
the figure.
G
SEM715A
Press in rear oil seal to the position as shown in the figure.

Using the drift [105 mm (4.13 in) dia.], press fit so that the
dimension is as specified in the figure.
Avoid inclined fitting. Force fit perpendicularly.
K
JEM232G
3.
EM-189
http://vnx.su
SECONDARY TIMING CHAIN

[YD22DDTi]

PFP:13028
EBS00LRT
CAUTION:
After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike
piston heads.
When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting
PBIC2326E
1.
Chain tensioner
2.
Spring
3.
Plunger
4.
Slack guide
5.
Front chain case
6.
Rubber washer
7.
Tension guide
8.
Gasket
9.
Secondary timing chain
REMOVAL
1.
2.
3.
4.
For preparative work for removing/installing secondary timing chain to remove/install fuel pump, refer to
EM-168, "FUEL PUMP" .
To prepare for removing/installing secondary timing chain to remove/install camshaft, refer to EM-177,
"HYDRAULIC LINE" .
CAUTION:
To avoid removing power steering reservoir tank out of brackets, move it with power steering piping aside.
Remove front chain case.
EM-190
http://vnx.su

[YD22DDTi]
Loosen fixing bolts in reverse order of that shown in the figure

and remove them.
Remove No. 6, 10 and 11 bolts with the rubber washer as
space is limited for pulling them out.
CAUTION:
While front chain case is removed, cover openings to
prevent entry of foreign material into engine.
EM
C
JEM121G
Do not remove two mass dampers on the back of

cover.
E
G
SBIA0189E
5.
Set the No. 1 piston to TDC on its compression stroke.

Turn crankshaft pulley clockwise so that the alignment mark
(punched mark) on each camshaft sprocket is positioned as
No position indicator is provided on crankshaft pulley.
When installing, color coded links on secondary timing
chain can be used as alignment marks. Marking may not
be necessary for removal; however, make alignment
marks as required because the alignment mark on fuel
pump sprocket may not be easy to see.
K
SEM515G
6.
a.
Remove chain tensioner as follows:

Push the plunger of chain tensioner and keep it pressed with a
push pin.
JEM124G
EM-191
http://vnx.su

[YD22DDTi]
b.
Using the hexagon wrench (special service tool), remove bolts

to remove chain tensioner.
SBIA0227E
7.
Remove slack guide.

Using the hexagon wrench (special service tool), remove bolt
to remove slack guide.
SBIA0228E
8.
9.
Remove tension guide.

Remove secondary timing chain.
Timing chain alone can be removed without removing sprockets.
JEM127G

Timing Chain
SEM984C
INSTALLATION
1.
Install secondary timing chain.
EM-192
http://vnx.su

[YD22DDTi]
When installing, match the alignment marks on sprockets with
color coded alignment marks (colored links) on the timing
chain.
Install tension guide.
The upper bolt has a longer shank than the lower bolt.
2.
EM
G
PBIC2596E
3.
Using the hexagon wrench (special service tool), install slack

guide.
SBIA0228E
4.
a.
b.
c.
Install chain tensioner.

Push the plunger of chain tensioner. While holding it with a push
pin, install chain tensioner.
Using the hexagon wrench (special service tool), tighten bolts.
Pull out the push pin, etc. holding the plunger.
Make sure again that the alignment marks on the sprockets and the colored alignment marks on the timing chain
are aligned.
SBIA0227E
5.
Install front chain case as follows:
EM-193
http://vnx.su

[YD22DDTi]
a.
Install tension guide on the back surface of front chain case.

Hold front chain case vertically when installing. Tension guide
may come off if front chain case is tilted.
SBIA0189E
b.
Apply a continuous bead of liquid gasket on both ends of arched

area (locations where rear chain case is adjoined) as shown in
the figure.
JEF370Y
c.
d.
e.
Install front chain case.

When installing, align dowel pin on oil pump housing with the pin hole.
Install No. 6, 10 and 11 bolts with the rubber washer to front chain case.
Tighten fixing bolts in numerical order shown in the figure.
After tightening all the bolts, re-tighten in the same order.
JEM121G
6.
EM-194
http://vnx.su
PRIMARY TIMING CHAIN

[YD22DDTi]

PFP:13028
A
EBS00LRU
CAUTION:
After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike EM
piston heads.
When installing camshafts, chain tensioners, oil seals or other sliding parts, lubricate contacting
C
EM-195
http://vnx.su

[YD22DDTi]
PBIC2327E
1.
Fuel pump
2.
Seal washer
3.
Chain tensioner
4.
Spring
5.
Slack guide
6.
Plunger
7.
Camshaft sprocket
8.
Washer
9.
Fuel pump sprocket
EM-196
http://vnx.su

[YD22DDTi]
10. O-ring
11. Chain guide
12. Tension guide
13. Spacer
14. Gasket
15. Front chain case
16. Rubber washer
17. Crankshaft pulley
18. Front oil seal
19. Power steering oil pump cover
20. Oil pump housing
21. Primary timing chain
22. Oil pump drive spacer
23. Crankshaft sprocket
24. Secondary timing chain
25. Rear chain case
26. Power steering oil pump
27. Key
EM
REMOVAL
1.
2.
3.
4.
5.
6.

Remove air cleaner and air duct. Refer to EM-139, "Removal and Installation" .
"HYDRAULIC LINE" .
CAUTION:
To avoid removing power steering reservoir tank out of brackets move it with power steering piping aside.
7. Remove oil pan (upper and lower). Refer to EM-154, "Removal and Installation" .
8. Remove oil filter bracket. Refer to LU-26, "OIL FILTER BRACKET" .
9. Remove fuel injector. Refer to EM-164, "Removal and Installation" .
10. Remove secondary timing chain and associated parts. Refer to EM-190, "Removal and Installation" .
11. When removing rear chain case, remove camshaft sprockets. Refer to EM-177, "Removal and Installation" .
12. Remove crankshaft pulley as follows:
a. Hold crankshaft pulley with the pulley holder (special service
tool).
b. Loosen crankshaft pulley fixing bolt and pull out the bolt approximately 10 mm (0.39 in).
L
JEM131G
c.
Using the pulley puller (special service tool), remove crankshaft

pulley.
Use two M6 bolts with approx. 60 mm (2.36 in) shank length
for securing crankshaft pulley.
JEM132G
13. Remove oil pump housing.
EM-197
http://vnx.su

[YD22DDTi]
Loosen bolts in reverse order of that shown in the figure and

remove them.
Use the seal cutter (special service tool: KV10111100) etc. for
removal.
JEM133G
14. Remove front oil seal from oil pump housing.

Punch out the seal off from the back surface of the oil pump housing using a flat-bladed screwdriver.
CAUTION:
Be careful not to damage oil pump housing.
15. Remove chain tensioner.
When removing chain tensioner, push the plunger of chain
tensioner and keep it pressed with a push pin, etc.
16. Remove slack guide.
JEM134G
17. Hold fuel pump sprocket and remove bolt.

a. Insert positioning stopper pin (special service tool) into the hole
6 mm (0.24 in) in the diameter on fuel pump sprocket.
b. Using the TORX wrench, turn pump shaft little by little to adjust
the position of fuel pump sprocket so that the holes align.
c. Push positioning stopper pin through fuel pump sprocket to fuel
pump body to hold fuel pump sprocket.
MBIA0049E
Insert the positioning stopper pin until its flange contacts fuel
pump sprocket.
PBIC2535E
EM-198
http://vnx.su

[YD22DDTi]
18. Using the hexagon wrench (special service tool) remove tightening bolts to fuel pump sprocket.
EM
C
PBIC2404E
G
MBIA0074E
19. Remove primary timing chain with fuel pump sprocket and
crankshaft sprocket.
K
MBIA0079E
20. Remove chain guide and tension guides.

L
PBIC2498E
21. Remove fuel pump. Refer to EM-168, "FUEL PUMP" .

22. Remove power steering oil pump.
EM-199
http://vnx.su

[YD22DDTi]
23. Remove rear chain case.
Loosen fixing bolts in reverse order of that shown in the figure
and remove them.
Use the seal cutter (special service tool: KV10111100) for
removal.
SBIA0211E

Timing Chain
SEM984C
INSTALLATION
PBIC2586E
1.
Install rear chain case as follows:
EM-200
http://vnx.su

[YD22DDTi]
a.

(special service tool: WS39930000) on locations shown in the
figure.
A
B. C
D
*
: Apply bead so that it does not protrude into the

oil passage.
: Minimize overlapping area of bead, by starting
and ending at areas of bead as shown in the figure. Apply so that the portion marked.
: Leave the start and end areas of the bead slightly
protruding from the case surface.
: comes at an external location but cannot be
viewed externally after engine assembly.
EM
G
PBIC1255E
b.
Install four O-rings to the grooves of the cylinder block and fuel
pump bracket.
J
JEM141G
c.
Install rear chain case.

When installing, align the dowel pin with the pin hole.
L
EM-201
http://vnx.su

[YD22DDTi]
d.
Tighten bolts in numerical order shown in the figure.

Install the following four types of bolts, referring to the figure.
16 mm (0.63 in)
20 mm (0.79 in)
25 mm (0.98 in)
35 mm (1.38 in)
: Bolt No. 1, 2, 16, 17, 18, 19, 20, 21, 22

: Bolt No. 3, 4, 6, 9, 10, 11, 13, 14
: Bolt No. 12, 15
: Bolt No. 5, 7, 8
The shank length under the bolt neck above is the length of
threaded part (pilot portion not included).
e.
SBIA0211E
2.
3.
4.
5.
Install power steering oil pump.

Install fuel pump. Refer to EM-168, "FUEL PUMP" .
Before installing, make sure that spacer and the hole 6 mm
(0.24 in) in diameter on coupling are aligned.
Install chain guide and tension guides.
Install crankshaft sprocket, aligning it with crankshaft key on the
far side.
PBIC2498E
6.
7.
Install primary timing chain with fuel pump sprocket.

When installing, match the alignment marks on sprockets with
color coded alignment marks (colored links) on primary timing
chain.
Install fuel pump sprocket washer with the surface marked F
(front mark) facing the front of the engine.
Install timing chain onto power steering oil pump sprocket and
through chain guide.
MBIA0079E
8.
Use the positioning stopper pin (special service tool) to hold the
fuel pump sprocket and install the bolt.
Using the TORX wrench (special service tool), turn the fuel
pump shaft little by little to adjust the position of the fuel pump
sprocket. Insert positioning stopper pin into the hole 6 mm
(0.24 in) in diameter on fuel pump sprocket so that the stopper pin goes through the fuel pump body. While the stopper
pin is in place, install the bolt.
MBIA0049E
EM-202
http://vnx.su

[YD22DDTi]
A
EM
C
PBIC2404E
9. Install slack guide.

10. Install chain tensioner.
Push the plunger of the chain tensioner. While keeping
plunger pressed down with a push pin, etc., install chain tensioner.
After installation, pull out the push pin holding the plunger.
CAUTION:
Check again that the alignment marks on sprockets and the
colored alignment marks on timing chain are aligned.
G
JEM134G
11. Install front oil seal to oil pump housing.

Using the suitable drift [62 mm (2.44 in) dia.], force fit the seal
until it hits the bottom.
CAUTION:
Do not touch lips of oil seal. Make sure seal surfaces are
free of foreign materials.
JEM142G
12. Install power steering oil pump cover to oil pump housing.
Apply liquid gasket on oil pump-side surface.
JEM143G
13. Install oil pump housing as follows:
EM-203
http://vnx.su

[YD22DDTi]
a.

A
B
: Leave the start and end areas of the bead slightly

protruding from the surface.
: Apply liquid gasket along upper end surface of oil
pump housing.
JEM144G
b.
c.
Install oil pump drive spacer to crankshaft.

Install with the front mark (punched mark) facing the front of
the engine.
Install O-ring into the groove of rear chain case.
JEM145G
d.
e.
f.
Install oil pump housing.

When installing, align the inner rotor in the direction of the two facing flats of oil pump drive spacer.
When installing, align the dowel pin with the pin hole.
Tighten fixing bolts in numerical order shown in the figure.
JEM133G
14. Check gaps on upper oil pan mounting surface.

Using straightedge and feeler gauge, measure gaps between
the locations of the following parts:
Oil pump housing and rear chain case:
Standard : 0.09 to 0.09 mm ( 0.0035 to 0.0035 in)
Rear chain case and cylinder block:
Standard : 0.19 to 0.07 mm ( 0.0075 to 0.0028 in)
If the measured value is out of the standard, install again.

JEM146G
15. Install crankshaft pulley as follows:

a. Install crankshaft pulley, taking care not to damage front oil seal.
CAUTION:
Do not tap pulley on the side surface where belt is installed (outer circumference).
EM-204
http://vnx.su

[YD22DDTi]
b.
c.
d.
Hold crankshaft pulley with the pulley holder (special service

tool).
Apply engine oil onto threaded parts of crankshaft pulley bolt
and seating area.
Tighten crankshaft pulley fixing bolt.
EM
: 24.5 Nm (2.5 kg-m, 18 ft-lb)

e.
Put an alignment mark on crankshaft pulley that aligns with one

of the punched marks on the bolt.
JEM131G
f.
Then turn all bolts 60 degrees clockwise (turn by one notch).

E
G
JEM147G
16. Install secondary timing chain and the associated parts. Refer to EM-192, "INSTALLATION" .
17. Rotate crankshaft pulley in normal direction (clockwise when viewed from engine front) to check for interference among parts.
18. Install in the reverse order of removal.
EM-205
http://vnx.su
CYLINDER HEAD
[YD22DDTi]
CYLINDER HEAD
On-Vehicle Service
PFP:11041
EBS00LRV
CHECKING COMPRESSION PRESSURE

1.
2.
3.
4.
5.
6.
7.
Warm up engine thoroughly. Then, stop it.

Using CONSULT-II, make sure no error codes are indicated for self-diagnosis items. Refer to EC-1007,
"Basic Inspection" (WITH EURO-ODB) or EC-1369, "Basic Inspection" (WITHOUT EURO-ODB).
Do not disconnect CONSULT-II until the end of this operation; it will be used to check engine rpm and
for error detection at the end of this operation.
Disconnect the battery cable from the negative terminal.
Remove charge air cooler. Refer to EM-141, "Removal and Installation"
To prevent fuel from being injected during inspection, remove
fuel pump fuse [ENG CONT 2 (20A)] from fuse box on the left
side of engine room.
Among marks on fuse box, [ENG CONT 2 (20A)] is for fuel
pump fuse.
Remove glow plugs from all the cylinders. Refer to EM-159,
CAUTION:
Before removal, clean the surrounding area to prevent
entry of any foreign materials into engine.
PBIC0680E
Carefully remove glow plugs to prevent any damage or
breakage.
Handle with care to avoid applying any shock to glow plugs.
Install compression gauge adapter (special service tool) to
installation holes of glow plugs and connect compression gauge
for diesel engine.
: 20 Nm (2.0 kg-m, 15 ft-lb)
8.
9.
Connect the battery cable to the negative terminal.

With accelerator pedal fully depressed, turn ignition switch to
START for cranking. When the gauge pointer stabilizes, read
the compression pressure and engine rpm. Perform these steps
to check each cylinder.
Always use a fully-charged battery to obtain specified engine
speed.
SEM112G
Unit: kPa (bar, kg/cm2 , psi)/rpm
Standard
Minimum
Difference limit between cylinders
2,991 (29.9, 30.5, 434)/200
2,452 (24.5, 25.0, 356)/200
490 (4.9, 5.0, 71)/200
When engine rpm is out of the specified range, check the specific gravity of battery liquid. Measure
again under corrected conditions.
If engine rpm exceeds the limit, check valve clearance and combustion chamber components (valves,
valve seats, cylinder head gaskets, piston rings, pistons, cylinder bores, cylinder block upper and lower
surfaces) and measure again.
If compression pressure is low in some cylinders, apply engine oil from glow plug installation hole. Then
check pressure again.
If compression pressure becomes normal after applying engine oil, piston ring may be worn or damaged. Check piston ring for malfunction. If any, replace piston ring.
If compression pressure is still low after applying engine oil, valve may be malfunctioning. Check valve
for malfunction. If contact malfunction is found, replace valve or valve seat.
If compression pressure in adjacent two cylinders is low after applying engine oil, pressure may be
leaking from gasket. In this case, replace cylinder head gasket.
EM-206
http://vnx.su
CYLINDER HEAD
[YD22DDTi]
10.
a.
b.
c.
d.
e.
f.
Complete this operation as follows:

Turn the ignition switch to OFF.
Install glow plug and install all the parts removed in step 4.
Install fuel pump fuse [ENG CONT (20A)].
Connect the battery cable to the negative terminal.
Using CONSULT-II make sure no DTC is indicated for items of self-diagnosis.
EM
C
EBS00LRW
PBIC2437E
1.
Glow plug
2.
Cylinder head assembly
3.
Cylinder head bolt
4.
Copper washer
5.
Engine coolant temperature sensor
6.
Gasket
7.
Water outlet
8.
Dowel pin
9.
Cylinder gasket
10. Glow harness
11. Glow plate
12. Cap
REMOVAL
1.
2.
3.

Remove the following:
Charge air cooler (Refer to EM-141, "Removal and Installation" .)
Rocker cover (Refer to EM-175, "Removal and Installation" .)
Air cleaner and air duct (Refer to EM-139, "Removal and Installation" .)
Vacuum pump (Refer to EM-160, "Removal and Installation" .)
Spill tube and fuel injector (Refer to EM-164, "Removal and Installation" .)
Intake manifold (Refer to EM-143, "Removal and Installation" .)
Exhaust manifold and turbocharger (Refer to EM-148, "Removal and Installation" .)
Secondary timing chain (Refer to EM-190, "Removal and Installation" .)
Camshaft (Refer to EM-177, "Removal and Installation" .)
Remove cylinder head assembly.
EM-207
http://vnx.su
CYLINDER HEAD
[YD22DDTi]
Remove cylinder head bolts in reverse order as shown in the
figure with the cylinder head bolt wrench (commercial service
tool).
Lift up cylinder head assembly to avoid interference with
dowel pins located between the cylinder block and cylinder
head, and remove cylinder head assembly.
CAUTION:
Remove glow plug in advance to avoid damage as the tip
of the glow plug projects from the bottom of cylinder
head, or, place wood blocks beneath both ends of cylinJEM149G
der head to keep the cylinder bottom from any contact.
For glow plug removal, the following shall be noted.
CAUTION:
To avoid breakage, do not remove glow plug unless necessary.
Perform continuity test with glow plug installed.
Keep glow plug from any impact. [Replace if dropped from a height 10 cm (3.94 in) or higher.]
Do not use air impact wrench.
Remove cylinder head gasket.
4.

Cylinder Head Bolt Deformation
Using micrometer, measure the outer diameters d1 and d2 of

bolt thread as shown in the figure.
If the necking point can be identified, set it as measuring point
d1.
Calculate the difference between d1 and d2.
Limit
: 0.15 mm (0.0059 in)
If it exceeds the limit, replace cylinder head bolt.

JEM171G
Cylinder Head Distortion

NOTE:
When performing this inspection, cylinder block distortion should be also checked. Refer to EM-242, "CYLINDER BLOCK TOP SURFACE DISTORTION" .
1. Wipe off oil and remove water scale (like deposit), gasket, sealer, carbon, etc. with scraper.
CAUTION:
Use utmost care not to allow gasket debris to enter passages for oil or water.
2. At each of several locations on bottom surface of cylinder head,
measure distortion in six directions.
Limit
: 0.1mm (0.004 in)
If it exceeds the limit, replace cylinder head.
SEM496G
EM-208
http://vnx.su
CYLINDER HEAD
[YD22DDTi]
Cylinder head- to- block Difference Check
Standard
After installing cylinder head, measure dimension from the front

end surface of cylinder block to that of cylinder head.
: 23.53 - 24.07 mm (0.9264 - 0.9476 in)
EM
If out of the standard, check fitting of dowel pins and cylinder

head.
C
JEM172G
INSTALLATION
Before installation, remove old liquid gasket from mating surface of all liquid gasket applied parts.
1. Install cylinder head gasket.
Cylinder head gasket to be installed is selected by its thickness through the following procedure.
When replacing gasket alone
Install a gasket with same thickness as that of the one removed.
Identify the thickness of gasket by the number of cut-outs on
the rear right side.
Gasket thickness* mm (in)
Number of grade
Number of cut-outs
0.900 (0.0354)
0.925 (0.0364)
0.950 (0.0374)
0.975 (0.0384)
1.000 (0.0394)
1.025 (0.0404)
MBIA0020E
*: Measured with head bolts tightened
Gasket thickness can be identified at the location shown in

the figure by the numbers of cut-outs before removal.
M
PBIC0682E
When the following parts have been repaired/replaced:

With cylinder block upper surface and/or crankshaft pin journal ground
With cylinder block, pistons, connecting rods, and/or crankshaft replaced
Set piston at a point close to TDC.
a.
EM-209
http://vnx.su
CYLINDER HEAD
[YD22DDTi]
b.
c.
d.
Set the dial indicator at the location as shown in the figure. Turning crankshaft gradually, set the indicator scale to 0 where the
piston protrusion is maximized.
Move the dial indicator stand so that the tip of dial indicator can
contact cylinder block. Read the difference.
Measure two points from each cylinder in order to obtain each
mean value of them. Choose a properly thick gasket corresponding the highest number of the four values.
PBIC2645E
Piston protrusion
mm (in)
Gasket thickness* mm (in)
Identification
Number of cut-outs
Less than 0.255 (0.0100)
0.900 (0.0354)
Less than 0.255 - 0.280 (0.0100 - 0.0110)
0.925 (0.0364)
Less than 0.280 - 0.305 (0.0110 - 0.0120)
0.950 (0.0374)
Less than 0.305 - 0.330 (0.0120 - 0.0130)
0.975 (0.0384)
Less than 0.330 - 0.355 (0.0130 - 0.0140)
1.000 (0.0394)
More than 0.355 (0.0140)
1.025 (0.0404)
*: Measured with head bolts tightened
2.

A : Apply bead so that it does not protrude into oil passage.
B : Minimize the overlapping area of the bead, with
start and end areas of bead as shown in the figure.
* : Comes at an external location but cannot be viewed
externally after engine is assembled.
PBIC1256E
3.
a.
b.
Install cylinder head assembly.

Apply engine oil to bolt threads and seat surfaces.
Tighten all bolts in numerical order as shown.
: 39.2 Nm (4.0 kg-m, 29 ft-lb)
JEM149G
EM-210
http://vnx.su
CYLINDER HEAD
[YD22DDTi]
c.
d.
Tighten 180 degrees in numerical order as shown (angle tightening).

Loosen completely in reverse order of that shown in the figure.
: 0 Nm (0 kg-m, 0 ft-lb)
e.
EM
Tighten all bolts in numerical order as shown.

:39.2 Nm (4.0 kg-m, 29 ft-lb)
f.
g.
4.
5.
Tighten 90 degrees in numerical order as shown (angle tightenJEM166G

ing).
Tighten another 90 degrees in numerical order as shown (angle
tightening).
CAUTION:
When the angle wrench (special service tool) is not used, paint an alignment mark on the head
of cylinder head bolt and cylinder head surface before tightening. Check the angle with a protractor.
Install glow plug.
CAUTION:
To avoid damage, glow plugs should be removed only when required.
Handle with care to avoid applying shock. When dropped from approx. 10 cm (3.94 in) or higher,
always replace with a new one.
Before installing, remove carbon depositing on mounting hole of glow plug with a reamer.


Item
Engine running
Engine coolant
Level
Leakage
Level
Engine oil
Level
Leakage
Level
Level
Leakage
Level
Leakage
Leakage
Leakage
Leakage
Fuel
Exhaust gases
EM-211
http://vnx.su
CYLINDER HEAD
[YD22DDTi]
EBS00LRX
PBIC2328E
1.
Adjusting shim
2.
4.
Valve spring retainer
5.
Valve spring
6.
Valve oil seal
7.
Valve spring seat
8.
Valve guide
9.
Cylinder head
10. Valve seat
Valve lifter
11. Valve (Exhaust)
3.
Valve collet
12. Valve (Intake)
DISASSEMBLY
1.
2.
Remove adjusting shims and valve lifters.

Check the installation positions, and keep them to avoid being confused.
Using the valve spring compressor, attachment and adapter
(special service tool), compress valve spring. Using magnet
hand, remove valve collets.
PBIC2388E
3.
4.
Remove valve spring retainers and valve springs.

Remove valves as pressing valve stems toward combustion chamber.
Before removing valve, check the valve guide clearance. Refer to EM-214, "Valve Guide Clearance" .
EM-212
http://vnx.su
CYLINDER HEAD
[YD22DDTi]
NOTE:
Refer to the figure for intake and exhaust valve positions.
Intake and exhaust valve driving cams are provided alternately for each camshaft.
EM
SBIA0196E
5.
Remove valve oil seals using the valve oil seal puller (special
service tool).
G
JEM153G
6.
7.
8.
Remove valve spring seats.

When removing valve seats must be replaced. Refer to EM-216, "Valve Seat Replacement" .
When removing valve guides must be replaced. Refer to EM-215, "Valve Guide Replacement" .
ASSEMBLY
1.
2.
3.
Install valve guides if removed. Refer to EM-215, "Valve Guide Replacement" .

Install valve seats if removed. Refer to EM-216, "Valve Seat Replacement" .
Using the valve oil seal drift (special service tool), install valve oil
seals referring to the dimension shown in the figure.
M
JEM165G
4.
5.
Install valve spring seats.

Install valves.
Install larger diameter to intake valve side.
Note that valve layout here is different from that of conventional engine.
SBIA0196E
6.
Install valve spring.
EM-213
http://vnx.su
CYLINDER HEAD
[YD22DDTi]
7.
8.
Install valve spring retainers.

Using the valve spring compressor, attachment and adapter
(special service tool), compress valve springs.
Then install valve collets using magnet hand.
After installing valve collets, tap the stem end using the plastic
hammer, and check the installation status.
PBIC2388E
9.
Install valve lifters and adjusting shims to the same positions as before.

Valve Dimension
Check dimensions of each valve. For dimensions, refer to EM252, "Valve Dimensions" .
If dimensions are out of the standard, replace valve.
SEM188A
Valve Guide Clearance

VALVE STEM DIAMETER
Measure diameter of valve stem with micrometer.

Standard
Intake
Exhaust
: 5.965 - 5.980 mm (0.2348 - 0.2354 in)

: 5.945 - 5.960 mm (0.2341 - 0.2346 in)
SEM938C
VALVE GUIDE INNER DIAMETER
Measure inner diameter of valve guide with bore gauge.

Standard
Intake and Exhaust
: 6.000 - 6.018 mm (0.2362 - 0.2369 in)
VALVE GUIDE CLEARANCE
(Valve guide clearance) = (Valve guide inner diameter) (Valve stem diameter).
Valve guide clearance:
Standard
Intake
: 0.020 - 0.053 mm (0.0008 - 0.0021 in)
Exhaust : 0.040 - 0.073 mm (0.0016 - 0.0029 in)
Limit
EM-214
http://vnx.su
CYLINDER HEAD
[YD22DDTi]
Intake
Exhaust
: 0.08 mm (0.0031 in)

: 0.10 mm (0.0039 in)
If it exceeds the limit, replace valve and/or valve guide.

EM
Valve Guide Replacement

When removing valve guide, replace it with oversized [0.2 mm (0.0008 in)] valve guide.
1. Heat cylinder head to 110 to 130C (230 to 266F) by soaking in
heated oil.
SEM008A
2.
Using the valve guide drift (commercial service tool), tap valve
guides out from the combustion chamber side.
CAUTION:
I
SEM931C
3.
Ream cylinder head valve guide hole with the valve guide
reamer (commercial service tool).
Valve guide hole diameter (for service parts)

Intake and Exhaust:
10.175 - 10.196 mm (0.4006 - 0.4014 in)
SEM932C
4.

heated oil.
SEM008A
EM-215
http://vnx.su
CYLINDER HEAD
[YD22DDTi]
5.
Using the valve guide drift (commercial service tool), press fit
valve guides from camshaft side, referring to the dimension
Projection length H
: 10.4 - 10.6 mm (0.409 - 0.417 in)
CAUTION:
PBIC2187E
6.
Using the valve guide reamer (commercial service tool), perform

reaming to the press-fitted valve guides.
Standard
Intake and Exhaust:
6.000 - 6.018 mm (0.2362 - 0.2369 in)
SEM932C
Valve Seat Contact
Before starting this check, confirm that the dimension of valve

guide and valves are as specified.
Apply red lead primer on contacting surfaces of valves seat and
of valve face to examine the conditions of contacting surfaces.
Make sure that the paint on contacting surfaces is continuous
along the entire circumference.
If there are abnormal indications, grind the valve and check the
contact again. If malfunction indications still persist, replace
valve seat. Refer to EM-216, "Valve Seat Replacement" .
SBIA0322E
Valve Seat Replacement

When removing valve seat, replace it with oversized [0.5 mm (0.020 in)] valve seat.
1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess
in cylinder head. Set the machine depth stop to ensure this. Refer to EM-254, "Valve Seat" .
2. Ream cylinder head recess diameter for service valve seat.
Oversize [0.5 mm (0.020 in)]:
Intake
: 30.500 - 30.516 mm (1.2008 - 1.2014 in)
Exhaust
: 29.500 - 29.516 mm (1.1614 - 1.1620 in)
Be sure to ream in circles concentric to the valve guide center.

This will enable valve seat to fit correctly.
SEM795A
EM-216
http://vnx.su
CYLINDER HEAD
[YD22DDTi]
3.
Heat cylinder head to approximately 110 to 130C (230 to

266F) by soaking in heated oil.
EM
C
SEM008A
4.
5.
After cooling valve seats sufficiently with dry ice, press fit it to cylinder head.
CAUTION:
Do not touch the cooled valve seats directly by hand.
Cylinder head contains heat, when working, wear protective equipment to avoid getting burned.
Using the valve seat cutter set (commercial service tool), finish
processing referring to the dimensions shown in the figure.
Refer to EM-254, "Valve Seat" .
CAUTION:
When using the valve seat cutter set, grasp cutter handle
with both hands, press cutter onto contacting face all
around, and cut thoroughly. If cutter is pressed unevenly or
repeatedly, the valve seat surface may be damaged.
SEM934C
6.
7.
Using compound, perform valve fitting.

Check again to make sure that contacting status is satisfactory.
For details, Refer to EM-216, "Valve Seat Contact" .
8.
Use the depth gauge to measure the distance between the

mounting surface of cylinder head spring seat and the valve
stem end. If the distance is shorter than specified, repeat step 5
above to adjust it. If it is longer, replace valve seat with a new
one.
M
JEM253G
Valve Spring Square

Position the try square to valve spring, turn the spring, and measure the maximum clearance value between top surface of
spring and the try square.
Limit
: 1.9 mm (0.075 in)
If it exceeds the limit, replace valve spring.
PBIC0080E
EM-217
http://vnx.su
Valve seat resurface limit L:

Intake
: 36.53 - 36.98 mm (1.4382 - 1.4559 in)
Exhaust
: 36.53 - 37.01 mm (1.4382 - 1.4571 in)
CYLINDER HEAD
[YD22DDTi]
Valve Spring Dimensions and Valve Spring Pressure Load
Using valve spring tester, check the following.

Standard:
Free height
Installation height
Installation load
Height during
valve open
Load with valve
open
: 43.7 mm (1.720 in)

: 32.82 mm (1.2921 in)
: 184 - 208 N
(18.77 - 21.22 kg, 41.4 - 46.8 lb)
: 24.82 mm (0.9772 in)
: 320 - 360 N
(32.65 - 36.73 kg, 71.9 - 80.9 lb)
If out of the standard, replace the valve spring.
EM-218
http://vnx.su
SEM113
ENGINE ASSEMBLY
[YD22DDTi]
ENGINE ASSEMBLY
PFP:10001
A
EBS00LRY
EM
I
PBIC3607E
1.
2.
Rubber seat
3.
4.
RH engine mounting insulator
5.
6.
Front engine mounting bracket
7.
8.
Grommet
9.
Center member
10. LH engine mounting insulator
11. Stopper
12. LH engine mounting bracket
WARNING:
Situate vehicle on a flat and solid surface.
Place chocks at front and back of rear wheels.
For engines not equipped with engine slingers, attach proper slingers and bolts described in
PARTS CATALOG.
CAUTION:
Always be careful to work safely, avoid forceful or uninstructed operations.
Do not start working until exhaust system and engine coolant are cool enough.
If items or work required are not covered by the engine main body section, refer to the applicable
sections.
Always use the support point specified for lifting.
Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for
unavoidable reasons, support at the rear axle jacking point with transmission jack or similar tool
before starting work, in preparation for the backward shift of center of gravity.
For supporting points for lifting and jacking point at rear axle, refer to GI-36, "Garage Jack and
Safety Stand" .
EM-219
http://vnx.su
ENGINE ASSEMBLY
[YD22DDTi]
REMOVAL
Description of work
Remove engine, transaxle and transfer assembly with front suspension member from vehicle downward. Separate suspension member, and then separate engine and transaxle.
Preparation
1.
2.
3.
4.
5.
Remove hood assembly. Refer to BL-12, "HOOD" .

Drain engine coolant from radiator drain plug. Refer to CO-32, "DRAINING ENGINE COOLANT" .
LH and RH engine undercover
LH and RH front wheels
Battery; Refer to SC-3, "BATTERY" .
Drive belts; Refer to EM-138, "Removal and Installation" .
Air duct and air cleaner case assembly; Refer to EM-139, "Removal and Installation" .
Alternator; Refer to SC-16, "Removal and Installation" .
Radiator and cooling fan assembly; Refer to CO-35, "Removal and Installation" and CO-37, "COOLING FAN" .
Charge air cooler; Refer to EM-141, "CHARGE AIR COOLER" .
Disconnect engine room harness from the engine side and set it aside for easier work.
Disconnect all vacuum hoses and air hoses connected to vehicle side at engine side.
Engine room LH
1.
2.
3.
4.
Disconnect fuel hose, and plug it to prevent fuel from draining. Refer to EM-143, "INTAKE MANIFOLD" .
Disconnect heater hose, and install plug it to prevent engine coolant from draining. Refer to EM-143,
"INTAKE MANIFOLD" .
Remove clutch operating cylinder from transaxle, and move it aside. Refer to MT-17, "TRANSAXLE
ASSEMBLY" and CL-12, "OPERATING CYLINDER" .
Disconnect shift cable from transaxle. Refer to MT-14, "CONTROL LINKAGE" .
Engine room RH
1.
2.

Remove A/C compressor with piping connected from engine. Temporarily secure it on body with a rope to
avoid putting load on it. Refer to ATC-144, "Removal and Installation of Compressor" .
Vehicle underbody
1.
2.
3.
4.
5.
6.
7.
8.
a.
b.
Remove exhaust front tube. Refer to EX-2, "Removal and Installation" .

Remove propeller shaft. Refer to PR-4, "Removal and Installation" .
Remove steering shaft from steering gear. Refer to PS-11, "STEERING COLUMN" .
Disconnect power steering fluid cooler piping at a point between body and engine. Refer to PS-37,
"HYDRAULIC LINE" .
Remove front wheel sensor (LH and RH) for ABS from brake caliper. Refer to BRC-45, "WHEEL SENSORS" (ABS), BRC-114, "WHEEL SENSORS" (ESP/TCS/ABS).
Remove brake caliper with piping connected from steering knuckle. Temporarily secure it on body with a
rope to avoid load on it. Refer to BR-27, "FRONT DISC BRAKE" .
Remove lower ends of LH and RH strut from steering knuckle. Refer to FSU-5, "FRONT SUSPENSION
ASSEMBLY" .
Preparation for the separation work of transaxle as follows:
Remove crankshaft position sensor from transmission. Refer toEM-154, "OIL PAN AND OIL STRAINER" .
Remove transaxle joint bolts which pierce at oil pan lower rear side. Refer to EM-154, "OIL PAN AND OIL
STRAINER" .
EM-220
http://vnx.su
ENGINE ASSEMBLY
[YD22DDTi]
Removal
1.
Install engine slingers into front right of cylinder head and rear
left of cylinder head.
Slinger bolts:
EM
: 33.5 Nm (3.4 kg-m, 25 ft-lb)
SBIA0191E
2.
Lift with hoist and secure engine in position.
3.
Use the manual lift table caddy (commercial service tool) or

equivalently rigid tool such as a jack or trestle. Securely support
bottom of engine and transaxle, and simultaneously adjust hoist
tension.
CAUTION:
Put a piece of wood or something similar as the supporting
surface, secure a completely stable condition.
H
KBIA0256E
4.
5.
Remove RH engine mounting insulator.

Pull LH engine mounting through-bolt out.
K
PBIC2188E
6.
7.
Remove mounting bolts at front end of center member.

Remove front suspension member mounting bolts and nuts.
Refer to FSU-5, "FRONT SUSPENSION ASSEMBLY" .
KBIA0270E
8.
Remove engine, transaxle and transfer assembly with suspension member and center member from vehicle downward by carefully operating supporting tools.
CAUTION:
During the operation, make sure that no part interferes with body side.
Before and during this lifting, always check if any harnesses are left connected.
During the removal operation, always be careful to prevent vehicle from falling off the lift due to
changes in the center of gravity.
If necessary, support vehicle by setting a jack or equivalent tool at the rear.
EM-221
http://vnx.su
ENGINE ASSEMBLY
[YD22DDTi]
9.
Remove power steering oil pump with piping connected from engine. Move it aside on suspension member. Refer to PS-37, "HYDRAULIC LINE" .
10. Remove front engine mounting and rear engine mounting through-bolts to remove suspension member.
11. Remove starter motor. Refer to SC-22, "STARTING SYSTEM" .
12. Separate engine and transaxle and transfer assembly. Refer to MT-17, "TRANSAXLE ASSEMBLY" .
INSTALLATION
Do not allow engine oil to get on mounting insulator. Be careful not to damage mounting insulator.
When installation directions are specified, install parts according to the direction marks on them referring
to figure of components. Refer to EM-219, "ENGINE ASSEMBLY" .
Make sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts.

Item
Engine running
Engine coolant
Level
Leakage
Level
Engine oil
Level
Leakage
Level
Level
Leakage
Level
Leakage
Leakage
Leakage
Leakage
Fuel
Exhaust gases
EM-222
http://vnx.su
CYLINDER BLOCK
[YD22DDTi]
CYLINDER BLOCK
PFP:11010
A
EBS00ODX
EM
PBIC2587E
EM-223
http://vnx.su
CYLINDER BLOCK
[YD22DDTi]
1.
Rear oil seal retainer
2.
Cylinder block
3.
Oil pressure switch
4.
Fuel pump bracket
5.
6.
Top ring
7.
Second ring
8.
Oil ring
9.
Oil jet
10. Piston pin
11. Snap ring
13. Main bearing upper
14. Thrust bearing
12. Piston
15. Connecting rod
16. Key
17. Connecting rod bearing
18. Connecting rod cap
19. Connecting rod nut
20. Main bearing lower
21. Crankshaft
22. Main bearing cap bolt
23. Main bearing cap
24. Pilot bushing
25. Flywheel
26. Washer
27. Oil jet relief valve
28. Drain plug
29. Rear oil seal
DISASSEMBLY
1.
2.
3.
a.
b.
c.
d.
Remove engine, transaxle and transfer assembly from the vehicle, then separate engine and transaxle
and transfer assembly. Refer to EM-219, "ENGINE ASSEMBLY" .
Remove clutch cover and disk. Refer to CL-16, "CLUTCH DISC, CLUTCH COVER AND FLYWHEEL" .
Install engine to engine stand as follows:
Remove flywheel.
Secure ring gear with the ring gear stopper (special service
tool), then loosen mounting bolts with TORX socket (size: T55,
Commercial Service Tools) and remove them. As an alternative
method hold crankshaft pulley with the pulley holder (special
service tool: KV10109300) to remove flywheel.
CAUTION:
Do not disassemble flywheel.
Do not place flywheel with signal plate facing down.
When handling signal plate, take care not to damage or
scratch it.
PBIC2406E
Handle signal plate in a manner that prevents it from
becoming magnetized.
Install the engine sub-attachment (special service tool) to the
rear side of cylinder block.
Align knock pins on cylinder block with pin holes on attachment to install.
NOTE:
Installation bolts are part of engine sub-attachment.
Install the engine stand shaft (special service tool).
NOTE:
Use commercially available M12 (0.47 in) mounting bolts and
nuts (4 sets) with strength grade of 9T (minimum).
EM-224
http://vnx.su
JEM192G
CYLINDER BLOCK
[YD22DDTi]
e.
Hoist engine and install it to the engine stand (special service

tool).
NOTE:
It is possible to set engine sub-attachment and engine stand
shaft to the engine stand at first, then install engine later.
EM
G
JEM193G
Widely use engine stand can be used.

CAUTION:
Use an engine stand that has a load capacity [219 kg (483
pound) or more] large enough for supporting the engine
weight.
NOTE:
The figure shows an example of general-purpose engine
stand that can hold mating surface of transmission with drive
plate and rear plate removed.
PBIC0085E
4.
If they need to be replaced, replace pilot bushing.

Using the pilot bushing puller (special service tool), remove
the pilot bushing from rear end of crankshaft.
PBIC2588E
5.
EM-225
http://vnx.su
CYLINDER BLOCK
[YD22DDTi]
6.
Drain engine coolant by removing drain plug from inside of

engine.
PBIC2439E
7.
Remove the following parts and related parts. (Only major parts are listed.)
Intake manifold (Refer to EM-143, "INTAKE MANIFOLD" .)
Exhaust manifold and turbocharger (Refer to EM-148, "Removal and Installation" .)
Rocker cover (Refer to EM-175, "ROCKER COVER" .)
Fuel injector (Refer to EM-164, "Removal and Installation" .)
Oil pan and oil strainer (Refer to EM-154, "OIL PAN AND OIL STRAINER" .)
Water pump (Refer to CO-43, "WATER PUMP" .)
Thermostat and water piping (Refer to CO-45, "THERMOSTAT AND WATER PIPING" .)
Vacuum pump (Refer to EM-160, "VACUUM PUMP" .)
Secondary timing chain (Refer to EM-190, "Removal and Installation" .)
Primary timing chain (Refer to EM-195, "PRIMARY TIMING CHAIN" .)
Fuel pump (Refer toEM-168, "FUEL PUMP" .)
Camshaft (Refer to EM-177, "Removal and Installation" .)
Cylinder head (Refer to EM-207, "Removal and Installation" .)
Oil cooler (Refer to LU-28, "OIL COOLER" .)
Accessory, accessory bracket and mount brackets
8. Remove fuel pump bracket.
9. Remove rear oil seal retainer.
Insert a flat-bladed screwdriver between main bearing cap and rear oil seal retainer to remove retainer.
10. Remove rear oil seal from rear oil seal retainer.
Punch out with a flat-bladed screwdriver.
CAUTION:
Be careful not to damage rear oil seal retainer.
11. Remove piston and connecting rod assembly as follows:
Before removing piston and connecting rod assembly, check connecting rod side clearance. Refer to
EM-239, "CONNECTING ROD SIDE CLEARANCE" .
a. Move crankshaft pin to be removed to approximately BDC.
b. Remove connecting rod caps.
c. Using the grip of a hammer, press the piston and connecting rod
assembly out to cylinder head side.
JEM195G
EM-226
http://vnx.su
CYLINDER BLOCK
[YD22DDTi]
CAUTION:
When removing piston and connecting rod assembly,
prevent the big end of connecting rod from interfering
with oil jet.
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod
big end.
EM
PBIC2232E
12. Remove connecting rod bearings from connecting rods and caps.
Keep them by cylinder to avoid confusion.
13. Remove piston rings from pistons using the piston ring expander
CAUTION:
When removing, prevent pistons from being damaged.
Do not expand piston rings excessively. This may damage piston rings.
H
JEM196G
14. Remove pistons from connecting rods as follows:

a. Using the snap ring pliers, remove snap rings.
JEM197G
b.
Using the industrial use dryer, heat pistons up to 60 to 70C (140

to 158F).
PBIC0089E
EM-227
http://vnx.su
CYLINDER BLOCK
[YD22DDTi]
c.
Using rod with outer diameter of 26 mm (1.02 in), press piston

pins out.
EMM0072D
15. Remove main bearing cap bolts.

With a TORX socket (size: E14, Commercial Service Tool),
loosen main bearing cap bolts in several stages in reverse
order of that shown in the figure and remove them.
Before loosening main bearing cap bolts, measure crankshaft
end play. Refer to EM-238, "CRANKSHAFT END PLAY" .
JEM200G
16. Remove main bearing caps.

Using main bearing cap bolts, remove by rocking bearing cap
back and forth.
JEM201G
17. Remove crankshaft.

18. Remove main bearings and thrust bearings from cylinder block and main bearing caps.
CAUTION:
Check the correct installation locations of removed parts. Store them so they do not get mixed up.
19. Remove oil jet.
20. Remove oil jet relief valve.
ASSEMBLY
1.
Blow air sufficiently to inside engine coolant passage, engine oil passage, crankcase and cylinder bore to
remove foreign matter.
CAUTION:
Use a goggles to protect your eye.
EM-228
http://vnx.su
CYLINDER BLOCK
[YD22DDTi]
2.
Install drain plug to cylinder block.

Apply liquid gasket.
: 9.8 Nm (1.0 kg-m, 87 in-lb)
EM
C
PBIC2439E
3.
4.
Install oil jet relief valve.

Install oil jet.
Align knock pin on back of oil jet with hole on block when
installing oil jet.
G
PBIC0389E
5.
a.
b.
Install main bearings and thrust bearings as follows:

Remove contamination, dust and engine oil from bearing mounting positions on cylinder block and main bearing caps.
Install thrust bearings on both sides of No. 3 housing on cylinder
block.
Install thrust bearings with face oil groove facing to crankshaft
arm (outside).
K
JEM224G
c.
6.
Being careful with the direction, install main bearings.

Install main bearings with the oil holes and grooves onto the
cylinder block side, and those without oil holes and grooves
onto the main cap side.
While installing bearings, apply engine oil to bearing surfaces
(inside). Do not apply engine oil to rear surfaces, but clean
them completely.
Align stopper notches on bearings to install them.
Make sure that the oil holes on the cylinder block body are
mated with the oil hole positions on the bearings.
Install crankshaft to cylinder block.
Make sure crankshaft rotates smoothly by hand.
EM-229
http://vnx.su
JEM213G
CYLINDER BLOCK
[YD22DDTi]
7.
Install main bearing caps.

Identify main bearing caps by the punched mark. Install correctly matching the journal No. on the bearing cap and the
journal with the front mark facing forward.
Main bearing caps are commonly processed with the cylinder
block. Therefore, caps and cylinder block should be replaced
as a set.
JEM225G
8.
Check the main bearing cap bolts for deformation. Refer to EM-247, "MAIN BEARING CAP BOLT
DEFORMATION" .
9.
With the TORX socket (size: E14, commercial service tool),

tighten the main bearing cap bolts according to the following
procedure:
Apply engine oil to the threaded part and seat surface of each
bolt.
Tighten all bolts in numerical order shown in the figure.
a.
b.
: 27 Nm (2.8 kg-m, 20 ft-lb)

c.
Put alignment marks (with paint) on each bolt and the main
bearing cap, all in the same direction. (When using a protractor)
Then, tighten 90 degrees. (angle tightening)

CAUTION:
Always use either the angle wrench (special service tool) or
protractor during angle tightening. Avoid tightening based
on visual checks alone.
After tightening bolts to specified torque, make sure that
crankshaft rotates smoothly.
Check crankshaft end play. Refer to EM-238, "CRANKSHAFT
END PLAY" .
10. Check the outer diameter of connecting rod bolts. Refer to EM247, "CONNECTING ROD BOLT DEFORMATION" .
11. Install piston to connecting rod.
a. Using the snap ring pliers, install snap rings to groove on piston rear side.
Fit snap ring correctly into grooves.
b. Install pistons to connecting rods.
Using the industrial use dryer, heat pistons up to approx. 60 to
70C (140 to 158F) until piston pin can be pressed down by
finger touch. Then insert piston pin into piston and connecting
rod from front side of piston toward rear.
JEM200G
d.
JEM226G
PBIC0089E
EM-230
http://vnx.su
CYLINDER BLOCK
[YD22DDTi]
Assemble piston and connecting rod with front mark of piston
head and cylinder No. stamped on connecting rod being positioned as shown in the figure.
Install snap ring to front side of piston.
Refer to above step a for precaution on snap ring installation.
After installation, check connecting rods for smooth movement.
c.
EM
C
MBIA0024E
12. Use the piston ring expander (commercial service tool) to install piston rings.
CAUTION:
When installing, prevent piston from being damaged.
Install top ring and second ring with punched mark surfaces
facing upward.
Punched mark:
Top ring
Second ring
: RTop
: R2nd
Install rings so that three closed gap position 120 degrees

apart one another.
Closed gaps do not need to face in a specific directions, as
long as each are positioned 120 degrees apart.
H
JEM228G
13. Install connecting rod bearing to connecting rod and cap.

While installing connecting rod bearing, apply engine oil to
bearing surfaces (inside). Do not apply engine oil to rear surfaces, but clean them completely.
Align protrusions on connecting rod bearings with connecting
rod cut-outs to install connecting rod bearings.
JEM229G
14. Install piston and connecting rod assembly to crankshaft.

Move crankshaft pin to be assembled to BDC.
Align cylinder position with cylinder No. on connecting rod to
install piston and connecting rod assembly.
Apply engine oil sufficiently to the cylinder bore, piston and
crankshaft pin.
Using the piston ring compressor (special service tool) or suitable tool, install piston and connecting rod assembly with front
mark on piston head facing toward the front side of engine.
CAUTION:
PBIC1619E
When removing piston and connecting rod assembly,
prevent the big end of connecting rod from interfering with oil jet.
Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference
of the connecting rod big end.
EM-231
http://vnx.su
CYLINDER BLOCK
[YD22DDTi]
15. Install connecting rod caps and mounting nuts.
Align cylinder No. stamped on connecting rod with that on cap
to install connecting rod cap.
Make sure that the front mark on connecting rod cap faces
towards the front of the engine.
MBIA0024E
16. Tighten connecting rod nuts according to the following procedure:

a. Apply engine oil on bolt threads and seat surface of nuts.
b. Tighten bolts.
: 29.4 Nm (3.0 kg-m, 22 ft-lb)
c.
Loosen completely.
: 0 Nm (0 kg-m, 0 in-lb)
d.
Tighten bolts.
: 19.6 Nm (2.0 kg-m, 14 ft-lb)
e.
Tighten 120 degrees. (angle tightening)

Always use either the angle wrench (special service tool)
or protractor during angle tightening. Avoid tightening
based on visual checks alone.
After tightening nuts, make sure that crankshaft rotates
smoothly.
Check connecting rod side clearance. Refer to EM-239,
"CONNECTING ROD SIDE CLEARANCE" .
JEM231G
17. Press fit rear oil seal into rear oil seal retainer.
Using the drift [105 mm (4.13 in) dia.], press fit so that the
dimension is as specified in the figure.
Avoid inclined fitting. Force fit perpendicularly.
JEM232G
EM-232
http://vnx.su
CYLINDER BLOCK
[YD22DDTi]
18. Install rear oil seal retainer to cylinder block.
Apply new engine oil to the oil and dust seal lips.
Apply liquid gasket to rear oil seal retainer using the tube
presser (special service tool: WS39930000) as shown in the
figure.
EM
C
JEM233G
19. Press fit pilot bush into crankshaft.

Using the drift with outer diameter of 19 mm (0.75 in), press fit
pilot bush until it stops.
G
JEM234G
20. Install fuel pump bracket.

Align the bracket with the dowel pins on cylinder block to
install.
The two bolts used for dowel pins have a longer shanks than
the other two.
PBIC2329E
21. Install parts to engine in the reverse order of disassembly.

22. Remove engine from engine stand in the reverse order of assembly.
23. Install flywheel.

When installing flywheel to crankshaft, be sure to correctly
align crankshaft side dowel pin and flywheel side dowel pin
hole.
CAUTION:
If these are not aligned correctly, engine runs roughly
and MI turns on.
PBIC2538E
EM-233
http://vnx.su
CYLINDER BLOCK
[YD22DDTi]
There is a mating mark on the clutch cover side, Refer it during installation.
PBIC2495E
Holding ring gear with the ring stopper (special service tool),
tighten securing bolts with TORX bit (size: T55, Commercial
Service Tool).
Tighten bolts uniformly in a crisscross manner.
Apply engine oil to bolt threads and seat surfaces.
PBIC2406E
How to Select Piston and Bearing
EBS00ODY
DESCRIPTION
Selection points
Between cylinder block to

crankshaft
Selection parts
Selection items
Main bearing
Selection methods
Main bearing grade (bearing

thickness)
Determined by match of cylinder block bearing housing

grade (inner diameter of housing) and crankshaft main journal grade (outer diameter of
main journal)
Between crankshaft to connecting rod
Connecting rod bearing
Connecting rod bearing grade

(bearing thickness)
Combining service grades for

connecting rod big end diameter and crankshaft pin journal
diameter determine connecting
rod bearing selection.
Between cylinder block to piston
Piston and piston pin assembly

The piston is available together
with piston pin as an assembly.
Piston grade (piston skirt diameter)
Piston grade = cylinder bore

grade (inner diameter of bore)
The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.
EM-234
http://vnx.su
CYLINDER BLOCK
[YD22DDTi]
HOW TO SELECT PISTON
When Using New Cylinder Block
1.
2.
Identify the cylinder bore grade (No. 1, 2, or 3) on LH surface at

the rear of cylinder block.
The part No. of piston is specified together with piston pin as
an assembly.
EM
D
PBIC2589E
MBIA0025E
When Re-using Old Cylinder Block

1.
2.
3.
Measure cylinder bore inner diameter. Refer to EM-243, "Cylinder Bore Inner Diameter" .
Referring to Cylinder bore inner diameter in Piston Selection Table, determine the bore grade.
Piston Selection Table

Unit: mm (in)
Grade (punched)
Cylinder bore
inner diameter
86.000 - 86.010 (3.3858 - 3.3862)
86.010 - 86.020 (3.3862 - 3.3866)
86.020 - 86.030 (3.3866 - 3.3870)
85.928 - 85.942 (3.3830 - 3.3835)
85.938 - 85.952 (3.3834 - 3.3839)
85.948 - 85.962 (3.3838 - 3.3843)
NOTE:
Piston is available together with piston pin as an assembly.
HOW TO SELECT CONNECTING ROD BEARING

When Using New Crankshaft and Connecting Rod
1.
2.
Identify the pin journal diameter grade (No. 0, 1, or 2) on front

surface of crankshaft.
Select connecting rod bearings of the same grade.
NOTE:
There is no grading for the inner diameter of the big end of the
connecting rod.
PBIC2590E
EM-235
http://vnx.su
CYLINDER BLOCK
[YD22DDTi]
When Re-using the Removed Crankshaft and Connecting Rod
1.
2.
3.
4.
Measure the inner diameter of the big end of connecting rod and make sure it is within the specified
range. Refer to EM-241, "CONNECTING ROD BIG END INNER DIAMETER" .
Measure the outer diameter of the crankshaft pin journal. Refer to EM-244, "CRANKSHAFT PIN JOURNAL DIAMETER" .
Determine the crankshaft pin journal grade by comparing the measurement with the values under the column Crankshaft pin journal diameter in Selection Table of connecting Rod Bearing.
Choose bearings of the same grade.
Selection Table of connecting Rod Bearing

Unit: mm (in)
Connecting rod big end inner diameter
55.000 - 55.013 (2.1654 - 2.1659)

Unit: mm (in)
Crankshaft pin journal diameter
Grade (Mark)
Dimension (Bearing thickness range)
Bearing grade No.
Color
51.968 - 51.974 (2.0460 - 2.0462)
1.492 - 1.496 (0.0587 - 0.0589)
STD 0
Black
51.961 - 51.968 (2.0457 - 2.0460)
1.496 - 1.500 (0.0589 - 0.0591)
STD 1
Brown
51.954 - 51.961 (2.0454 - 2.0457)
1.500 - 1.504 (0.0591 - 0.0592)
STD 2
Green
Under Size Bearing Usage
If bearing clearance is out of the specifications for connecting rod bearings in standard size, use under
size bearings.
When using under size bearings, measure bearing inner diameter with bearing installed, and grind crankshaft pins to adjust clearance to specification.
Connecting Rod Bearing Under Size List

Unit: mm (in)
Size
Thickness
US 0.08 (0.0031)
1.536 - 1.540 (0.0605 - 0.0606)
US 0.12 (0.0047)
1.556 - 1.560 (0.0613 - 0.0614)
US 0.25 (0.0098)
1.621 - 1.625 (0.0638 - 0.0640)
CAUTION:
When grinding the crankshaft pin journal to use an under size
bearing, avoid damaging the fillet R.
Standard dimension R
: 1.5 - 1.7 mm (0.0591 - 0.0669 in)
PBIC2200E
EM-236
http://vnx.su
CYLINDER BLOCK
[YD22DDTi]
HOW TO SELECT MAIN BEARING
When Using New Cylinder Block and Crankshaft
1.
Identify the main bearing housing grade (No. 0, 1, or 2) on LH

surface at the rear of the cylinder block, and locate the applicable grade on the Grade row in the Main Bearing Grade Table.
EM
D
PBIC2589E
2.
Identify the main journal grade (No. 0, 1, or 2) on the front surface of crankshaft, and locate the applicable grade under the
Grade column in the Main Bearing Grade Table.
PBIC2590E
3.
The main bearing to be used (STD 0 to STD 4) can be located in the cell where the row and column cross.
I
When Re-using Removed Cylinder Block and Crankshaft

1.
2.
3.
4.
5.
Measure the inner diameter of cylinder block main bearing housing. Refer to EM-242, "MAIN BEARING
HOUSING INNER DIAMETER" .
Locate the applicable cell where the measurement falls, on Inner diameter of Cylinder block main bearing
housing row in the Main Bearing Grade Table.
Measure the outer diameter of crankshaft main journal. Refer to EM-244, "CRANKSHAFT MAIN JOURNAL DIAMETER" .
Locate the applicable cell where the measurement falls, under Crankshaft main journal diameter column
in the Main Bearing Grade Table.
The main bearing to be used (STD 0 to STD 4) can be located in the cell where the row and column cross.
Main Bearing Grade Table

Unit: mm (in)
Inner diameter of Cylinder block main bearing housing
Crankshaft main
journal diameter
62.967 - 62.975
(2.4790 - 2.4793)
66.654 - 66.663
(2.6242 - 2.6245)
66.663 - 66.672
(2.6245 - 2.6249)
66.672 - 66.681
(2.6249 - 2.6252)
STD 0
1.816 - 1.820
(0.0715 - 0.0717)
0.039 - 0.066
(0.0015 - 0.0026)
Black
STD 1
1.820 - 1.824
(0.0717 - 0.0718)
0.039 - 0.066
(0.0015 - 0.0026)
Brown
STD 2
1.824 - 1.828
(0.0718 - 0.0720)
0.039 - 0.066
(0.0015 - 0.0026)
Green
Grade
(punched)
Bearing grade No.
Bearing thickness
Oil clearance
EM-237
http://vnx.su
CYLINDER BLOCK
[YD22DDTi]
62.959 - 62.967
(2.4787 - 2.6790)
Bearing grade No.
Bearing thickness
Oil clearance
Bearing grade No.
Bearing thickness
Oil clearance
62.951 - 62.959
(2.4784 - 2.4787)
STD 1
1.820 - 1.824
(0.0717 - 0.0718)
0.039 - 0.066
(0.0015 - 0.0026)
Brown
STD 2
1.824 - 1.828
(0.0718 - 0.0720)
0.039 - 0.066
(0.0015 - 0.0026)
Green
STD 3
1.828 - 1.832
(0.0720 - 0.0721)
0.039 - 0.066
(0.0015 - 0.0026)
Yellow
STD 2
1.824 - 1.828
(0.0718 - 0.0720)
0.039 - 0.066
(0.0015 - 0.0026)
Green
STD 3
1.828 - 1.832
(0.0720 - 0.0721)
0.039 - 0.066
(0.0015 - 0.0026)
Yellow
STD 4
1.832 - 1.836
(0.0721 - 0.0723)
0.039 - 0.066
(0.0015 - 0.0026)
Blue
Under Size Bearing Usage
If bearing clearance is out of the specifications for main bearings in standard size, use under size bearings.
When using under size bearings, measure bearing inner diameter with bearing installed, and grind crankshaft journals to adjust clearance to the specification.
Main Bearing Under Size List

Unit: mm (in)
Size
Thickness
US 0.25 (0.0098)
1.949 - 1.953 (0.0767 - 0.0769)
CAUTION:
When grinding crankshaft main journals to use under size bearings, keep corners radius of fillet R.
Standard dimension R
: 1.5 - 1.7 mm (0.0591 - 0.0669 in)
PBIC2200E
EBS00ODP
CRANKSHAFT END PLAY
Using dial indicator, measure crankshaft travel amount by moving the crankshaft forward or backward.
Standard
Limit
: 0.10 - 0.25 mm (0.0039 - 0.0098 in)

: 0.30 mm (0.0118 in)
If the value exceeds the limit, replace thrust bearings with new
ones and measure again.
If the measurement exceeds the limit again, replace crankshaft
with a new one.
PBIC2377E
EM-238
http://vnx.su
CYLINDER BLOCK
[YD22DDTi]
CONNECTING ROD SIDE CLEARANCE
Standard
Limit
Using feeler gauge, measure side clearance between connecting rod and crankshaft arm.
: 0.20 - 0.35 (0.0079 - 0.0138 in)
: 0.40 mm (0.0157 in)
EM
If measured value exceeds the limit, replace connecting rod and

repeat measurement.
If measured value still exceeds the limit, replace crankshaft.
JEM203G
PISTON TO PISTON PIN CLEARANCE

Piston Pin Bore Diameter
Using inside micrometer, measure piston pin bore diameter.

Standard
: 28.003 - 28.009 mm (1.1025 - 1.1027 in)

F
H
PBIC0116E

I
Using micrometer, measure piston pin outer diameter.

Standard
: 27.995 - 28.000 mm (1.1022 - 1.1024 in)

J
L
PBIC0117E
Calculation of Piston to Piston Pin Clearance

(Piston pin clearance) = (Piston pin bore diameter) (Piston pin outer diameter)
Standard
: 0.003 - 0.014 mm (0.0001 - 0.0006 in)
If out of the standard, replace piston/piston pin assembly.

When replacing piston and piston pin assembly, refer to EM-243, "PISTON TO CYLINDER BORE
CLEARANCE" .
NOTE:
Piston is available together with piston pin as assembly.
EM-239
http://vnx.su
CYLINDER BLOCK
[YD22DDTi]
PISTON RING SIDE CLEARANCE
Using feeler gauge, measure the side clearance between piston

ring and piston ring groove.
Unit: mm (in)
Item
Standard
Limit
Top ring
0.050 - 0.090 (0.0020 - 0.0035)
0.2 (0.008)
2nd ring
0.050 - 0.090 (0.0020 - 0.0035)
0.1 (0.004)
Oil ring
0.030 - 0.070 (0.0012 - 0.0028)
SEM024AA
Align top ring and external surface of piston. Measure lower side
clearance of top ring with top ring pressed onto upper side of
ring groove.
If side clearance exceeds the limit, replace piston ring.
Check clearance again. If side clearance still exceeds the limit,
replace piston.
FEM100
PISTON RING END GAP
Make sure that cylinder bore diameter is within the specifications. Refer to EM-243, "PISTON TO CYLINDER BORE
CLEARANCE" .
Lubricate with new engine oil to piston and piston ring, and then
insert piston ring until middle of cylinder with piston, and measure piston ring end gap with feeler gauge.
Unit: mm (in)
Item
Standard
Top ring
0.20 - 0.30 (0.0079 - 0.0118)
2nd ring
0.31 - 0.51 (0.0122 - 0.0201)
Oil ring
0.30 - 0.55 (0.0118 - 0.0217)
Limit
1.0 (0.039)
FEM101
If out of the limit, replace piston ring. If gap still exceeds the limit even with a new ring, re-bore cylinder
and use oversized piston and piston ring. Refer to EM-243, "PISTON TO CYLINDER BORE CLEARANCE" .
EM-240
http://vnx.su
CYLINDER BLOCK
[YD22DDTi]
CONNECTING ROD BEND AND TORSION
Bend limit
Torsion limit
Use connecting rod aligner to check bend and torsion.

: 0.12 mm (0.0047 in)/100 mm (3.94 in)
: 0.12 mm (0.0047 in)/100 mm (3.94 in)
EM
If it exceeds the limit, replace connecting rod assembly.

C
G
PBIC2077E
CONNECTING ROD BIG END INNER DIAMETER
Install connecting rod caps without connecting rod bearings and

tighten connecting rod nuts to the specified torque. Refer to EM228, "ASSEMBLY" .
Using inside micrometer, measure connecting rod big end inner
diameter.
Standard
: 55.000 - 55.013 mm (2.1654 - 2.1659 in)
If out of the standard, replace connecting rod.

K
PBIC1641E
CONNECTING ROD BUSHING OIL CLEARANCE

Connecting Rod Bushing Inner Diameter
Use inside micrometer to measure bushing inner diameter.

Standard
: 28.026 - 28.038 mm (1.1034 - 1.1039 in)
PBIC0120E
EM-241
http://vnx.su
CYLINDER BLOCK
[YD22DDTi]
Use micrometer to measure piston pin outer diameter.
Standard
: 27.995 - 28.000 mm (1.1022 - 1.1024 in)
PBIC0117E
Calculation of Connecting Rod Bushing Clearance

(Connecting rod bushing clearance) = (Connecting rod bushing inner diameter) (Piston pin outer diameter)
Standard
Limit
: 0.026 - 0.044 mm (0.0010 - 0.0017 in)

: 0.057 mm (0.0022 in)
If it exceeds the limit, replace connecting rod and/or piston and piston pin assembly. Refer to EM-235,
"HOW TO SELECT CONNECTING ROD BEARING" and/or EM-235, "HOW TO SELECT PISTON" .
CYLINDER BLOCK TOP SURFACE DISTORTION
Using scraper, remove gasket installed onto cylinder block surface. Remove contamination such as engine oil, scale, and carbon.
CAUTION:
Keep broken pieces of gasket clear of engine oil and engine
coolant passages.
Use straightedge and feeler gauge to check block upper surface
for six distortion.
Limit
: 0.1 mm (0.004 in)
If it exceeds the limit, replace cylinder block.
SEM501G
MAIN BEARING HOUSING INNER DIAMETER
Without installing main bearings, install main bearing caps, and

tighten bolts to the specified torque. Refer to EM-228, "ASSEMBLY" .
Measure the inner diameter of main bearing housing with a bore
gauge.
Standard
: 66.654 - 66.681 mm (2.6242 - 2.6252 in)
If the measurement is out of the standard, replace cylinder block

and main bearing caps.
NOTE:
These components cannot be replaced as a single unit, because
they were processed together.
EM-242
http://vnx.su
PBIC1643E
CYLINDER BLOCK
[YD22DDTi]
PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter
Using bore gauge, measure cylinder inner diameters at six positions; top, middle, and bottom (A, B, C) in 2 directions (X,
Y).
Cylinder bore inner diameter
: 86.000 - 86.030 mm (3.3858 - 3.5870 in)
Wear limit
: 0.20 mm (0.008 in)
Out-of-round limit (Difference between X and Y)
: 0.015 mm (0.0006 in)
Taper limit (Difference between A and C)
: 0.010 mm (0.0004 in)
EM
D
JEM207G
If the measured value exceeds the limit, or if there are scratches

and/or seizure on the cylinder inner wall, hone or bore the inner
wall.
Oversize piston is provided. When using oversize piston, hone
the cylinder so that the clearance between piston and cylinder
satisfies the standard.
CAUTION:
If oversize piston is used, use it for all cylinders with oversize piston rings.
Oversize (OS)
: 0.25 mm (0.0098 in)

: 0.50 mm (0.0197 in)
H
PBIC2246E
Piston Skirt Diameter

Use micrometer to measure piston skirt diameter.
Measurement position
Standard
0.25 (0.0098) O/S
0.50 (0.0197) O/S
: 11.0 mm (0.43 in)

Distance from the bottom
: 85.928 - 85.962 mm
(3.3830 - 3.3843 in)
: 86.188 - 86.202
(3.3932 - 3.3938 in)
: 86.438 - 86.452
(3.4031 - 3.4036 in)
PBIC0125E
Calculation of Piston to Cylinder Bore Clearance
Calculate using piston skirt diameter and cylinder bore inner diameter (direction X, position B).
(Clearance) = (Cylinder bore inner diameter) (Piston skirt diameter)
Specifications at room temperature [20C (68F)]:
Standard
: 0.058 - 0.082 mm (0.0023 - 0.0032 in)
If it exceeds the limit, replace piston and piston pin assembly. Refer to EM-235, "HOW TO SELECT PISTON" .
Reboring Cylinder Bore

1.
Determine the cylinder bore size by adding piston-to-cylinder bore clearance to piston skirt diameter.
Rebore size calculation:
D=A+BC
Where,
EM-243
http://vnx.su
CYLINDER BLOCK
[YD22DDTi]
D: Bored diameter
A: Piston skirt diameter as measured
B: Piston-to-cylinder bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
2.
3.
4.
5.
Install main bearing caps and tighten bolts to the specified torque. Refer to EM-228, "ASSEMBLY" . This
will prevent distortion of cylinder bores.
Cut cylinder bore.
NOTE:
When any cylinder needs boring, all other cylinders must also be bored.
Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so at a time.
Hone cylinders to obtain the specified piston-to-cylinder bore clearance.
Measure finished cylinder bore for the out-of-round and taper.
NOTE:
Measurement should be done after cylinder bore cools down.
CRANKSHAFT MAIN JOURNAL DIAMETER
Use micrometer to measure main journal diameter.

Standard : 62.951 - 62.975 mm (2.4784 - 2.4793 in)
If out of the standard, measure the main bearing oil clearance.

then use the undersize bearing. Refer to EM-246, "MAIN BEARING OIL CLEARANCE" .
FEM114
CRANKSHAFT PIN JOURNAL DIAMETER
Use micrometer to measure crankshaft pin journal diameter.

Standard
: 51.954 - 51.974 mm (2.0454 - 2.0462 in)
If out of the standard, measure the connecting rod bearing oil

clearance. then use the undersize bearing. Refer to EM-245,
"CONNECTING ROD BEARING OIL CLEARANCE" .
PBIC0127E
CRANKSHAFT OUT-OF-ROUND AND TAPER
Using micrometer, measure each main journal and pin journal at

four points shown in the figure.
Out-of-round value is indicated by difference in dimensions
between directions X and Y at points A and B.
Taper value is indicated by difference in dimensions between
points A and B in directionsX andY.
Out-of-round: (Difference between X and Y)
Standard : 0.003 mm (0.0001 in)
Limit
: 0.005 mm (0.0002 in)
Taper: (Difference between A and B)
Standard : 0.003 mm (0.0001 in)
Limit
: 0.005 mm (0.0002 in)
EM-244
http://vnx.su
PBIC2203E
CYLINDER BLOCK
[YD22DDTi]
If the measured value exceeds the limit, correct or replace crankshaft.

If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then
select the main bearing or connecting rod bearing. Refer to EM-246, "MAIN BEARING OIL CLEARANCE"
and/or EM-245, "CONNECTING ROD BEARING OIL CLEARANCE" .
EM
CRANKSHAFT RUNOUT
Place V-block onto surface plate to support main journal at both

ends of crankshaft.
Position dial indicator vertically onto No. 3 journal.
Rotate crankshaft to read needle movement on dial indicator
(total indicator reading).
Standard
Limit
: 0.05 mm (0.0020 in)

: 0.10 mm (0.0039 in)
E
If it exceeds the limit, replace crankshaft.

PBIC2378E
CONNECTING ROD BEARING OIL CLEARANCE

Method by Measurement
Install connecting rod bearings to connecting rod and cap, and

tighten connecting nuts to the specified torque. Refer to EM-228,
"ASSEMBLY" . Use inside micrometer to measure connecting
rod bearing inner diameter.
(Bearing oil clearance) = (Connecting rod bearing inner diameter) (Crankshaft pin journal diameter)
Standard
: 0.031 - 0.061 mm (0.0012 - 0.0024 in)
If clearance exceeds the standard, select proper connecting rod

bearing according to connecting rod big end diameter and
crankshaft pin journal diameter to obtain specified bearing oil
clearance. Refer to EM-235, "HOW TO SELECT CONNECTING
ROD BEARING" .
I
PBIC1642E
Remove contamination such as engine oil, dust completely from

crankshaft pin journal and each bearing surface.
Cut plastigage slightly shorter than bearing width, place it in
crankshaft direction, avoiding oil holes.
Install connecting rod bearings to caps, and tighten connecting
rod nuts to the specified torque. Refer to EM-228, "ASSEMBLY"
for the tightening procedure.
CAUTION:
Remove connecting rod caps and bearings, and measure plastigage width using scale on plastigage bag.
NOTE:
If out of specification, take same action mentioned in Method by Measurement.
EM-245
http://vnx.su
EM142
CYLINDER BLOCK
[YD22DDTi]
MAIN BEARING OIL CLEARANCE
Method by Measurement
Install main bearings to cylinder block and bearing cap, and

tighten the bolts to the specified torque. Refer to EM-228,
"ASSEMBLY" . Then, measure the inner diameter of main bearings.
(Bearing clearance) = (Bearing inner diameter) (Crankshaft
main journal diameter)
Standard
: 0.039 - 0.066 mm (0.0015 - 0.0026 in)
If out of the standard, check main bearing housing inner diameter and crankshaft main journal diameter, and select appropriate
main bearing to adjust clearance to specifications. Refer to EM237, "HOW TO SELECT MAIN BEARING" .
PBIC1644E
Remove contamination such as engine oil and dust completely

from crankshaft main journal and each bearing surface.
Cut plastigage slightly shorter than bearing width. Place it in
crankshaft turning direction, avoiding oil holes.
Install main bearings and bearing cap and tighten to the specified torque. Refer to EM-228, "ASSEMBLY" for the tightening
procedure.
CAUTION:
Remove main bearings and bearing caps, and measure plastigage width using scale on plastigage bag.
NOTE:
If out of specification, take same action mentioned in Method by Measurement.
EM142
CRUSH HEIGHT OF MAIN BEARING
When bearing cap is removed after being tightened to the specified torque with main bearings installed, the tip end of bearing
must protrude. Refer to EM-228, "ASSEMBLY" .
Standard
If out of the standard, replace main bearings.
SEM502G
CRUSH HEIGHT OF CONNECTING ROD BEARING
When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings
installed, the tip end of bearing must protrude. Refer to EM-228,
"ASSEMBLY" .
Standard
If out of the standard, replace connecting rod bearings.
PBIC1646E
EM-246
http://vnx.su
CYLINDER BLOCK
[YD22DDTi]
MAIN BEARING CAP BOLT DEFORMATION
Limit
Measure the outer diameter of threaded area, d1 and d2, at

the points specified in the figure.
When the necked point is identified at a point other than where
specified, measure at the point as d2.
Calculate the difference between d1 and d2.
EM
: 0.13 mm (0.0051 in)
If it exceeds the limit, replace main bearing cap bolt.

JEM219G
CONNECTING ROD BOLT DEFORMATION
Install nuts to connecting rod bolts. Make sure that the nut can
be screwed smoothly on bolt threads by hand to the last thread
on the bolt.
If the nut does not screw in smoothly, measure the outer diameter of the bolt thread at the point specified in the figure.
If a necked point is identified, measure at that point.
Standard
Limit
: 8.90 - 9.00 mm (0.3504 - 0.3543 in) dia.

: 8.75 mm (0. 3445 in) dia.
If it exceeds the limit, replace connecting rod bolts and nuts.
JEM220G
OIL JET
Check nozzle for deformation and damage.

Blow compressed air from nozzle, and check for clogs.
Standard
: No deformation and no damage.

J
If out of the standard, replace oil jet.
JEM221G
OIL JET RELIEF VALVE
Using clean plastic stick, press check valve in oil jet relief valve.
Make sure that valve moves smoothly with proper reaction
force.
Standard:
Valve moves smoothly with proper reaction force.
If out of the standard, replace oil jet relief valve.
JEM222G
EM-247
http://vnx.su
CYLINDER BLOCK
[YD22DDTi]
FLYWHEEL DEFLECTION
Measure the deflection of flywheel contact surface to clutch with

a dial indicator.
Measure the deflection at 210 mm (8.27 in) dia.
Standard
: 0.45 mm (0.0177 in) or less.

CAUTION:
When measuring, keep magnetic fields (such as dial indicator
stand) away from signal plate of the rear end of crankshaft.
PBIC2646E
MOVEMENT AMOUNT OF FLYWHEEL

CAUTION:
Do not disassemble double mass flywheel.
Movement Amount of Thrust (Fore-and-Aft) Direction
Measure the movement amount of thrust (fore-and-aft) direction when 100 N (10.2 kg, 22 lb) force is
added at the portion of 125 mm (4.92 in) radius from the center of flywheel.
Standard
: 1.3 mm (0.051 in) or less
Movement Amount in Radial (Rotation) Direction

Check the movement amount of radial (rotation) direction with the following procedure:
1. Install a bolt to clutch cover mounting hole, and place a torque wrench on the extended line of the flywheel
center line.
Tighten bolt at a force of 9.8 Nm (1.0 kg-m, 87 in-lb) to keep it from loosening.
2. Put a mating mark on circumferences of the two flywheel
masses without applying any load (Measurement standard
points).
3. Apply a force of 9.8 Nm (1.0 kg-m, 87 in-lb) in each direction,
and mark the movement amount on the mass on the transaxle
side.
4. Measure the dimensions of movement amounts A and B on
circumference of the flywheel on the transaxle side.
Standard: 26.2 mm (1.031 in) or less.
EM-248
http://vnx.su
PBIC1263E

[YD22DDTi]

Standard and Limit
PFP:00030
A
EBS01FCM
GENERAL SPECIFICATIONS
Cylinder arrangement
In-line 4
Displacement
Unit: cm
Bore and stroke
Unit: mm (in)
86 x 94 (3.39 x 3.70)
Valve arrangement
DOHC
Firing order
1-3-4-2
Number of piston rings
EM
2,184 (133.27)
(cu in)
Compression
Oil
Number of main bearings
Compression ratio
16.7
Unit: kPa (bar, kg/cm2 , psi)/200 rpm
Standard
2,991 (29.9, 30.5, 434)
Minimum
2,452 (24.5, 25.0, 356)
490 (4.9, 5.0, 71)
H
Valve timing
EM120
Unit: degree
a
224
212
30
-2
46
INTAKE MANIFOLD AND EXHAUST MANIFOLD

Unit: mm (in)
Item
Limit
Intake manifold
0.1 (0.004)
Exhaust manifold
0.3 (0.012)
Surface distortion
DRIVE BELTS
Belt Deflection:
Unit: mm (in)
Belt deflection with 98 N (10 kg, 22 lb) force applied*
Applied belt
A/C compressor belt
New
Adjusted
Limit for re-adjusting
4-5
(0.16 - 0.20)
6-7
(0.24 - 0.28)
8.5 (0.335)
9.0 - 10.5
(0.354 - 0.413)
11.0 - 12.5
(0.433 - 0.492)
16.5 (0.650)
*: When engine is cold.
EM-249
http://vnx.su

[YD22DDTi]
CAMSHAFT
Unit: mm (in)
Item
Standard
Camshaft journal oil clearance
Limit
0.045 - 0.086 (0.0018 - 0.0034)
Camshaft bracket inner diameter
Camshaft journal outer diameter
No.1
30.500 - 30.521 (1.2008 - 1.2016)
No. 2, 3, 4, 5
24.000 - 24.021 (0.9449 - 0.9457)
No. 1
30.435 - 30.455 (1.1982 - 1.1990)
No. 2, 3, 4, 5
23.935 - 23.955 (0.9423 - 0.9431)
Camshaft runout [TIR*]
Camshaft sprocket runout [TIR*]

Camshaft end play
0.02 (0.0008)
0.15 (0.0059)
0.070 - 0.148 (0.0028 - 0.0058)
0.24 (0.0094)
SEM671
Cam nose height A
Intake
39.505 - 39.695 (1.5553 - 1.5628)
Exhaust
39.905 - 40.095 (1.5711 - 1.5785)
Valve Lifter
Unit: mm (in)
Item
Standard
Valve lifter outer diameter
29.960 - 29.975 (1.1795 - 1.1801)
Valve lifter hole diameter
30.000 - 30.021 (1.1811 - 1.1819)
Valve lifter clearance
0.025 - 0.061 (0.0010 - 0.0024)
Valve Clearance
Unit: mm (in)
Item
Cold
Hot* (Reference data)
Intake
0.24 - 0.32 (0.0094 - 0.0126)
0.274 - 0.386 (0.0108 - 0.0152)
Exhaust
0.26 - 0.34 (0.0102 - 0.0134)
0.308 - 0.432 (0.0121 - 0.0170)
*: Approximately 80C (176F)
Available Shims
Stamped mark
Thickness
mm (in)
2.10
2.10 (0.0827)
2.12
2.12 (0.0835)
2.14
2.14 (0.0843)
2.16
2.16 (0.0850)
2.18
2.18 (0.0858)
2.20
2.20 (0.0866)
2.22
2.22 (0.0874)
2.24
2.24 (0.0882)
EM-250
http://vnx.su

[YD22DDTi]
Stamped mark
Thickness
mm (in)
2.26
2.26 (0.0890)
2.28
2.28 (0.0898)
2.30
2.30 (0.0906)
2.32
2.32 (0.0913)
2.34
2.34 (0.0921)
2.36
2.36 (0.0929)
2.38
2.38 (0.0937)
2.40
2.40 (0.0954)
2.42
2.42 (0.0953)
2.44
2.44 (0.0961)
2.46
2.46 (0.0969)
2.48
2.48 (0.0976)
2.50
2.50 (0.0984)
2.52
2.52 (0.0992)
2.54
2.54 (0.1000)
2.56
2.56 (0.1008)
2.58
2.58 (0.1016)
2.60
2.60 (0.1024)
2.62
2.62 (0.1031)
2.64
2.64 (0.1039)
2.66
2.66 (0.1047)
2.68
2.68 (0.1055)
2.70
2.70 (0.1063)
2.72
2.72 (0.1071)
2.74
2.74 (0.1079)
EM
SEM512G
EM-251
http://vnx.su

[YD22DDTi]
CYLINDER HEAD
Unit: mm (in)
Item
Cylinder head distortion
Standard
Limit
Less than 0.03 (0.0012)
0.1 (0.004)
JEM204G
VALVE
Valve Dimensions
Unit: mm (in)
SEM188
Valve head diameter D
Valve length L
Valve stem diameter d
Valve seat angle
Intake
28.0 - 28.3 (1.102 - 1.114)
Exhaust
26.0 - 26.3 (1.024 - 1.035)
Intake
106.72 (4.2016)
Exhaust
106.36 (4.1874)
Intake
5.965 - 5.980 (0.2348 - 0.2354)
Exhaust
5.945 - 5.960 (0.2341 - 0.2346)
Intake
45 degrees 15 - 45 degrees 45
Exhaust
Valve margin T
Intake
1.38 (0.0543)
Exhaust
1.48 (0.0583)
Valve margin T limit
More than 1.0 (0.039)
Valve stem end surface grinding limit
Less than 0.2 (0.008)
EM-252
http://vnx.su

[YD22DDTi]
Valve Guide
Unit: mm (in)
EM
D
JEM156G
Item
Valve guide
Outer diameter
Valve guide
Inner diameter (Finished size)
Cylinder head valve guide hole diameter
Standard
Service
10.023 - 10.034 (0.3946 - 0.3950)
10.223 - 10.234 (0.4025 - 0.4029)
6.000 - 6.018 (0.2362 - 0.2369)

9.975 - 9.996 (0.3927 - 0.3935)
Interference fit of valve guide
10.175 - 10.196 (0.4006 - 0.4014)
0.027 - 0.059 (0.0011 - 0.0023)
Item
Valve guide clearance
Standard
Limit
Intake
0.020 - 0.053 (0.0008 - 0.0021)
0.08 (0.0031)
Exhaust
0.040 - 0.073 (0.0016 - 0.0029)
0.10 (0.0039)
Projection length
10.4 - 10.6 (0.409 - 0.417)
EM-253
http://vnx.su

[YD22DDTi]
Valve Seat
Unit: mm (in)
SEM546G
JEM253G
Item
Cylinder head seat recess diameter (D)
Valve seat interference fit
Valve seat outer diameter (d)
Height (h)
Standard
Service
Intake
30.000 - 30.016 (1.1811 - 1.1817)
30.500 - 30.516 (1.2008 - 1.2014)
Exhaust
29.000 - 29.016 (1.1417 - 1.1424)
29.500 - 29.516 (1.1614 - 1.1620)
Intake
0.064 - 0.100 (0.0025 - 0.0039)
Exhaust
0.064 - 0.096 (0.0025 - 0.0038)
Intake
30.080 - 30.100 (1.1842 - 1.1850)
30.580 - 30.600 (1.2039 - 1.2047)
Exhaust
29.080 - 29.096 (1.1449 - 1.1455)
29.580 - 29.596 (1.1646 - 1.1652)
Intake
7.0 - 7.1 (0.276 - 0.280)
6.60 - 6.70 (0.2598 - 0.2638)
Exhaust
6.7 - 6.8 (0.264 - 0.268)
6.3 - 6.4 (0.248 - 0.252)
EM-254
http://vnx.su

[YD22DDTi]
Depth (H)
Projection (L)
Intake
8.83 - 9.13 (0.3476 - 0.3594)
Exhaust
9.06 - 9.36 (0.3567 - 0.3685)
Intake
36.53 - 36.98 (1.4382 - 1.4559)
Exhaust
36.53 - 37.01 (1.4382 - 1.4571)
EM
Valve Spring
Valve spring square
mm (in)
1.9 (0.075)
Free height
mm (in)
43.7 (1.720)
Pressure
N (kg, lb) at height mm (in)
Height during valve open
184 - 208 (18.77 - 21.22, 41.4 - 46.8) at 32.82 (1.2921)
mm (in)
Load with valve open
N (kg, lb)
24.82 (0.9772)
320 - 360 (32.65 - 36.73, 71.9 - 80.9)
CYLINDER BLOCK
Unit: mm (in)
H
JEM207G
Top surface distortion
Standard
Less than 0.03 (0.0012)
Limit
Cylinder bore
Inner diameter
0.1 (0.004)
Standard
Grade No. 1
86.000 - 86.010 (3.3858 - 3.3862)
Grade No. 2
86.010 - 86.020 (3.3862 - 3.3866)
Grade No. 3
86.020 - 86.030 (3.3866 - 3.3870)
Wear limit
Out-of-round (Difference
between X and Y)
Taper (Difference between A
and C)
0.20 (0.008)
0.015 (0.0006)
Limit
0.010 (0.0004)
Main bearing housing inner diameter (Without bearing)

Difference in inner diameter
between cylinders
66.654 - 66.681 (2.6242 - 2.6252)
M
Limit
0.05 (0.0020)
EM-255
http://vnx.su

[YD22DDTi]
PISTON, PISTON RING AND PISTON PIN
Available Piston
Unit: mm (in)
MBIA0026E
Piston outer diameter A
Standard
Grade No. 1
85.928 - 85.942 (3.3830 - 3.3835)
Grade No. 2
85.938 - 85.952 (3.3834 - 3.3839)
Grade No. 3
85.948 - 85.962 (3.3838 - 3.3843)
0.25 (0.0098) O/S (Service)
86.188 - 86.202 (3.3932 - 3.3938)
0.50 (0.0197) O/S (Service)
86.438 - 86.452 (3.4031 - 3.4036)
a dimension
11.0 (0.43)
Piston pin bore diameter
28.003 - 28.009 (1.1025 - 1.1027)
Piston to cylinder bore clearance
0.058 - 0.082 (0.0023 - 0.0032)
Piston Ring
Unit: mm (in)
Item
Side clearance
End gap
Standard
Limit
Top
0.050 - 0.090 (0.0020 - 0.0035)
0.2 (0.008)
2nd
0.050 - 0.090 (0.0020 - 0.0035)
0.1 (0.004)
Oil ring
0.030 - 0.070 (0.0012 - 0.0028)
Top
0.20 - 0.30 (0.0079 - 0.0118)
1.0 (0.039)
2nd
0.31 - 0.51 (0.0122 - 0.0201)
1.0 (0.039)
Oil ring
0.30 - 0.55 (0.0118 - 0.0217)
1.0 (0.039)
Piston Pin
Unit: mm (in)
27.995 - 28.000 (1.1022 - 1.1024)
Piston to piston pin clearance
0.003 - 0.014 (0.0001 - 0.0006)

Standard
Limit
0.026 - 0.043 (0.0010 - 0.0017)

0.057 (0.0022)
EM-256
http://vnx.su

[YD22DDTi]
CONNECTING ROD
Unit: mm (in)
Center distance
Bend [per 100 (3.94)]
Limit
0.12 (0.0047)
Torsion [per 100 (3.94)]
Limit
0.12 (0.0047)
EM
Connecting rod bushing inner diameter*
28.026 - 28.038 (1.1034 - 1.1039)
Connecting rod big end inner diameter*
55.000 - 55.013 (2.1654 - 2.1659)
Standard
Side clearance
157.5 (6.201)
0.20 - 0.35 (0.0079 - 0.0138)
Limit
0.40 (0.0157)
*: After installing in connecting rod
CRANKSHAFT
Unit: mm (in)
Main journal dia. Dm
62.951 - 62.975 (2.4784 - 2.4793)
Pin journal dia. Dp
51.954 - 51.974 (2.0454 - 2.0462)
Center distance r
46.97 - 47.03 (1.8492 - 1.8516)
Out-of-round (Difference between X

and Y)
Runout [TIR*]
End play
Standard
0.003 (0.0001)
Limit
0.005 (0.0002)
Standard
0.003 (0.0001)
Limit
0.005 (0.0002)
Standard
0.05 (0.0020)
Limit
0.10 (0.0039)
Standard
0.10 - 0.25 (0.0039 - 0.0098)
Limit
0.30 (0.0118)
L
SBIA0535E
SEM645
EM-257
http://vnx.su

[YD22DDTi]
AVAILABLE MAIN BEARING
Main bearing
Unit: mm (in)
SEM255G
Grade number
Thickness T
Width W
STD 0
1.816 - 1.820 (0.0715 - 0.0717)
Black
STD 1
1.820 - 1.824 (0.0717 - 0.0718)
Brown
19.9 - 20.1 (0.783 - 0.791)
STD 2
1.824 - 1.828 (0.0718 - 0.0720)
STD 3
1.828 - 1.832 (0.0720 - 0.0721)
Yellow
Green
STD 4
1.832 - 1.836 (0.0721 - 0.0723)
Blue
Under size
Unit: mm (in)
Size
Thickness
Main journal diameter Dm
0.25 (0.0098)
1.949 - 1.953 (0.0767 - 0.0769)
Grind so that bearing clearance is the

specified value.
Bearing oil clearance

Unit: mm (in)
Standard
0.039 - 0.066 (0.0015 - 0.0026)
AVAILABLE CONNECTING ROD BEARING

Connecting Rod Bearing
Unit: mm (in)
Grade number
Thickness T
Width W
STD 0
1.492 - 1.496 (0.0587 - 0.0589)
STD 1
1.496 - 1.500 (0.0589 - 0.0591)
STD 2
1.500 - 1.504 (0.0591 - 0.0592)
Identification color (mark)

Black
22.9 - 23.1
(0.902 - 0.909)
Brown
Green
Under size
Unit: mm (in)
Size
Thickness
0.08 (0.0031)
1.536 - 1.540 (0.0605 - 0.0606)
0.12 (0.0047)
1.556 - 1.560 (0.0613 - 0.0614)
0.25 (0.0098)
1.621 - 1.625 (0.0638 - 0.0640)
EM-258
http://vnx.su
Crankshaft pin journal diameter Dp

Grind so that bearing clearance is the
specified value.

[YD22DDTi]
Unit: mm (in)
Connecting rod bearing oil
clearance
Standard
0.031 - 0.061 (0.0012 - 0.0024)
EM
Tightening Torque
EBS01FCN
*1: Parts to be tightened in particular orders.

1)-: Order of tightening when tightening two or more times separately.
Unit: Nm (kg-m, in-lb)*2
Idler pulley
Nut A
35 (3.6, 26)
Alternator
Nut C
21.5 (2.2, 16)
Nut D
50.5 (5.2, 37)
Charge air cooler Bracket
7.0 (0.71, 62)*
70 (7.1, 52)
*1
Exhaust manifold side
64.5 (6.6, 48)
EGR volume control

valve side
70 (7.1, 52)
E
2
EGR volume control valve bracket
23.5 (2.4, 17)
Exhaust manifold insulator
7.4 (0.75, 65)*2
Exhaust manifold
31 (3.2, 23)
Turbocharger
48.5 (4.9, 36)
Catalyst
48.5 (4.9, 36)
33.5 (3.4, 25)
Catalyst insulator
Catalyst side
7.4 (0.75, 65)*2

side
9.6 (0.97, 85)*2
Oil pan lower
7 (0.7, 62)*2
Oil pan drain plug
34 (3.5, 25)
Oil strainer
17 (1.7, 13)
22 (2.2, 16)
Charge air cooler cover
EGR cooler
L
*1
Oil pan upper
M6 bolt
7 (0.7, 62)*2
M8 bolt
21.5 (2.2, 16)
M10 bolt
33.5 (3.4, 25)
Vacuum pump
Cylinder head rear cover
Injection tube
23.5 (2.4, 17)

M6 bolt
9.7 (0.98, 86) *2
M8 bolt
17 (1.7, 13)
Nozzle side
23.0 (2.3, 17)
Fuel rail side
23.0 (2.3, 17)
Injection tube center
23.0 (2.3, 17)
Nozzle support
26.2 (2.7, 19)
Spill tube
Nozzle side
18.7 (1.9, 14)
Cylinder head side
18.7 (1.9, 14)
Fuel rail
57.5 (5.9, 42)
Fuel pump
31.4 (3.2, 23)
Fuel pump sprocket
39 (4.0, 29)
EM-259
http://vnx.su

[YD22DDTi]
*1
*1
*1
*1
*1
*1
*1
1)
7.8 (0.8, 69)*2
2)
7.8 (0.8, 69) *2
13 to 15 bolts
1)
2 (0.2, 1)
1 to 12 bolts
2)
2 (0.2, 1)
3)
6 (0.6, 4)
4)
12.5 (1.3, 9)
Rocker cover
Camshaft bracket
Front chain case
7.9 (0.8, 70)*2
Chain tensioner
9.6 (0.98, 85)*2
Tension guide
23.5 (2.4, 18)
Slack guide
23.5 (2.4, 18)
Camshaft sprocket
143 (15, 105)
Oil pump housing
12.5 (1.3, 9)
Power steering oil pump
53.5 (5.5, 39)
Rear chain case
12.5 (1.3, 9)
13.5 (1.4, 10)
Cylinder head
1)
39.2 (4.0, 29)
2)
180 degrees
3)
0 (0, 0)
4)
39.2 (4.0, 29)
5)
90 degrees (angle tightening)
6)
90 degrees (angle tightening)
Glow plug
20.5 (2.1, 15)
Flywheel
108 (11, 80)
Oil pressure switch
15 (1.5, 11)
Oil jet
8.4 (0.86, 74)*2
Oil jet relief valve
49 (5.0, 36)
Rear oil seal retainer
12.5 (1.3, 9)
EM-260
http://vnx.su
ENGINE LUBRICATION SYSTEM
B ENGINE
SECTION
LU
ENGINE LUBRICATION SYSTEM
LU
CONTENTS
QR
PRECAUTIONS .......................................................... 3
PREPARATION ........................................................... 4
LUBRICATION SYSTEM ............................................ 5
Lubrication Circuit .................................................... 5
System Chart ........................................................... 6
ENGINE OIL ............................................................... 7
Inspection ................................................................. 7
ENGINE OIL LEVEL ............................................. 7
ENGINE OIL APPEARANCE ................................ 7
ENGINE OIL LEAKAGE ........................................ 7
OIL PRESSURE CHECK ...................................... 7
Changing Engine Oil ................................................ 8
OIL FILTER ............................................................... 10
REMOVAL ........................................................... 10
INSTALLATION ................................................... 10
INSPECTION AFTER INSTALLATION ............... 10
OIL COOLER .............................................................11
Removal and Installation .........................................11
REMOVAL ............................................................11
INSPECTION AFTER REMOVAL ........................11
INSTALLATION ....................................................11
INSPECTION AFTER INSTALLATION ................11
OIL PUMP ................................................................. 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 13
Disassembly and Assembly ................................... 13
DISASSEMBLY ................................................... 13
INSPECTION AFTER DISASSEMBLY ............... 14
ASSEMBLY ......................................................... 15
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 16
Standard and Limit ................................................. 16
OIL PRESSURE .................................................. 16
ENGINE OIL CAPACITY (APPROXIMATE) ........ 16

OIL PUMP ........................................................... 16
REGULATOR VALVE .......................................... 16
Tightening Torque ................................................... 16
YD22DDTi
PRECAUTIONS ........................................................ 17
Precautions for Liquid Gasket ................................ 17
LIQUID GASKET APPLICATION PROCEDURE... 17
PREPARATION ......................................................... 18
Special Service Tools ............................................. 18
Commercial Service Tools ...................................... 18
LUBRICATION SYSTEM .......................................... 19
Lubrication Circuit ................................................... 19
ENGINE OIL .............................................................. 20
Inspection ............................................................... 20
ENGINE OIL LEVEL ............................................ 20
ENGINE OIL APPEARANCE .............................. 20
ENGINE OIL LEAKAGE ...................................... 20
ENGINE OIL PRESSURE CHECK ..................... 20
Changing Engine Oil ............................................... 21
OIL FILTER ............................................................... 23
Removal and Installation (TYPE A) ........................ 23
REMOVAL ........................................................... 23
INSTALLATION ................................................... 23
Removal and Installation (TYPE B) ........................ 24
REMOVAL ........................................................... 24
INSTALLATION ................................................... 25
OIL FILTER BRACKET ............................................. 26
Removal and Installation (TYPE A) ........................ 26
REMOVAL ........................................................... 26
INSTALLATION ................................................... 26
Removal and Installation (TYPE B) ........................ 27
REMOVAL ........................................................... 27
INSTALLATION ................................................... 27
LU-1
http://vnx.su
OIL COOLER ............................................................ 28

REMOVAL ........................................................... 28
INSTALLATION .................................................... 28
OIL PUMP ................................................................. 30
REMOVAL ........................................................... 30
INSTALLATION .................................................... 30

Disassembly and Assembly ....................................30
DISASSEMBLY ....................................................30
INSPECTION AFTER DISASSEMBLY ................30
ASSEMBLY ..........................................................32
SERVICE DATA AND SPECIFICATIONS (SDS) ......33
Standard and Limit ..................................................33
OIL PRESSURE ..................................................33
OIL PUMP ............................................................33
REGULATOR VALVE ...........................................33
OIL CAPACITY (APPROXIMATE) .......................33
Tightening Torque ...................................................33
LU-2
http://vnx.su
PRECAUTIONS
[QR]
PRECAUTIONS
[QR]
PFP:00001
A
EBS011UN

1.
2.
3.
Remove old liquid gasket adhering to the liquid gasket application surface and the mating surface.
LU
Remove liquid gasket completely from the liquid gasket application surface, mounting bolts, and bolt
holes.
Wipe the liquid gasket application surface and the mating surface with white gasoline (lighting and heating
C
use) to remove adhering moisture, grease and foreign materials.
tool).
D
E
If liquid gasket protrudes, wipe it off immediately.
Do not retighten mounting bolts or nuts after the installation.
F
PBIC2160E
LU-3
http://vnx.su
PREPARATION
[QR]
PREPARATION
PFP:00002
EBS00KO0
Tool number
Tool name
Description
ST25051001
Oil pressure gauge
Measuring oil pressure

Maximum measuring range:
2,452 kPa (24.52 bar, 25 kg/cm2 , 356 psi)
S-NT050
ST25052000
Hose
Adapting oil pressure gauge to cylinder block
S-NT559
KV10115801
Oil filter wrench
Removing and installing oil filter

a: 64.3 mm (2.531 in)
S-NT375
WS39930000
Tube presser
S-NT052
EBS011TG
Tool name
Description
Deep socket
Removing and installing oil pressure switch

a: 26 mm (1.02 in)
PBIC2072E
LU-4
http://vnx.su
LUBRICATION SYSTEM
[QR]
LUBRICATION SYSTEM
Lubrication Circuit
PFP:15010
A
EBS00KO1
LU
I
PBIC2270E
LU-5
http://vnx.su
LUBRICATION SYSTEM
[QR]
System Chart
EBS00KO2
PBIC2753E
LU-6
http://vnx.su
ENGINE OIL
[QR]
ENGINE OIL
Inspection
PFP:KLA92
A
EBS00KO3
ENGINE OIL LEVEL

NOTE:
LU
Before starting engine, put vehicle horizontally and check the engine oil level. If engine is already started, stop
it and allow 10 minutes before checking.
1. Pull out oil level gauge and wipe it clean.
C
2. Insert oil level gauge and make sure the engine oil level is within
the range shown in the figure.
3. If it is out of range, adjust it.
D
F
PBIC0249E
ENGINE OIL APPEARANCE
Check engine oil for white turbidity or heavy contamination.

If engine oil becomes turbid and white, it is highly probable that it is contaminated with engine coolant.
Repair or replace damaged parts.
ENGINE OIL LEAKAGE

Check for engine oil leakage around the following area.
Oil pan
Oil pan drain plug
Oil pressure switch
Oil filter
Oil cooler
Intake valve timing control cover and intake valve timing control solenoid valve
Front cover
Mating surface between cylinder block and lower cylinder block
Mating surface between cylinder block and cylinder head
Mating surface between cylinder head and rocker cover
Crankshaft oil seals (front and rear)
OIL PRESSURE CHECK
WARNING:
Be careful not to burn yourself, as engine oil may be hot.
Engine oil pressure check should be in Parking position (A/T models) or Neutral position (M/T
models), and should apply parking brake securely.
1. Check engine oil level. Refer to LU-7, "ENGINE OIL LEVEL" .
2. Remove RH undercover.
LU-7
http://vnx.su
ENGINE OIL
[QR]
3.
Disconnect harness connector at oil pressure switch, and

remove oil pressure switch using a deep socket (commercial
service tool).
PBIC2272E
4.
Install oil pressure gauge and hose (special service tool).
SLC926-A
5.
6.
Start engine and warm it up to normal operating temperature.

Check oil pressure with engine running under no-load.
NOTE:
When engine oil temperature is low, engine oil pressure becomes high.
Engine oil pressure [Engine oil temperature at 80C (176F)]
7.
a.
b.
Engine speed
rpm
Approximate discharge pressure
Idle speed
More than 98 (0.98, 1.0, 14)
2,000
More than 294 (2.94, 3.0, 43)
kPa (bar, kg/cm2 , psi)
If difference is extreme, check oil passage and oil pump for oil leaks.
After the inspections, install oil pressure switch as follows:
Remove old liquid gasket adhering to oil pressure switch and engine.
Apply liquid gasket and tighten oil pressure switch to specification.
Use Genuine Thread Sealant or equivalent.
: 14.8 Nm (1.5 kg-m, 11 ft-lb)
c.
After warming up engine, make sure there is no leaks of engine oil with running engine.
Changing Engine Oil
EBS00KO4
WARNING:
Be careful not to burn yourself, as engine oil may be hot.
Prolonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct
skin contact with used engine oil. If skin contact is made, wash thoroughly with soap or hand
cleaner as soon as possible.
1. Warm up engine, put vehicle horizontally and check for oil leakage from engine components. Refer to LU7, "ENGINE OIL LEAKAGE" .
2. Stop engine and wait for 10 minutes.
LU-8
http://vnx.su
ENGINE OIL
[QR]
3.
4.
5.
Loosen oil filler cap and then remove drain plug.

Drain engine oil.
Install drain plug with new washer. Refer to EM-27, "OIL PAN
AND OIL STRAINER" .
CAUTION:
Be sure to clean drain plug and install with new washer.
LU
Oil pan drain plug:
: 34.3 Nm (3.5 kg-m, 25 ft-lb)

6.
Refill with new engine oil.

Engine oil specification and viscosity:
Refer to MA-17, "RECOMMENDED FLUIDS AND LUBRICANTS" .
PBIC2410E
Engine oil capacity (Approximate):

Unit:
Drain and refill
With oil filter change
4.1 (3-5/8)
Without oil filter change
3.7 (3-1/4)
Dry engine (Overhaul)
7.
8.
9.
(lmp qt)
4.7 (4-1/8)
CAUTION:
The refill capacity depends on the engine oil temperature and drain time. Use these specifications for reference only.
Always use oil level gauge to determine the proper amount of engine oil in the engine.
Warm up engine and check area around drain plug and oil filter for oil leakage.
Check the engine oil level. Refer to LU-7, "ENGINE OIL LEVEL" .
LU-9
http://vnx.su
OIL FILTER
[QR]
OIL FILTER
PFP:15208
EBS011TI
REMOVAL
1.
2.
Open oil filter installation/removal cover on RH undercover.

Using an oil filter wrench (special service tool), remove oil filter.
CAUTION:
Oil filter is provided with relief valve. Use Genuine NISSAN Oil Filter or equivalent.
Be careful not to get burned when engine and engine oil
may be hot.
When removing, prepare a shop cloth to absorb any
engine oil leakage or spillage.
Do not allow engine oil to adhere to drive belt.
Completely wipe off any engine oil that adheres to engine
and vehicle.
KBIA0303E
INSTALLATION
1.
2.
Remove foreign materials adhering to the oil filter installation surface.

Apply new engine oil to the oil seal contact surface of new oil filter.
SMA010
3.
Screw oil filter manually until it touches the installation surface,

then tighten it by 2/3 turn. Or tighten to specification.
Oil filter:
: 17.6 Nm (1.8 kg-m, 13 ft-lb)
SMA229B

1.
2.
3.
Start engine, and make sure there is no leaks of engine oil.

Check the engine oil level and adjust engine oil. Refer to LU-7, "ENGINE OIL" .
LU-10
http://vnx.su
OIL COOLER
[QR]
OIL COOLER
PFP:21305
A
EBS00KO8
LU
PBIC2273E
1.
Oil pressure switch
2.
Relief valve
3.
Oil cooler bracket
4.
O-ring
5.
Oil cooler
6.
O-ring
7.
Gasket
8.
Clamp
9.
Water hose
10. Water hose
WARNING:
Be careful not to get burned when engine and engine oil may be hot.
CAUTION:
When removing oil cooler and oil cooler bracket, prepare a shop cloth to absorb any engine oil
leakage or spillage.
Completely wipe off any engine oil that adhere to engine and vehicle.
REMOVAL
1.
2.
3.
4.
Remove RH front road wheel and tyre and RH undercover.

Drain engine coolant by removing water drain plug on cylinder block and radiator drain plug. Refer to EM86, "CYLINDER BLOCK" and CO-9, "Changing Engine Coolant" .
Disconnect water hoses from oil cooler.
Remove oil cooler and oil cooler bracket.
NOTE:
For reference when installing, put a mating mark on oil cooler and oil cooler bracket.

Oil Cooler
Check oil cooler for cracks. Check oil cooler for clogging by blowing through engine coolant inlet. If necessary,
replace oil cooler assembly.
Relief Valve
Inspect relief valve for movement, cracks and breaks by pushing the ball. If replacement is necessary, remove
valve by prying it out with a suitable tool. Install a new valve in place by tapping it.
INSTALLATION

1.
Check the engine oil level and the engine coolant level, and adjust engine oil and engine coolant. Refer to
LU-7, "ENGINE OIL" and CO-9, "ENGINE COOLANT" .
LU-11
http://vnx.su
OIL COOLER
[QR]
2.
3.
4.
Start engine, and make sure there is no leaks of engine oil or engine coolant.
Check the engine oil level and the engine coolant level again. Refer to LU-7, "ENGINE OIL" and CO-9,
"ENGINE COOLANT" .
LU-12
http://vnx.su
OIL PUMP
[QR]
OIL PUMP
PFP:15010
A
EBS00KO6
REMOVAL
Remove front cover. Refer to EM-46, "TIMING CHAIN" .
NOTE:
Oil pump is built into front cover.
LU
INSTALLATION
When installing, align crankshaft flat faces with inner rotor flat faces.
D

1.
2.
3.
After warming up engine, make sure there is no leaks of engine oil.

E
EBS00KO7
K
PBIC2430E
1.
Front cover (Oil pump body is united)
2.
Outer rotor
3.
Inner rotor
4.
Oil pump cover
5.
Regulator valve
6.
Regulator valve spring
7.
Regulator valve plug
DISASSEMBLY
1.
2.
3.
Remove oil pump cover.

Remove inner rotor and outer rotor from front cover.
After removing regulator valve plug, remove regulator spring and regulator valve.
LU-13
http://vnx.su
OIL PUMP
[QR]
Clearance of Oil Pump Parts
Measure the clearance with feeler gauge.

Clearance between outer rotor and front cover (Position 1)
Standard
If out of the standard, replace oil pump assembly.

Tip clearance between inner rotor and outer rotor (Position 2)
Standard
: 0.114 - 0.179 mm (0.0045 - 0.0070 in)
: Below 0.220 mm (0.0087 in)
If out of the standard, replace inner rotor and outer rotor.

PBIC0251E
Measure the clearance with feeler gauge and straightedge.

Side clearance between inner rotor and front cover (Position 3)
Standard

Side clearance between outer rotor and front cover (Position 4)
Standard
: 0.030 - 0.070 mm (0.0012 - 0.0028 in)
: 0.060 - 0.110 mm (0.0024 - 0.0043 in)

Calculate the clearance between inner rotor and front cover with
the following procedure:
Measure the outer diameter of protruded portion of inner rotor
with micrometer. (Position 5)
PBIC3465E
PBIC3466E
Measure the inner diameter of front cover with inside micrometer. (Position 6)
PBIC3467E
(Clearance) = (Inner diameter of front cover) (Outer diameter of inner rotor)

Standard
: 0.035 - 0.070 mm (0.0014 - 0.0028 in)
LU-14
http://vnx.su
OIL PUMP
[QR]
Regulator Valve Clearance
A
(Clearance) = (Valve hole diameter D1) (Regulator valve outer

diameter D2)
Standard
: 0.040 - 0.097 mm (0.0016 - 0.0038 in)
LU

CAUTION:
Coat regulator valve with new engine oil.
Make sure that it falls smoothly into valve hole by its own
weight.
KBIA0043E
ASSEMBLY
Note the following, and assemble in the reverse order of disassembly.
Install inner rotor and outer rotor with the punched marks on the
oil pump cover side.
H
PBIC0255E
LU-15
http://vnx.su

[QR]

Standard and Limit
PFP:00030
EBS00KO9
OIL PRESSURE
Engine speed
rpm
Approximate discharge pressure*
Idle speed
More than 98 (0.98, 1.0, 14)
2,000
More than 294 (2.94, 3.0, 43)
*: Engine oil temperature at 80 (176F)
ENGINE OIL CAPACITY (APPROXIMATE)

Unit:
Drain and refill
(Imp qt)
4.1 (3-5/8)
3.7 (3-1/4)
4.7 (4-1/8)
OIL PUMP
Unit: mm (in)
Front cover to outer rotor radial clearance
0.114 - 0.179 (0.0045 - 0.0070)
Inner rotor to outer rotor tip clearance
Below 0.220 (0.0087)
Front cover to inner rotor side clearance
0.030 - 0.070 (0.0012 - 0.0028)
Front cover to outer rotor side clearance
0.060 - 0.110 (0.0024 - 0.0043)
Inner rotor to front cover clearance
0.035 - 0.070 (0.0014 - 0.0028)
REGULATOR VALVE
Unit: mm (in)
Regulator valve to valve hole clearance
0.040 - 0.097 (0.0016 - 0.0038)
Tightening Torque
EBS00KOA

Unit: Nm (kg-m, in-lb)*
Oil pressure switch
14.8 (1.5, 11)
Oil pan drain plug
34.3 (3.5, 25)
Oil filter
17.6 (1.8, 13)
Oil pump cover
Bolt
7.0 (0.71, 62)*
Screw
6.9 (0.70, 61)*
Regulator valve plug
54.0 (5.5, 40)
Oil cooler
39.2 (4.0, 29)
Oil cooler bracket
21.6 (2.2, 16)
LU-16
http://vnx.su
PRECAUTIONS
[YD22DDTi]
PRECAUTIONS
[YD22DDTi]
PFP:00001
A
EBS011SZ

1.
Remove the old liquid gasket adhering to the gasket application surface and the mating surface.
LU
Remove the liquid gasket completely from the gasket application surface, mounting bolts, and bolt holes.
2. Wipe the liquid gasket application surface and the mating surface with white gasoline (lighting and heating
C
3. Attach liquid gasket tube to the tube presser (special service
tool).
D
Within five minutes of gasket application, install the mating component.

E
Do not retighten mounting bolts and nuts after the installation.
Wait 30 minutes or more after installation before filling the

engine with engine oil and engine coolant.
F
PBIC2160E
LU-17
http://vnx.su
PREPARATION
[YD22DDTi]
PREPARATION
PFP:00002
EBS00B01
Tool number
Tool name
Description
ST25051001
Oil pressure gauge
Measuring oil pressure

Maximum measuring range:
2,452 kPa (25 kg/cm2, 356 psi)
S-NT050
ST25052000
Hose
Adapting oil pressure gauge to cylinder block
S-NT559
EBS011WH
Tool name
Description
Deep socket
Removing and installing oil pressure switch

a: 26 mm (1.02 in)
PBIC2072E
LU-18
http://vnx.su
LUBRICATION SYSTEM
[YD22DDTi]
LUBRICATION SYSTEM
Lubrication Circuit
PFP:15010
A
EBS00B02
LU
PBIC2500E
LU-19
http://vnx.su
ENGINE OIL
[YD22DDTi]
ENGINE OIL
Inspection
PFP:KLA92
EBS00B03
ENGINE OIL LEVEL

NOTE:
Before starting engine, put vehicle horizontally and check the engine oil level. If engine is already started, stop
it and allow 10 minutes before checking.
1. Pull out oil level gauge and wipe it clean.
2. Insert oil level gauge and make sure the engine oil level is within
the range shown in the figure.
3. If it is out of range, adjust it.
SBIA0122E
ENGINE OIL APPEARANCE
Check engine oil for white turbidity or heavy contamination.

If engine oil becomes turbid and white, it is highly probable that it is contaminated with engine coolant.
Repair or replace damaged parts.
ENGINE OIL LEAKAGE

Check for engine oil leakage around the following area.
Oil pan
Oil pan drain plug
Oil pressure switch
Oil filter bracket
Oil cooler
Oil pump housing
Vacuum pump
Cylinder head rear cover assembly
Front and rear chain cases
Mating surface between cylinder block and cylinder head
Mating surface between cylinder head and rocker cover
Front and rear oil seals
Turbocharger
Oil tube connecting parts from turbocharger
ENGINE OIL PRESSURE CHECK

WARNING:
Be careful not to burn yourself, as the engine oil is hot.
Be sure to check oil pressure in Neutral position and parking brake should be applied securely.
1. Check the engine oil level. Refer to LU-20, "ENGINE OIL LEVEL" .
2. Remove RH engine undercover.
3. Remove exhaust front tube. Refer to EX-2, "EXHAUST SYSTEM" .
LU-20
http://vnx.su
ENGINE OIL
[YD22DDTi]
4.
Disconnect harness connector at oil pressure switch, and using

deep socket (commercial service tool), remove oil pressure
switch.
LU
C
SBIA0123E
5.
Install the oil pressure gauge and hose (special service tool).
E
G
SLC926-A
6.
7.
Install exhaust front tube. Refer to EX-2, "EXHAUST SYSTEM"

After warming up engine, make sure that oil pressure corresponding to the engine speed is produced.
NOTE:
When engine oil temperature is low, engine oil pressure becomes high.
Engine oil pressure [Engine oil temperature at 80 C (176 F)]

Engine speed (rpm)
Engine pressure
8.
a.
b.
Idle speed
2,000
140 (1.40, 1.43, 20.3) or more
270 (2.70, 2.75, 39.2) or more
After checking, install oil pressure switch as follows.

CAUTION:
Be careful not to get burned when engine is hot.
Remove old liquid gasket adhering to oil pressure switch and engine.
Apply liquid gasket and tighten oil pressure switch to specification.
Use Genuine Thread Sealant or equivalent.
Oil pressure switch:

: 15 Nm (1.5 kg-m, 11 ft-lb)
c.
After warming up engine, check for oil leakage with running engine.
Changing Engine Oil
EBS00B04
WARNING:
Be careful not to burn yourself, as the engine oil is hot.
Prolonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct
skin contact with used engine oil. If skin contact is made, wash thoroughly with soap or hand
cleaner as soon as possible.
1. Warm up engine, put vehicle horizontally and check for engine oil leakage from engine components. Refer
to LU-20, "ENGINE OIL LEAKAGE" .
2. Stop engine and wait for 10 minutes.
LU-21
http://vnx.su
ENGINE OIL
[YD22DDTi]
3.
Loosen oil filler cap and then remove drain plug.
PBIC0527E
4.
5.
Drain engine oil.

Install drain plug with new washer. Refer to EM-154, "OIL PAN AND OIL STRAINER" .
CAUTION:
Be sure to clean drain plug and install with new washer.
Oil pan drain plug:
: 34 Nm (3.5 kg-m, 25 ft-lb)
6.
Refill with new engine oil.

Engine oil specification and viscosity:
Engine oil capacity (Approximate):
Unit:
5.2 (4-5/8)
4.9 (4-3/8)
(lmp qt)
Drain and refill

7.
8.
9.
6.3 (5-1/2)
CAUTION:
The refill capacity depends on the engine oil temperature and drain time. Use these specifications for reference only.
Always use the oil level gauge to determine the proper amount of engine oil in the engine.
Warm up engine and check area around drain plug and oil filter for oil leakage.
Check the engine oil level. Refer to LU-20, "ENGINE OIL LEVEL" .
LU-22
http://vnx.su
OIL FILTER
[YD22DDTi]
OIL FILTER
Removal and Installation (TYPE A)
PFP:15208
A
EBS00B05
REMOVAL
1. Open oil filter installation/removal cover on RH engine undercover.
2. Using the oil filter wrench, remove oil filter.
CAUTION:
Be careful not to get burned when engine and engine oil are hot.
When removing, prepare a shop cloth to absorb any engine oil leakage or spillage.
Do not allow engine oil to adhere to drive belts.
Oil filter is provided with a relief valve.
LU
INSTALLATION
1.
2.
Remove foreign materials adhering to the oil filter installation surface.

Apply new engine oil to the oil seal circumference of new oil filter.
H
SMA010
3.
Screw oil filter manually until it touches the installation surface, then tighten it by 1/2 turn. Or tighten to
specification.
Oil filter:
: 18 Nm (1.8 Kg-m, 13 ft-lb)

1.
2.
3.
Start engine, and check there is no leakage of engine oil.

LU-23
http://vnx.su
OIL FILTER
[YD22DDTi]
Removal and Installation (TYPE B)
EBS011WI
REMOVAL
CAUTION:
Be careful not to get burned when engine and engine oil are
hot.
When removing, prepare a shop cloth to absorb any engine

oil leakage or spillage.
Do not allow engine oil to adhere to drive belts.
Completely wipe off any engine oil that adhere to engine

and vehicle.
PBIC2536E
1.
2.
Open oil filter installation/removal cover on RH engine undercover.

Using a socket wrench [plane-to-plane width: 17 mm (0.67 in)],
loosen oil filter body approximately four turns.
JLC290B
3.
4.
Drain engine oil after matching the "DRAIN" arrow mark at the
bottom of oil filter body to the protrusion on oil filter bracket.
Catch engine oil with a pan or cloth.
CAUTION:
The drained engine oil flows over the right surface of
oil filter body.
Completely wipe clean any engine oil remaining on oil
filter body or vehicle.
Remove oil filter body, then remove oil filter.
JLC291B
LU-24
http://vnx.su
OIL FILTER
[YD22DDTi]
5.
Remove O-ring from oil filter body.

Push O-ring in one direction, lift the slack part using fingers,
and remove O-ring from oil filter body.
CAUTION:
Do not use a screwdrivers etc. as they may cause damage to oil filter body.
LU
C
JLC292B
INSTALLATION
1.
2.
3.
Completely remove all foreign objects adhering to the inside of oil filter body or O-ring mounting area
(body side and bracket side).
Install oil filter and O-ring to oil filter body.
Push oil filter into filter body completely.
Install oil filter body to oil filter bracket.
Oil filter body:

: 22 Nm (2.2 Kg-m, 16 ft-lb)

1.
2.
3.
After warming up engine, check there is no leaks of engine oil.

LU-25
http://vnx.su
OIL FILTER BRACKET

[YD22DDTi]
OIL FILTER BRACKET

Removal and Installation (TYPE A)
PFP:15238
EBS00BL8
PBIC2380E
1.
Oil pump housing
4.
Oil filter
2.
Gasket
3.
Oil filter bracket
REMOVAL
CAUTION:
2. Remove oil filter. Refer to LU-23, "Removal and Installation (TYPE A)" .
3. Remove oil filter bracket.
INSTALLATION
Install all removed parts in the reverse order of removal.
Insert the top mounting bolt to oil filter bracket beforehand, and set oil filter bracket to the installation location.

1.
2.
3.

LU-26
http://vnx.su
OIL FILTER BRACKET

[YD22DDTi]
Removal and Installation (TYPE B)
EBS011WJ
LU
F
PBIC2537E
1.
Oil pump housing
2.
Gasket
3.
Oil filler bracket
4.
Oil filler
5.
O-ring
6.
Oil filter body
REMOVAL
CAUTION:
2. Remove oil filter. Refer to LU-24, "Removal and Installation (TYPE B)" .
3. Remove oil filter bracket.
INSTALLATION
Install all removed parts in the reverse order of removal.
Insert the top mounting bolt to oil filter bracket beforehand, and set oil filter bracket to the installation location.

1.
2.
3.

LU-27
http://vnx.su
OIL COOLER
[YD22DDTi]
OIL COOLER
PFP:21305
EBS00OE8
PBIC2441E
1.
Oil cooler
2.
O-ring
3.
Water hose
4.
Gasket
5.
Water hose connector
6.
Connecting bolt
CAUTION:
Be careful not to get burned when engine and engine oil are hot.
When removing, prepare a shop cloth to absorb any engine oil leakage or spillage.
REMOVAL
1.
2.
3.
4.
5.

Drain engine coolant by removing cylinder block drain plug and radiator drain plug. Refer to CO-32,
"DRAINING ENGINE COOLANT" and EM-223, "CYLINDER BLOCK" .
Remove water hoses.
Loosen connecting bolt and remove oil cooler.

Check oil cooler for cracks. Check oil cooler for clogging by blowing through coolant inlet. If necessary, replace
oil cooler.
INSTALLATION
Confirm that no foreign objects are adhering to the installation

planes of oil cooler or cylinder block.
Tighten the connecting bolt after aligning the stopper on the cylinder block side with protrusion of oil cooler.
SBIA0126E

1.
Check the engine oil level and the engine coolant level, and adjust engine oil and engine coolant. Refer to
LU-20, "ENGINE OIL" and CO-32, "ENGINE COOLANT" .
LU-28
http://vnx.su
OIL COOLER
[YD22DDTi]
2.
3.
4.
Start engine, and make sure that there is no leaks of engine oil or engine coolant.
Check the engine oil level and the engine coolant level again. Refer to LU-20, "ENGINE OIL" and CO-32,
"ENGINE COOLANT" .
LU
LU-29
http://vnx.su
OIL PUMP
[YD22DDTi]
OIL PUMP
PFP:15010
EBS01AJ3
PBIC2381E
1.
Oil pump housing
2.
Outer rotor
3.
Inner rotor
4.
Oil pump cover
5.
Regulator valve
6.
Outer regulator spring
7.
Inner regulator spring
8.
Regulator plug
REMOVAL
Remove oil pump assembly. Refer to EM-195, "PRIMARY TIMING CHAIN" .
INSTALLATION

1.
2.
3.

EBS01AI7
DISASSEMBLY
1.
2.
3.
Remove oil pump cover.

Remove inner rotor and outer rotor from oil pump housing.
After removing regulator plug, remove inner and outer regulator springs and regulator valve.

Clearance of Oil Pump Parts
Measure the clearance with feeler gauge.

Clearance between outer rotor and oil pump housing (position 1)
Standard
: 0.114 - 0.260 mm (0.0045 - 0.0102 in)
Tip clearance between inner rotor and outer rotor (position 2)

Standard
: Below 0.18 mm (0.0071in)
JLC355B
LU-30
http://vnx.su
OIL PUMP
[YD22DDTi]
Measure the clearance with the feeler gauge and the straightedge.
Side clearance between inner rotor and oil pump housing (position 3)
Standard
: 0.050 - 0.090 mm (0.0020 - 0.0035 in)
LU
Side clearance between outer rotor and oil pump housing (position 4)
Standard
: 0.030 - 0.190 mm (0.0012 - 0.0075 in)

JLC356B
Calculate the clearance between inner rotor and oil pump housing as follows.
Measure the outer diameter of protruded portion of inner rotor
(position 5).
G
PBIC3466E
Measure the inner diameter of oil pump housing with the inside
micrometer (position 6).
(Clearance) = (Inner diameter of oil pump housing) (Outer
diameter of inner rotor)
Standard
: 0.045 - 0.091mm (0.0018 - 0.0036 in)

J
K
SBIA0124E
Regulator Valve Clearance
(Clearance) = (Valve hole diameter) (Regulator valve outer diameter)

Standard
: 0.040 - 0.097 mm (0.0016 - 0.0038 in)

CAUTION:
Coat regulator valve with new engine oil.
Make sure that it falls smoothly into valve hole by its own
weight.
PBIC2382E
LU-31
http://vnx.su
OIL PUMP
[YD22DDTi]
ASSEMBLY
Assembly is the reverse order of disassembly.

Install inner rotor and outer rotor with the punched marks on the
oil pump cover side.
JLC286B
LU-32
http://vnx.su

[YD22DDTi]

Standard and Limit
PFP:00030
A
EBS00CTZ
OIL PRESSURE
Engine speed rpm
Approximate discharge pressure kPa (bar, kg/cm2 , psi)
Idle speed
2,000
140 (1.40, 1.43, 20.3) or more

270 (2.70, 2.75, 39.2) or more
LU
OIL PUMP
Unit: mm (in)
Oil pump housing to outer rotor radial clearance
0.114 - 0.260 (0.0045 - 0.0102)
Inner rotor to outer rotor tip clearance
Below 0.18 (0.0071)
Oil pump housing to inner rotor side clearance
0.050 - 0.090 (0.0020 - 0.0035)
Oil pump housing to outer rotor side clearance
0.030 - 0.190 (0.0012 - 0.0075)
Inner rotor to oil pump housing clearance
0.045 - 0.091 (0.0018 - 0.0036)
REGULATOR VALVE
Unit: mm (in)
Regulator valve to valve hole clearance
0.040 - 0.097 (0.0016 - 0.0038)
OIL CAPACITY (APPROXIMATE)
G
Unit:
5.2 (4-5/8 Imp qt)
4.9 (4-3/8 Imp qt)
Dry engine (engine overhaul)
6.3 (5-1/2 Imp qt)
Tightening Torque
(Imp qt)
EBS00B0F

Oil pressure switch
15 (1.5, 11)
Oil pan drain plug
34 (3.5, 25)
Oil filter bracket
21.5 (2.2, 16)
Oil filter (TYPE A)
18 (1.8, 13)
Oil filler body (TYPE B)
22 (2.2, 16)
Oil pump cover
Bolts
6.9 (0.7, 61)*
Screws
6.9 (0.7, 61)*
Regulator plug
54 (5.5, 40)
Water hose connector
23.6 (2.4, 17)
Oil cooler
24.5 (2.5, 18)
LU-33
http://vnx.su

[YD22DDTi]
LU-34
http://vnx.su
ENGINE COOLING SYSTEM
B ENGINE
SECTION
CO
ENGINE COOLING SYSTEM
CO
CONTENTS
QR
PRECAUTIONS .......................................................... 3
PREPARATION ........................................................... 4
OVERHEATING CAUSE ANALYSIS .......................... 5
Troubleshooting Chart .............................................. 5
COOLING SYSTEM .................................................... 7
Cooling Circuit .......................................................... 7
System Chart ........................................................... 8
ENGINE COOLANT .................................................... 9
Inspection ................................................................. 9
LEVEL CHECK ..................................................... 9
LEAK CHECK ....................................................... 9
Changing Engine Coolant ........................................ 9
DRAINING ENGINE COOLANT ........................... 9
REFILLING ENGINE COOLANT ........................ 10
FLUSHING COOLING SYSTEM ......................... 10
RADIATOR ................................................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 13
Checking Radiator Cap .......................................... 13
Checking Radiator .................................................. 13
RADIATOR (ALUMINUM TYPE) .............................. 15
PREPARATION ................................................... 15
DISASSEMBLY ................................................... 15
ASSEMBLY ......................................................... 16
INSPECTION ...................................................... 18
COOLING FAN ......................................................... 19
REMOVAL ........................................................... 19
INSTALLATION ................................................... 19
DISASSEMBLY ................................................... 20
INSPECTION AFTER DISASSEMBLY ................ 20
ASSEMBLY ......................................................... 20
WATER PUMP .......................................................... 21
REMOVAL ........................................................... 21
INSTALLATION ................................................... 22
THERMOSTAT AND WATER CONTROL VALVE ... 23
REMOVAL ........................................................... 23
INSTALLATION ................................................... 24
Standard and Limit .................................................. 25
CAPACITY ........................................................... 25
RADIATOR .......................................................... 25
THERMOSTAT .................................................... 25
WATER CONTROL VALVE ................................. 25
YD22DDTi
PRECAUTIONS ........................................................ 26
Precautions For Liquid Gasket ............................... 26
LIQUID GASKET APPLICATION PROCEDURE... 26
PREPARATION ......................................................... 27
OVERHEATING CAUSE ANALYSIS ........................ 28
Troubleshooting Chart ............................................ 28
COOLING SYSTEM .................................................. 30
Cooling Circuit ........................................................ 30
System Chart .......................................................... 31
ENGINE COOLANT .................................................. 32
Inspection ............................................................... 32
CO-1
http://vnx.su
LEVEL CHECK .................................................... 32

CHECKING RADIATOR SYSTEM FOR LEAKS... 32
Changing Engine Coolant ....................................... 32
DRAINING ENGINE COOLANT .......................... 32
REFILLING ENGINE COOLANT ......................... 33
FLUSHING COOLING SYSTEM ......................... 34
RADIATOR ................................................................ 35
REMOVAL ........................................................... 35
INSTALLATION .................................................... 35
Checking Radiator Cap .......................................... 36
Checking Radiator .................................................. 36
COOLING FAN .......................................................... 37
REMOVAL ........................................................... 37
INSTALLATION .................................................... 37
DISASSEMBLY AND ASSEMBLY ....................... 37
RADIATOR (ALUMINUM TYPE) ............................... 39
PREPARATION ................................................... 39
DISASSEMBLY ................................................... 39
ASSEMBLY ......................................................... 40
INSPECTION ....................................................... 42
WATER PUMP ...........................................................43

REMOVAL ............................................................43
INSTALLATION ....................................................44
THERMOSTAT AND WATER PIPING .......................45
REMOVAL ............................................................45
INSTALLATION ....................................................46
SERVICE DATA AND SPECIFICATIONS (SDS) ......47
Standard and Limit ..................................................47
CAPACITY ...........................................................47
THERMOSTAT .....................................................47
RADIATOR ...........................................................47
Tightening Torque ...................................................47
CO-2
http://vnx.su
PRECAUTIONS
[QR]
PRECAUTIONS
[QR]
PFP:00001
A
EBS00MRX

1.
2.
3.
CO
holes.
C
tool).
D
E
F
PBIC2160E
CO-3
http://vnx.su
PREPARATION
[QR]
PREPARATION
PFP:00002
EBS00KOC
Tool number
Tool name
Description
EG17650301
Radiator cap tester adapter
Adapting radiator cap tester to radiator cap

and radiator filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
S-NT564
KV99103510
Radiator plate pliers A
Installing radiator upper and lower tanks
S-NT224
KV99103520
Radiator plate pliers B
Removing radiator upper and lower tanks
S-NT225
WS39930000
Tube presser
S-NT052
EBS011T8
Tool name
Description
Radiator cap tester
Checking radiator and radiator cap
PBIC1982E
CO-4
http://vnx.su
OVERHEATING CAUSE ANALYSIS

[QR]

Troubleshooting Chart
PFP:00012
A
EBS00KOD
Symptom
Check items
Water pump malfunction
CO
Worn or loose drive belt
Thermostat and water control valve stuck closed
Dust contamination or
paper clogging
Poor heat transfer

Damaged fins
Physical damage
Clogged radiator cooling
tube
Excess foreign material

(rust, dirt, sand, etc.)
Cooling fan does not operate

Reduced air flow
High resistance to fan rotation
E
Fan assembly
Damaged fan blades
Cooling system parts

malfunction
Damaged radiator shroud
Improper engine coolant

mixture ratio
Poor engine coolant quality
Engine coolant viscosity
Loose clamp
Cooling hose
Water pump
Engine coolant leaks
Poor sealing
Radiator
Overflowing reservoir tank
Exhaust gas leaks into

cooling system
Cracked radiator tank

Cracked radiator core
Reservoir tank
Poor sealing
O-ring for damage, deterioration or improper fitting
Insufficient engine coolant
Cracked hose
Loose
Radiator cap
Cracked reservoir tank

Cylinder head deterioration
Cylinder head gasket deterioration
CO-5
http://vnx.su

[QR]
Symptom
Check items
High engine rpm under no
load
Abusive driving
Driving in low gear for

extended time
Driving at extremely high
speed
Overload on engine
Power train system malfunction

Installed improper size
wheels and tires
Except cooling system

parts malfunction
Dragging brakes
Improper ignition timing
Blocked bumper
Installed car brassiere
Blocked radiator grille

Blocked or restricted air
flow
Blocked radiator
Mud contamination or
paper clogging
Blocked condenser
Installed large fog lamp
CO-6
http://vnx.su
Blocked air flow
COOLING SYSTEM
[QR]
COOLING SYSTEM
Cooling Circuit
PFP:21020
A
EBS00KOE
CO
I
PBIC2592E
CO-7
http://vnx.su
COOLING SYSTEM
[QR]
System Chart
EBS00KOF
PBIC1232E
CO-8
http://vnx.su
ENGINE COOLANT
[QR]
ENGINE COOLANT
Inspection
PFP:KQ100
A
EBS00KOG
LEVEL CHECK
Check if the reservoir tank engine coolant level is within MIN to

MAX range when engine is cool.
Adjust engine coolant level as necessary.
CO
SMA412B
LEAK CHECK
To check for leakage, apply pressure to the cooling system with

a radiator cap tester (commercial service tool) and a radiator
cap tester adapter (special service tool).
Testing pressure:
G
157 kPa (1.57 bar, 1.6 kg/cm2 , 23 psi)
WARNING:
Do not remove radiator cap when engine is hot. Serious
burns could occur from high-pressure engine coolant
escaping from radiator.
CAUTION:
Higher test pressure than specified may cause radiator
damage.
NOTE:
In a case that engine coolant decreases, replenish radiator with engine coolant.
If anything is found, repair or replace damaged parts.
Changing Engine Coolant
SLC134B
EBS00KOH
WARNING:
To avoid being scalded, do not change engine coolant when engine is hot.
Wrap a thick cloth around radiator cap and carefully remove the cap. First, turn the cap a quarter
of a turn to release built-up pressure. Then turn the cap all the way.
Be careful not to allow engine coolant to contact drive belt.
DRAINING ENGINE COOLANT

1.
2.
Remove RH and LH undercovers.

Open radiator drain plug at the bottom of radiator, and then
remove radiator cap.
PBIC2250E
3.
When drain all of engine coolant in the system, open water drain plug on cylinder block. Refer to
EM-91, "ASSEMBLY" .
Remove reservoir tank as necessary, and drain engine coolant and clean reservoir tank before installing.
CO-9
http://vnx.su
ENGINE COOLANT
[QR]
4.
Check drained engine coolant for contaminants such as rust, corrosion or discoloration. If contaminated,
flush the engine cooling system. Refer to CO-10, "FLUSHING COOLING SYSTEM" .
REFILLING ENGINE COOLANT

1.
2.
3.
Install reservoir tank if removed, and radiator drain plug.

CAUTION:
Be sure to clean drain plug and install with new O-ring.
If water drain plug on cylinder block is removed, close and tighten it. Refer to EM-86, "CYLINDER BLOCK" .
Make sure that each hose clamp has been firmly tightened.
Fill radiator and reservoir tank to specified level.
Pour engine coolant through engine coolant filler neck
slowly of less than 2 (1-3/4 lmp qt) a minute to allow air
in system to escape.
Use Genuine NISSAN Anti-freeze Coolant or equivalent
mixed with water (distilled or demineralized). Refer to
MA-17, "RECOMMENDED FLUIDS AND LUBRICANTS".
Engine coolant capacity
(with reservoir tank at MAX level)
: Approx. 7.1
(6-1/4 lmp qt)
SMA182B
Reservoir tank capacity (at MAX level)

: 0.7
(5/8 lmp qt)
SMA412B
4.
5.
Install radiator cap.

Warm up until opening thermostat and water control valve. Standard for warming-up time is approximately
10 minutes at 3,000 rpm.
Make sure thermostat opening condition by touching radiator hose (lower) to see a flow of warm water.
CAUTION:
Watch water temperature gauge so as not to overheat the engine.
6. Stop the engine and cool down to less than approximately 50C (122F).
Cool down using fan to reduce the time.
If necessary, refill radiator up to filler neck with engine coolant.
7. Refill reservoir tank to MAX level line with engine coolant.
8. Repeat steps 3 through 6 two or more times with radiator cap installed until the engine coolant level no
longer drops.
9. Check cooling system for leaks with the engine running.
10. Warm up the engine, and check for sound of engine coolant flow while running the engine from idle up to
3,000 rpm with heater temperature controller set at several position between COOL and WARM.
Sound may be noticeable at heater unit.
11. Repeat step 10 three times.
12. If sound is heard, bleed air from cooling system by repeating step 3 through 6 until the engine coolant
level no longer drops.
FLUSHING COOLING SYSTEM

1.
CO-10
http://vnx.su
ENGINE COOLANT
[QR]
2.
3.
4.
5.
6.
7.
CAUTION:
A
If water drain plug on cylinder block is removed, close and tighten it. Refer to EM-86, "CYLINDER BLOCK" .
Fill radiator and reservoir tank with water and reinstall radiator cap.
CO
Run the engine and warm it up to normal operating temperature.
Rev the engine two or three times under no-load.
C
Stop the engine and wait until it cools down.
Drain water from the system. Refer to CO-9, "DRAINING ENGINE COOLANT" .
Repeat steps 1 through 6 until clear water begins to drain from radiator.
D
CO-11
http://vnx.su
RADIATOR
[QR]
RADIATOR
PFP:21400
EBS00KOI
PBIC3640E
1.
Reservoir tank
2.
Reservoir tank cap
3.
Reservoir tank hose
4.
Radiator mounting bracket
5.
Mounting rubber (upper)
6.
Radiator cap
7.
Radiator
8.
O-ring
9.
Radiator drain plug
10. Mounting rubber (lower)
11. A/T fluid cooler hose
12. Radiator hose (lower)
13. Radiator hose (upper)
14. Bracket
15. Radiator cooling fan assembly
WARNING:
Do not remove radiator cap when the engine is hot. Serious burns could occur from high-pressure
engine coolant escaping from radiator. Wrap a thick cloth around the cap. Slowly turn it a quarter of a
turn to release built-up pressure. Carefully remove radiator cap by turning it all the way.
REMOVAL
1.
2.
3.
4.
5.
6.
7.
8.
Remove RH and LH undercovers.

CAUTION:
Do not spill engine coolant on drive belt.
Remove air duct (inlet) and air duct assembly. Refer to EM-16, "AIR CLEANER AND AIR DUCT" .
Disconnect harness connector from fan motor, and move it aside.
Disconnect radiator hoses (upper and lower).
Remove A/T fluid cooler hoses. (A/T models)
Install blind plug to avoid leakage of A/T fluid.
Remove radiator mounting brackets.
Remove radiator and radiator cooling fan assembly.
CAUTION:
Do not damage or scratch radiator core when removing.
CO-12
http://vnx.su
RADIATOR
[QR]
INSTALLATION
A
Check for leaks of engine coolant using a radiator cap tester adapter (special service tool: EG17650301) CO
and a radiator cap tester (commercial service tool). Refer to CO-9, "LEAK CHECK" .
Start and warm up engine. Visually check if there is no leaks of engine coolant and A/T fluid (A/T models).
Checking Radiator Cap
EBS00KOK
Check valve seat of radiator cap.

Check if valve seat is swollen to the extent that the edge of the
plunger cannot be seen when watching it vertically from the top.
Check if valve seat has no soil and damage.
F
PBIC2816E
Pull negative-pressure valve to open it, and make sure that it is

completely closed when released.
Make sure that there is no dirt or damage on the valve seat of
radiator cap negative-pressure valve.
Make sure that there are no unusualness in the opening and
closing conditions of negative-pressure valve.
J
SMA967B
Check radiator cap relief pressure.
Standard:
78 - 98 kPa (0.78 - 0.98bar, 0.8 - 1.0 kg/cm2 , 11 - 14 psi)
Limit:
59 kPa (0.59bar, 0.6 kg/cm2 , 9 psi)
When connecting radiator cap to the radiator cap tester (commercial service tool) and the radiator cap tester adapter [SST],
apply engine coolant to the cap seal surface.
SLC755AC
Replace radiator cap if there is an unusualness related to the above three.

CAUTION:
When installing radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy residue
or foreign material.
Checking Radiator
EBS00KOL
Check radiator for mud or clogging. If necessary, clean radiator as follows.
Be careful not to bend or damage radiator fins.
When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radiator
shroud and horns. Then tape harness and connectors to prevent water from entering.
1. Apply water by hose to the back side of the radiator core vertically downward.
2. Apply water again to all radiator core surface once per minute.
CO-13
http://vnx.su
RADIATOR
[QR]
3.
4.
Stop washing if any stains no longer flow out from the radiator.
Blow air into the back side of radiator core vertically downward.
Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2 , 71 psi) and keep distance more than 30 cm
(11.8 in).
Blow air again into all the radiator core surfaces once per minute until no water sprays out.
5.
CO-14
http://vnx.su
RADIATOR (ALUMINUM TYPE)

[QR]

PFP:21460
A
EBS00KOM
CO
G
PBIC2493E
1.
Upper tank
2.
Sealing rubber
4.
Lower tank
5.
Lower tank (with A/T fluid cooler)
3.
Core
PREPARATION
1.
Attach the spacer to the tip of radiator plate pliers A (special service tool).
Spacer specification: 1.5 mm (0.059 in) thick 18 mm (0.71 in)
wide 8.5 mm (0.335 in) long.
SLC655C
2.
3.
Make sure that when radiator plate pliers A (special service tool) are closed dimension H is approx. 7.6
mm (0.299 in).
Adjust dimension H with the spacer thickness, if necessary.
DISASSEMBLY
1.
Remove upper and lower tanks with a radiator plate pliers B

(special service tool).
CAUTION:
Do not disassemble lower tank and A/T fluid cooler. (A/T
models)
NOTE:
Regard lower tank and A/T fluid cooler as an assembly. (A/T
models)
SLC903
CO-15
http://vnx.su

[QR]
Grip the crimped edge and bend it upwards so that radiator

plate pliers B slips off.
CAUTION:
Do not bend excessively.
SLC893
In areas where radiator plate pliers B cannot be used, use

screwdriver to bend the edge up.
CAUTION:
Be careful not to damage tank.
SLC930
2.
Remove sealing rubber.
3.
Make sure the edge stands straight up.
SLC931
ASSEMBLY
1.
Clean contact portion of tank.
SLC932
CO-16
http://vnx.su

[QR]
2.
Install sealing rubber while pushing it in with fingers.

CAUTION:
Be careful not to twist sealing rubber.
CO
C
SLC917A
3.
Caulk tank in numerical order as shown in the figure with radiator plate pliers A (special service tool).
E
G
SLC904
PBIC2076E
Use pliers in the locations where plate pliers A cannot be

used.
SLC897
CO-17
http://vnx.su

[QR]
4.
Make sure that the rim is completely crimped down.

Standard height H
: 8.0 - 8.4 mm (0.315 - 0.331 in)
SLC554A
5.
Make sure that there is no leakage.

Refer to CO-18, "INSPECTION" .
INSPECTION
1.
Apply pressure with radiator cap tester adapter (special service

tool) and radiator cap tester (commercial service tool).
Testing pressure
: 157 kPa (1.57 bar, 1.6 kg/cm2 , 23 psi)
WARNING:
To prevent the risk of hose coming undone while under
pressure, securely fasten it down with hose clamp.
CAUTION:
Attach hose to A/T fluid cooler to seal its inlet and outlet.
(A/T models)
2.
SLC933
Check for leakage by soaking radiator in water container with

the testing pressure applied.
SLC934
CO-18
http://vnx.su
COOLING FAN
[QR]
COOLING FAN
PFP:21140
A
EBS011TD
CO
I
PBIC2593E
1.
Fan motor (LH)
2.
Fan motor (RH)
4.
Cooling fan (RH)
5.
Cooling fan (LH)
3.
Fan shroud
REMOVAL
1.
2.
3.
4.
5.
Drain engine coolant from radiator. Refer to CO-9, "Changing Engine Coolant" .
CAUTION:
Disconnect radiator hose (upper) at radiator side. Refer to CO-12, "RADIATOR" .
CAUTION:
Disconnect harness connectors from fan motors, and move them to aside.
Remove radiator cooling fan assembly.
CAUTION:
Be careful not to damage or scratch on radiator core.
INSTALLATION
NOTE:
Cooling fans are controlled by ECM. For details, refer to EC-351, "DTC P1217 ENGINE OVER TEMPERATURE" (WITH EURO-OBD) or EC-752, "DTC P1217 ENGINE OVER TEMPERATURE" (WITHOUT EUROOBD).
CO-19
http://vnx.su
COOLING FAN
[QR]
EBS01FCL
DISASSEMBLY
1.
2.
Remove cooling fans (RH and LH) from fan motors (RH and LH).
Put marks to identify installation positions of cooling fans (RH and LH).
Remove fan motors (RH and LH) from fan shroud.
Put marks to identify installation positions of cooling fan motors (RH and LH).

Cooling Fan
Inspect cooling fan for crack or unusual bend.
If anything is found, replace cooling fan.
ASSEMBLY
CAUTION:
RH and LH cooling fans and fan motors are different. Be careful not to misassemble them.
CO-20
http://vnx.su
WATER PUMP
[QR]
WATER PUMP
PFP:21020
A
EBS00KON
CO
G
PBIC2253E
1.
Water pump
2.
Gasket
3.
Gasket
4.
Water pump housing
5.
Gasket
6.
Water pipe
7.
O-ring
REMOVAL
1.
2.
3.
4.
a.
b.
c.
d.
5.
6.

CAUTION:
RH undercover
Drive belt auto-tensioner; Refer to EM-14, "Removal and Installation of Drive Belt Auto-Tensioner" .
Remove water pump.
Engine coolant will leak from cylinder block, so have a receptacle ready below.
CAUTION:
Handle water pump vane so that it does not contact any other parts.
Water pump cannot be disassembled and should be replaced as a unit.
Remove water pump housing with the following procedure;
Remove alternator. Refer to SC-12, "CHARGING SYSTEM" .
Remove oil level gauge and oil level gauge guide. Refer to EM-27, "OIL PAN AND OIL STRAINER" .
CAUTION:
Plug the oil level gauge guide opening to prevent oil pan from entering foreign materials.
Remove mounting bolts for water pipe.
Remove water pump housing.
Remove exhaust manifold and three way catalyst assembly. Refer to EM-25, "EXHAUST MANIFOLD
AND THREE WAY CATALYST" .
Remove water pipe.
CO-21
http://vnx.su
WATER PUMP
[QR]
Visually check if there is no significant dirt or rusting on water

pump body and vane.
Make sure that there is no looseness in vane shaft, and that it
turns smoothly when rotated by hand.
Replace water pump, if necessary.
KBIA0155E
INSTALLATION
When inserting water pipe end into cylinder block, apply a neutral detergent to O-ring. Then insert it immediately.
Check for engine coolant leaks using a radiator cap tester adapter (special service tool: EG17650301)
and radiator cap tester (commercial service tool). Refer to CO-9, "LEAK CHECK" .
Start and warm up engine. Visually check if there is no leaks of engine coolant.
CO-22
http://vnx.su
THERMOSTAT AND WATER CONTROL VALVE

[QR]

PFP:21200
A
EBS00KOO
CO
PBIC3597E
1.
Thermostat
2.
O-ring
3.
Water inlet
4.
Water control valve
5.
O-ring
6.
Gasket
7.
Water control valve housing (water outlet)
8.
Washer
9.
10. Water hose
11. Heater hose
12. O-ring
13. Heater pipe
14. Water hose
15. Heater hose
2.
3.
4.
a.
b.
c.
d.
e.
REMOVAL
1.

CAUTION:
Disconnect radiator hose (lower) at water inlet side. Refer to CO-12, "RADIATOR" .
Remove water inlet and thermostat.
Remove water control valve with the following procedure:
Disconnect radiator hose (upper) at water control valve housing (water outlet) side.
Disconnect harness connector from engine coolant temperature sensor.
Disconnect water hoses.
Remove heater pipe and heater hose.
After removing water control valve housing (water outlet) and water control valve.
CO-23
http://vnx.su

[QR]
Place a thread so that it is caught in the valves of thermostat and

water control valve. Immerse fully in a container filled with water.
Heat while stirring. (The example in the figure shows thermostat.)
The valve opening temperature is the temperature at which the
valve opens and falls from the thread.
Continue heating. Check the maximum valve lift amount.
NOTE:
The maximum valve lift amount standard temperature for water
control valve is the reference value.
After checking the maximum valve lift amount, lower the water
temperature and check the valve closing temperature.
SLC252B
Standard:
Items
Valve opening temperature
Maximum valve lift
Valve closing temperature
Thermostat
Water control valve
80.5 - 83.5C (177 - 182F)
93.5 - 96.5C (200 - 206F)
8 mm/ 95C (0.315 in/ 203F)
8 mm/ 108C (0.315 in/ 226F)
77C (171F)
90C (194F)
If out of the standard, replace either or both thermostat and water control valve.
INSTALLATION
Thermostat and Water Control Valve
Install thermostat with making rubber ring groove fit to thermostat flange with the whole circumference. (The example in the
figure shows thermostat.)
NOTE:
Same procedure is applied for installation of water control valve.
PBIC0157E
Install thermostat with jiggle valve facing upwards. (The position

deviation may be within the range of 20 degrees as shown in the
figure.)
Install water control valve with the arrow facing up and the frame
center part facing upwards. (The position deviation may be
within the range of 20 degrees as shown in the figure.)
PBIC0158E
Heater Pipe Installation

Apply a neutral detergent to O-ring, then quickly insert the insertion part of heater pipe into cylinder block.
Check for leaks of engine coolant using a radiator cap tester adapter (special service tool: EG17650301)
and a radiator cap tester (commercial service tool). Refer to CO-9, "LEAK CHECK" .
Start and warm up engine. Visually check if there is no leaks of engine coolant and A/T fluid (A/T models).
CO-24
http://vnx.su

[QR]

Standard and Limit
PFP:00030
A
EBS00KOP
CAPACITY
Unit:
Engine coolant capacity (With reservoir tank at MAX level)
(lmp qt)
Reservoir tank
0.7 (5/8)
RADIATOR
Unit: kPa (bar,
Standard
Cap relief pressure
CO
Approx. 7.1 (6-1/4)
kg/cm2
, psi)
78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11- 14)
Limit
59 (0.59, 0.6, 9)
Leakage test pressure
157 (1.57, 1.6, 23)
THERMOSTAT
80.5 - 83.5C (177 - 182F)
Maximum valve lift
8 mm/ 95C (0.315 in/ 203F)
77C (171F)
WATER CONTROL VALVE

93.5 - 96.5C (200 - 206F)
Maximum valve lift
8 mm/ 108C (0.315 in/ 226F)*
90C (194F)
*: Reference data
Tightening Torque
EBS00KOQ

5.5 (0.56, 49)*
Radiator cooling fan assembly
5.5 (0.56, 49)*
Cooling fan
3.43 (0.35, 30)*
Fan motor
4.41 (0.45, 39)*
Water pump
24.5 (2.5, 18)
Water pump housing
28.0 (2.9, 21)
Water pipe
28.0 (2.9, 21)
Water inlet
28.0 (2.9, 21)
Water control valve housing (water outlet)
28.0 (2.9, 21)
Hater pipe
28.0 (2.9, 21)
24.5 (2.5, 18)
CO-25
http://vnx.su
PRECAUTIONS
[YD22DDTi]
PRECAUTIONS
Precautions For Liquid Gasket
[YD22DDTi]
PFP:00001
EBS01276

1.
2.
3.
holes.
tool).
After 30 minutes or more have passed from the installation, fill
PBIC2160E
CO-26
http://vnx.su
PREPARATION
[YD22DDTi]
PREPARATION
PFP:00002
A
EBS00BAV
Tool number
Tool name
Description
EG17650301
Radiator cap tester adapter
CO
Adapting radiator cap tester to radiator cap

and radiator filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
S-NT564
KV99103510
Radiator plate pliers A
Installing radiator upper and lower tanks
F
S-NT224
KV99103520
Radiator plate pliers B
Removing radiator upper and lower tanks
H
S-NT225
EBS011UY
Tool name
Description
Radiator cap tester
Checking radiator and radiator cap
PBIC1982E
CO-27
http://vnx.su

[YD22DDTi]

Troubleshooting Chart
PFP:00012
EBS00BAW
Symptom
Check items
Water pump malfunction
Worn or loose drive belt
Thermostat stuck closed

Poor heat transfer
Dust contamination or
paper clogging
Damaged fins
Physical damage
Reduced air flow
Clogged radiator cooling

tube
Excess foreign material

(rust, dirt, sand, etc.)
Cooling fan does not operate
Refer to DTC in EC1217

(cooling system)
High resistance to fan rotation
Fan assembly
Damaged fan blades
Cooling system parts

malfunction
Damaged radiator shroud
Improper engine coolant

mixture ratio
Poor engine coolant quality
Engine coolant density
Loose clamp
Cooling hose
Water pump
Cracked hose
Poor sealing
Loose
Radiator cap
Engine coolant leaks
Poor sealing
O-ring for damage, deterioration or improper fitting
Insufficient engine coolant

Radiator
Cracked radiator tank

Cracked radiator core
Reservoir tank
Cracked reservoir tank

Cylinder head deterioration
Overflowing reservoir tank
CO-28
http://vnx.su
Exhaust gas leaks into

cooling system
Cylinder head gasket deterioration

[YD22DDTi]
Symptom
Check items
High engine rpm under no
load
Abusive driving
Driving in low gear for

extended time
CO
Driving at extremely high

speed
Overload on engine
Installed improper size

wheels and tires
Except cooling system

parts malfunction
Powertrain system malfunction
Dragging brakes
Blocked bumper
Installed car brassiere

Blocked or restricted air
flow
Blocked radiator
Mud contamination or
paper clogging
Blocked condenser
Installed large fog lamp
Blocked air flow
CO-29
http://vnx.su
COOLING SYSTEM
[YD22DDTi]
COOLING SYSTEM
Cooling Circuit
PFP:21020
EBS00BAX
PBIC0935E
CO-30
http://vnx.su
COOLING SYSTEM
[YD22DDTi]
System Chart
EBS00LS1
CO
MBIA0056E
CO-31
http://vnx.su
ENGINE COOLANT
[YD22DDTi]
ENGINE COOLANT
Inspection
PFP:KQ100
EBS00BAY
LEVEL CHECK
Check if the reservoir tank engine coolant level is within MIN to

MAX when engine is cool.
Adjust engine coolant level as necessary.
SMA412B
CHECKING RADIATOR SYSTEM FOR LEAKS
To check for leaks, apply pressure to the cooling system with the
radiator cap tester (commercial service tool) and the radiator
cap tester adapter (special service tool).
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2 , 23 psi)
WARNING:
Do not remove radiator cap when engine is hot. Serious
burns could occur from high pressure engine coolant
escaping from radiator.
CAUTION:
Higher test pressure than specified may cause radiator
damage.
NOTE:
In a case that engine coolant decreases, replenish radiator with engine coolant.
Changing Engine Coolant
SLC134B
EBS00BAZ
WARNING:
To avoid being scalded, do not change engine coolant when engine is hot.
Wrap a thick cloth around cap and carefully remove radiator cap. First, turn radiator cap a quarter
of a turn to release built-up pressure. Then turn the cap all the way.
DRAINING ENGINE COOLANT

1.
2.

Open radiator drain plug at the bottom of radiator, and remove
radiator cap.
CAUTION:
Be careful not to allow engine coolant to contact drive
belts.
Cover the exhaust tube heat shield to prevent from
splashing engine coolant.
PBIC0236E
When draining all engine coolant in the system, open water drain plug on engine cylinder block. Refer
to EM-224, "DISASSEMBLY".
3. Remove reservoir tank, drain engine coolant, then clean reservoir tank.
4. Check drained engine coolant for contaminants such as rust, corrosion or discoloration.
CO-32
http://vnx.su
ENGINE COOLANT
[YD22DDTi]
If contaminated, flush engine cooling system. Refer to CO-34, "FLUSHING COOLING SYSTEM" .
A
REFILLING ENGINE COOLANT

1.
2.
Install reservoir tank, and radiator drain plug.

CAUTION:
CO
Be sure to clean radiator drain plug and install with new O-ring.
If water drain plug on cylinder block is removed, close and tighten it. Refer to EM-228, "ASSEMBLY" .
C
Remove air relief plug.
D
F
PBIC3608E
3.
Fill radiator and reservoir tank to the specified level.

Pour engine coolant through engine coolant filler neck
slowly of less than 2 (1-3/4 lmp qt) a minute to allow air
in system to escape.
Use Genuine Nissan Anti-freeze Coolant or equivalent
mixed with water (distilled or demineralized). Refer to
MA-17, "RECOMMENDED FLUIDS AND LUBRICANTS".
Engine coolant capacity

(with reservoir tank at MAX level)
: Approx. 9.5
(8-3/8 lmp qt)
SMA182B
Reservoir tank capacity (at MAX level)

: 0.7
(5/8 lmp qt)
When engine coolant overflows air relief hole, install air relief
plug with new copper washer.
L
Air relief plug

: 7.4 Nm (0.75 kg-m, 65 in-lb)
M
SMA412B
4.
5.
6.
7.
8.
9.
Install radiator cap.

Warm up until opening thermostat and water control valve. Standard for warming-up time is approximately
10 minutes at 3,000 rpm.
Make sure thermostat opening condition by touching radiator hose (lower) to see a flow of warm water.
CAUTION:
Watch water temperature gauge so as not to overheat engine.
Stop engine and cool down to less than approximately 50C(122F).
Cool down using a fan to reduce the time.
If necessary, refill radiator up to filler neck with engine coolant.
Refill reservoir tank to MAX level line with engine coolant.
Repeat steps 3 through 6 two or more times with radiator cap installed until engine coolant level no longer
drops.
Check cooling system for leaks with engine running.
CO-33
http://vnx.su
ENGINE COOLANT
[YD22DDTi]
10. Warm up engine, and check for sound of engine coolant flow while running engine from idle up to 3,000
rpm with heater temperature controller set at several position between COOL and WARM.
Sound may be noticeable at heater unit.
11. Repeat step 10 three times.
12. If sound is heard, bleed air from cooling system by repeating steps 3 through 6 until engine coolant level
no longer drops.
FLUSHING COOLING SYSTEM

1.
2.
3.
4.
5.
6.
7.

CAUTION:
If water drain plug on cylinder block is removed, close and tighten it. Refer to EM-228, "ASSEMBLY" .
Fill radiator with water until water spills from the air relief hole, then close air relief plug. Fill radiator and
reservoir tank with water and reinstall radiator cap.
Run engine and warm it up to normal operating temperature.
Rev engine two or three times under no-load.
Stop engine and wait until it cools down.
Drain water from the system. Refer to CO-32, "DRAINING ENGINE COOLANT" .
Repeat steps 1 through 6 until clear water begins to drain from radiator.
CO-34
http://vnx.su
RADIATOR
[YD22DDTi]
RADIATOR
PFP:21400
A
EBS00BB0
CO
I
PBIC3609E
1.
Radiator
2.
3.
Mounting rubber (upper)
4.
Radiator cap
5.
Mounting rubber (lower)
6.
O-ring
7.
Drain plug
8.
Radiator hose (lower)
9.
Cooling fan assembly
10. Reservoir tank bracket
11. Reservoir tank
12. Reservoir tank hose
13. Radiator hose (upper)
WARNING:
Do not remove radiator cap when engine is hot. Serious burns could occur from high-pressure engine
coolant escaping from radiator.
REMOVAL
1.
2.
3.
4.
Drain engine coolant from radiator. Refer to CO-32, "DRAINING ENGINE COOLANT" .
CAUTION:
Do not spill engine coolant on drive belts.
Disconnect radiator hose (upper and lower), reservoir tank hose and radiator mounting bracket.
Remove reservoir tank hose and radiator mounting bracket.
Remove radiator and cooling fan assembly.
CAUTION:
Do not damage or scratch radiator core when removing.
INSTALLATION
Check for leaks of engine coolant using the radiator cap tester adapter (special service tool:
EG17650301) and the radiator cap tester (commercial service tool). Refer to CO-32, "CHECKING RADIATOR SYSTEM FOR LEAKS" .
CO-35
http://vnx.su
RADIATOR
[YD22DDTi]
Checking Radiator Cap
EBS01FA3
Check valve seat of radiator cap.

Check if valve seat is swollen to the extent that the edge of the
plunger cannot be seen when watching it vertically from the top.
Check if valve seat has no soil and damage.
PBIC2816E
Pull negative-pressure valve to open it, and make sure that it is

completely closed when released.
Make sure that there is no dirt or damage on the valve seat of
radiator cap negative-pressure valve.
Make sure that there are no unusualness in the opening and
closing conditions of negative-pressure valve.
SMA967B
Check radiator cap relief pressure.

Standard:
78 - 98 kPa (0.78 - 0.98bar, 0.8 - 1.0 kg/cm2 , 11 - 14 psi)
Limit:
59 kPa (0.59bar, 0.6 kg/cm2 , 9 psi)
When connecting radiator cap to the radiator cap tester (commercial service tool) and the radiator cap tester adapter (special
service tool), apply engine coolant to the cap seal surface.
SLC755AC
Replace radiator cap if there is an unusualness related to the above three.

CAUTION:
When installing radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy residue
or foreign material.
Checking Radiator
EBS011WN
Check radiator for mud or clogging. If necessary, clean radiator as follows.
Be careful not to bend or damage the radiator fins.
When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radiator
shroud and horns. Then tape the harness and connectors to prevent water from entering.
1. Apply water by hose to the back side of the radiator core vertically downwards.
2. Apply water again to all radiator core surface once per minute.
3. Stop washing if any stains no longer flow out from the radiator.
4. Blow air into the back side of radiator core vertically downwards.
Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2 , 71psi) and keep distance more than 30 cm
(11.8 in).
Blow air again into all the radiator core surface once per minute until no water sprays out.
5.
CO-36
http://vnx.su
COOLING FAN
[YD22DDTi]
COOLING FAN
PFP:21140
A
EBS011WO
CO
I
PBIC3610E
1.
Cooling fan motor (LH)
4.
Cooling fans
2.
Cooling fan motor (RH)
3.
Cooling fan shroud
REMOVAL
1.
2.
3.
4.
5.
Drain engine coolant from radiator. Refer to CO-32, "Changing Engine Coolant" .
CAUTION:
Perform when engine is cold.
Disconnect radiator hose (upper) at radiator side. Refer to CO-12, "RADIATOR" .
CAUTION:
Disconnect harness connectors from fan motors, and move them to aside.
Remove radiator cooling fan assembly. Refer to CO-35, "RADIATOR" .
CAUTION:
Be careful not to damage or scratch on radiator core.
INSTALLATION
Cooling fans are controlled by ECM. For details, refer to EC-1116, "DTC P0217 ENGINE OVER TEMPERATURE" (WITH EURO-OBD), EC-1465, "DTC P0217 ENGINE OVER TEMPERATURE" (WITHOUT
EURO-OBD).
DISASSEMBLY AND ASSEMBLY

Disassembly
1.
2.
Remove cooling fans.

Remove cooling fan motor (RH and LH) from cooling fan shroud.
Put marks to identify installation positions of cooling fan motor.
CO-37
http://vnx.su
COOLING FAN
[YD22DDTi]
Assembly
CAUTION:
RH and LH cooling fan motors are different. Be careful not to misassemble them.
CO-38
http://vnx.su

[YD22DDTi]

PFP:21460
A
EBS00BB3
CO
G
PBIC2075E
1.
Upper tank
4.
Lower tank
2.
Sealing rubber
3.
Core
PREPARATION
1.
2.
3.
Attach the spacer to the tip of the radiator plate pliers A (special
service tool).
Spacer specification: 1.5 mm (0.059 in) thick x 18 mm (0.71 in)
wide x 8.5 mm (0.335 in) long.
Make sure that when radiator plate pliers A (special service tool)
are closed dimension H is approx. 7.6 mm (0.299 in).
Adjust dimension H with the spacer, if necessary.
SLC655C
DISASSEMBLY
1.
Remove upper or lower tanks with radiator plate pliers B (special

service tool).
SLC903
CO-39
http://vnx.su

[YD22DDTi]
Grip the crimped edge and bend it upwards so that radiator

plate pliers B slips off.
CAUTION:
Do not bend excessively.
SLC893
In areas where radiator plate pliers B cannot be used, use a

screwdriver to bend the edge up.
CAUTION:
Be careful not to damage tank.
SLC930
2.
Remove sealing rubber.
3.
Make sure the edge stands straight up.
SLC931
ASSEMBLY
1.
Clean contact portion of tank.
SLC932
CO-40
http://vnx.su

[YD22DDTi]
2.
Install sealing rubber while pushing it with fingers.

CAUTION:
Be careful not to twist sealing rubber.
CO
C
SLC917A
3.
Caulk tank in numerical order as shown in the figure with radiator plate pliers A (special service tool).
E
G
SLC904
PBIC2076E
Use pliers in the locations where radiator plate pliers A cannot

be used.
L
SLC897
4.
Make sure that the rim is completely crimped down.

Standard height H: 8.0 - 8.4 mm (0.315 - 0.331 in)
5.
Make sure that there is no leakage.

Refer to CO-42, "INSPECTION" .
SLC554A
CO-41
http://vnx.su

[YD22DDTi]
INSPECTION
1.
Apply pressure with the radiator cap tester adapter (special service tool) and the radiator cap tester (commercial service tool).
Testing pressure
: 157 kPa (1.57 bar, 1.6 kg/cm2 , 23 psi)
WARNING:
To prevent the risk of hose coming undone while under
pressure, securely fasten it down with hose clamp.
SLC933
2.
Check for leakage by soaking radiator in water container with

the testing pressure applied.
SLC934
CO-42
http://vnx.su
WATER PUMP
[YD22DDTi]
WATER PUMP
PFP:21020
A
EBS00BB4
CO
G
PBIC2384E
1.
Gasket
4.
Water pump pulley
2.
Water pump
3.
WARNING:
Do not remove radiator cap when the engine is hot. Serious burns could occur from high pressure
engine coolant escaping from the radiator.
REMOVAL
1.
2.
3.
4.
5.
6.
7.

Remove drive belt. Refer to EM-137, "DRIVE BELTS" .
Drain engine coolant. Refer to CO-32, "DRAINING ENGINE COOLANT" .
CAUTION:
Support the bottom of oil pan with a floor jack etc, and remove RH engine mounting insulator (front side of
engine). Refer to EM-219, "ENGINE ASSEMBLY" .
Remove water pump pulley.
Loosen the pulley bolts after fixing the pulley using a screwdriver etc.
Remove RH engine mounting bracket.
Remove water pump.
Engine coolant will leak from cylinder block, so have a receptacle ready below.
CAUTION:
Handle the water pump vane so that it does not contact any other parts.
Water pump cannot be disassembled and should be replaced as a unit.
CO-43
http://vnx.su
WATER PUMP
[YD22DDTi]
Visually check if there is no significant dirt or rusting on the

water pump body and vane.
Make sure that there is no looseness in the vane shaft, and that
it turns smoothly when rotated by hand.
If there are any unusualness, replace water pump assembly as
necessary.
SBIA0132E
INSTALLATION

Install water pump pulley with the front mark (painted white, used to prevent errors during assembly) facing the front of engine. Refer to CO-43, "WATER PUMP" .
CO-44
http://vnx.su
THERMOSTAT AND WATER PIPING

[YD22DDTi]

PFP:21200
A
EBS00BK9
CO
I
PBIC2018E
1.
Heater return pipe
2.
Gasket
3.
Thermostat housing
4.
Thermostat
5.
Rubber ring
6.
Water inlet
7.
Water inlet pipe
8.
Radiator hose (lower)
WARNING:
Do not remove radiator cap when engine is hot. Serious burns could occur from high pressure engine
coolant escaping from radiator.
3.
4.
5.
REMOVAL
1.
2.

Drain engine coolant. Refer to CO-32, "DRAINING ENGINE COOLANT" .
CAUTION:
Remove radiator hose (lower) from water inlet side. Refer to CO-35, "RADIATOR" .
Remove water inlet and thermostat.
Remove thermostat housing.
CO-45
http://vnx.su

[YD22DDTi]
Thermostat
Place a string so that it is caught in the valves of the thermostat.

Immerse fully in a container filled with water. Heat while stirring.
The valve opening temperature is the temperature at which the
valve opens and falls from the thread.
Continue heating. Check the full-open lift amount.
After checking the full-open lift amount, lower the water temperature and check the valve closing temperature.
SLC252B
Standard values
Item
Thermostat
80 - 84C (176 - 183 F)

More than 10 mm/ 95C (0.39 in/ 203 F)
Full-open lift amount

More than 77C (171F)
If out of the standard, replace thermostat.
INSTALLATION
Install the thermostat with the whole circumference of each

flange part fit securely inside the rubber ring.
Install the thermostat with the jiggle valve facing upwards.
JLC300B
CO-46
http://vnx.su

[YD22DDTi]

Standard and Limit
PFP:00030
A
EBS00CU0
CAPACITY
Unit:
Engine coolant capacity (With reservoir tank at MAX level)
(lmp qt)
Reservoir tank
0.7 (5/8)
THERMOSTAT
80 - 84C (176 - 183F)
Full open lift amount
More than 10 mm/ 95C (0.39 in/203F)
RADIATOR
Unit: kPa (bar, kg/cm2 , psi)
Standard
Cap relief pressure
CO
Approx 9.5 (8-3/8)
78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14)
Limit
59 (0.59, 0.6, 9)
Leakage test pressure
157 (1.57, 1.6, 23)
Tightening Torque
EBS00BKE

Air relief plug
7.4 (0.75, 65)*

Cooling fan assembly
Cooling fan
Cooling fan motor (RH and LH)
5.5 (0.56, 49)*

5.5 (0.56, 49)*
3.43 (0.35, 30)*
4.41 (0.45, 39)*
Water pump
Water pump pulley
Water inlet
Thermostat housing
Water inlet pipe
Heater return pipe
26.5 (2.7, 20)

8.5 (0.86, 75)*
25 (2.6, 18)
25 (2.6, 18)
25 (2.6, 18)
25 (2.6, 18)
CO-47
http://vnx.su

[YD22DDTi]
CO-48
http://vnx.su
ENGINE CONTROL SYSTEM
B ENGINE
SECTION
EC
EC
CONTENTS
QR (WITH EURO-OBD)
INDEX FOR DTC ...................................................... 19
Alphabetical Index .................................................. 19
DTC No. Index ....................................................... 21
PRECAUTIONS ........................................................ 24
Precautions for Supplemental Restraint System
(SRS) AIR BAG and SEAT BELT PRE-TENSIONER ................................................................ 24
On Board Diagnostic (OBD) System of Engine and
A/T .......................................................................... 24
Precaution .............................................................. 24
Wiring Diagrams and Trouble Diagnosis ................ 27
PREPARATION ......................................................... 28
ENGINE CONTROL SYSTEM .................................. 30
System Diagram ..................................................... 30
Vacuum Hose Drawing ........................................... 32
System Chart ......................................................... 34
Multiport Fuel Injection (MFI) System .................... 35
Electronic Ignition (EI) System ............................... 37
Air Conditioning Cut Control ................................... 38
Fuel Cut Control (at No Load and High Engine
Speed) .................................................................... 38
CAN Communication Unit ...................................... 39
BASIC SERVICE PROCEDURE .............................. 44
Idle Speed and Ignition Timing Check .................... 44
Accelerator Pedal Released Position Learning ...... 45
Throttle Valve Closed Position Learning ................ 46
Idle Air Volume Learning ........................................ 46
Fuel Pressure Check .............................................. 48
ON BOARD DIAGNOSTIC (OBD) SYSTEM ............ 51
Introduction ............................................................ 51
Two Trip Detection Logic ........................................ 51
Emission-related Diagnostic Information ................ 52
NATS (Nissan Anti-theft System) ........................... 63
Malfunction Indicator (MI) ....................................... 63
OBD System Operation Chart ................................ 66
TROUBLE DIAGNOSIS ............................................ 72
Trouble Diagnosis Introduction ............................... 72
DTC Inspection Priority Chart ................................. 76

Fail-safe Chart ........................................................ 77
Basic Inspection ..................................................... 78
Symptom Matrix Chart ............................................ 83
Engine Control Component Parts Location ............ 87
Circuit Diagram ....................................................... 92
ECM Harness Connector Terminal Layout ............. 94
ECM Terminals and Reference Value ..................... 94
CONSULT-II Function (ENGINE) .......................... 102
Generic Scan Tool (GST) Function ....................... 112
CONSULT-II Reference Value in Data Monitor Mode
. 114
Major Sensor Reference Graph in Data Monitor
Mode ..................................................................... 117
TROUBLE DIAGNOSIS - SPECIFICATION VALUE. 119
Description ............................................................ 119
Testing Condition .................................................. 119
Inspection Procedure ............................................ 119
Diagnostic Procedure ........................................... 120
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT ....................................................................... 123
Description ............................................................ 123
POWER SUPPLY AND GROUND CIRCUIT ........... 124
Wiring Diagram ..................................................... 124
Component Inspection .......................................... 131
Ground Inspection ................................................ 131
DTC U1000, U1001 CAN COMMUNICATION LINE. 132
Description ............................................................ 132
On Board Diagnosis Logic .................................... 132
DTC Confirmation Procedure ............................... 132
Wiring Diagram ..................................................... 133
DTC P0011 IVT CONTROL ..................................... 135
Description ............................................................ 135
. 135
EC-1
http://vnx.su

DTC P0031, P0032 HO2S1 HEATER ..................... 138
Description ............................................................ 138
. 138
Wiring Diagram ..................................................... 140
DTC P0037, P0038 HO2S2 HEATER ..................... 144
Description ............................................................ 144
. 144
Wiring Diagram ..................................................... 146
DTC P0102, P0103 MAF SENSOR ......................... 150
Component Description ........................................ 150
. 150
Wiring Diagram ..................................................... 152
DTC P0112, P0113 IAT SENSOR ........................... 158
Wiring Diagram ..................................................... 160
DTC P0117, P0118 ECT SENSOR .......................... 164
Wiring Diagram ..................................................... 166
DTC P0122, P0123 TP SENSOR ............................ 170
. 170
Wiring Diagram ..................................................... 172
DTC P0132 HO2S1 ................................................. 178

.178
DTC Confirmation Procedure ................................ 179
Wiring Diagram ..................................................... 180
Diagnostic Procedure ............................................ 181
Removal and Installation ....................................... 184
DTC P0133 HO2S1 ................................................. 185
.185
Overall Function Check ......................................... 187
Wiring Diagram ..................................................... 188
DTC P0134 HO2S1 ................................................. 195
.195
Wiring Diagram ..................................................... 198
DTC P0138 HO2S2 ................................................. 203
.203
Wiring Diagram ..................................................... 205
DTC P0139 HO2S2 ................................................. 210
.210
Wiring Diagram ..................................................... 213
DTC P0171 FUEL INJECTION SYSTEM FUNCTION.218
Wiring Diagram ..................................................... 220
EC-2
http://vnx.su
DTC P0172 FUEL INJECTION SYSTEM FUNCTION. 224

On Board Diagnosis Logic ................................... 224
Wiring Diagram .................................................... 226
DTC P0222, P0223 TP SENSOR ........................... 230
. 230
Wiring Diagram .................................................... 232
Component Inspection ......................................... 237
DTC P0300 - P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 - 4 CYLINDER MISFIRE ..................... 238
DTC P0327, P0328 KS ........................................... 244
Wiring Diagram .................................................... 245
DTC P0335 CKP SENSOR (POS) .......................... 249
. 249
Wiring Diagram .................................................... 250
DTC P0340 CMP SENSOR (PHASE) ..................... 256
Wiring Diagram .................................................... 257
DTC P0420 THREE WAY CATALYST FUNCTION. 263
Overall Function Check ........................................ 264
DTC P0444 EVAP CANISTER PURGE VOLUME
CONTROL SOLENOID VALVE .............................. 268
Description ........................................................... 268
. 268
Wiring Diagram .................................................... 270

DTC P0500 VSS ...................................................... 275
Description ............................................................ 275
DTC P0550 PSP SENSOR ..................................... 277
. 277
Wiring Diagram ..................................................... 278
DTC P0605 ECM ..................................................... 282
DTC P1065 ECM POWER SUPPLY ....................... 285
Wiring Diagram ..................................................... 286
DTC P1111 IVT CONTROL SOLENOID VALVE ..... 289
. 289
Wiring Diagram ..................................................... 290
DTC P1121 ELECTRIC THROTTLE CONTROL
ACTUATOR ............................................................. 293
FUNCTION .............................................................. 295
Description ............................................................ 295
Wiring Diagram ..................................................... 296
DTC P1124, P1126 THROTTLE CONTROL MOTOR
RELAY ..................................................................... 305
EC-3
http://vnx.su
EC

. 305
Wiring Diagram ..................................................... 307
DTC P1128 THROTTLE CONTROL MOTOR ......... 313
Wiring Diagram ..................................................... 314
DTC P1143 HO2S1 ................................................. 321
. 321
DTC P1144 HO2S1 ................................................. 327
. 327
DTC P1146 HO2S2 ................................................. 333
. 333
Wiring Diagram ..................................................... 336
DTC P1147 HO2S2 ................................................. 341
. 341
Wiring Diagram ..................................................... 344
DTC P1211 TCS CONTROL UNIT .......................... 349
Description ............................................................ 349

DTC P1212 TCS COMMUNICATION LINE ............. 350
Description ............................................................ 350
DTC P1217 ENGINE OVER TEMPERATURE ........ 351
System Description ............................................... 351
.352
Wiring Diagram ..................................................... 355
Main 12 Causes of Overheating ........................... 365
DTC P1225 TP SENSOR ........................................ 367
DTC P1226 TP SENSOR ........................................ 369
DTC P1229 SENSOR POWER SUPPLY ................ 371
Wiring Diagram ..................................................... 372
DTC P1564 ASCD STEERING SWITCH ................ 376
.376
Wiring Diagram ..................................................... 378
DTC P1572 ASCD BRAKE SWITCH ...................... 386
.386
Wiring Diagram ..................................................... 388
DTC P1574 ASCD VEHICLE SPEED SENSOR ..... 395
EC-4
http://vnx.su
DTC P1706 PNP SWITCH ...................................... 397

. 397
Wiring Diagram .................................................... 399
DTC P1720 VSS ..................................................... 402
Description ........................................................... 402
. 402
DTC P1805 BRAKE SWITCH ................................ 404
Description ........................................................... 404
. 404
FAIL-SAFE MODE ............................................... 404
Wiring Diagram .................................................... 405
DTC P2122, P2123 APP SENSOR ........................ 408
. 408
Wiring Diagram .................................................... 410
DTC P2127, P2128 APP SENSOR ........................ 415
. 415
Wiring Diagram .................................................... 417
DTC P2135 TP SENSOR ........................................ 423
. 423
Wiring Diagram .................................................... 425
DTC P2138 APP SENSOR ..................................... 431
. 431
Wiring Diagram ..................................................... 433
IGNITION SIGNAL .................................................. 439
Wiring Diagram ..................................................... 440
INJECTOR CIRCUIT ............................................... 450
. 450
Wiring Diagram ..................................................... 451
VIAS ........................................................................ 456
Description ............................................................ 456
. 457
Wiring Diagram ..................................................... 458
FUEL PUMP CIRCUIT ............................................ 465
Description ............................................................ 465
. 465
Wiring Diagram ..................................................... 466
REFRIGERANT PRESSURE SENSOR .................. 473
Wiring Diagram ..................................................... 474
ELECTRICAL LOAD SIGNAL ................................ 479
. 479
Wiring Diagram ..................................................... 480
ASCD BRAKE SWITCH ......................................... 505
. 505
Wiring Diagram ..................................................... 506
ASCD INDICATOR .................................................. 513
. 513
EC-5
http://vnx.su
EC
Wiring Diagram ..................................................... 514

MI & DATA LINK CONNECTORS ........................... 516
Wiring Diagram ..................................................... 516
EVAPORATIVE EMISSION SYSTEM ..................... 520
Description ............................................................ 520
POSITIVE CRANKCASE VENTILATION ............... 525
Description ............................................................ 525
AUTOMATIC SPEED CONTROL DEVICE (ASCD). 527
Fuel Pressure ....................................................... 529
Idle Speed and Ignition Timing ............................. 529
Calculated Load Value .......................................... 529
Mass Air Flow Sensor ........................................... 529
Intake Air Temperature Sensor ............................. 529
Engine Coolant Temperature Sensor ................... 529
Heated Oxygen Sensor 1 Heater ......................... 529
Heated Oxygen sensor 2 Heater .......................... 530
Crankshaft Position Sensor (POS) ....................... 530
Camshaft Position Sensor (PHASE) .................... 530
Throttle Control Motor ........................................... 530
Injector .................................................................. 530
Fuel Pump ............................................................ 530
QR (WITHOUT EURO-OBD)
INDEX FOR DTC ..................................................... 531
Alphabetical Index ................................................ 531
DTC No. Index ...................................................... 533
PRECAUTIONS ....................................................... 535
(SRS) AIR BAG and SEAT BELT PRE-TENSIONER ............................................................... 535
On Board Diagnostic (OBD) System of Engine .... 535
Precaution ............................................................ 535
Wiring Diagrams and Trouble Diagnosis .............. 538
PREPARATION ....................................................... 539
ENGINE CONTROL SYSTEM ................................ 541
System Diagram ................................................... 541
Vacuum Hose Drawing ......................................... 543
System Chart ........................................................ 545
Multiport Fuel Injection (MFI) System ................... 546
Electronic Ignition (EI) System ............................. 548
Air Conditioning Cut Control ................................. 549
Fuel Cut Control (at No Load and High Engine
Speed) .................................................................. 549
CAN Communication Unit ..................................... 550
BASIC SERVICE PROCEDURE ............................. 555
Idle Speed and Ignition Timing Check .................. 555
Accelerator Pedal Released Position Learning .... 556
Throttle Valve Closed Position Learning ............... 557
Idle Air Volume Learning ...................................... 557
Fuel Pressure Check ............................................ 559
ON BOARD DIAGNOSTIC (OBD) SYSTEM ........... 562

Introduction ........................................................... 562
Two Trip Detection Logic ....................................... 562
Emission-related Diagnostic Information .............. 562
NATS (Nissan Anti-theft System) .......................... 564
Malfunction Indicator (MI) ..................................... 565
TROUBLE DIAGNOSIS .......................................... 569
Trouble Diagnosis Introduction ............................. 569
DTC Inspection Priority Chart ............................... 573
Fail-safe Chart ...................................................... 574
Basic Inspection .................................................... 575
Symptom Matrix Chart .......................................... 581
Engine Control Component Parts Location ........... 585
Circuit Diagram ..................................................... 590
ECM Harness Connector Terminal Layout ............ 592
ECM Terminals and Reference Value ................... 592
CONSULT-II Function (ENGINE) .......................... 601
.612
Mode ..................................................................... 615
TROUBLE DIAGNOSIS - SPECIFICATION VALUE.617
Description ............................................................ 617
Testing Condition .................................................. 617
Inspection Procedure ............................................ 617
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT ....................................................................... 621
Description ............................................................ 621
POWER SUPPLY AND GROUND CIRCUIT ........... 622
Wiring Diagram ..................................................... 622
Ground Inspection ................................................. 629
DTC U1000, U1001 CAN COMMUNICATION LINE.630
Description ............................................................ 630
Wiring Diagram ..................................................... 631
DTC P0011 IVT CONTROL ..................................... 633
Description ............................................................ 633
.634
Wiring Diagram ..................................................... 637
DTC P0102, P0103 MAF SENSOR ......................... 641
.641
Wiring Diagram ..................................................... 643
EC-6
http://vnx.su

DTC P0117, P0118 ECT SENSOR ......................... 649
Wiring Diagram .................................................... 651
DTC P0122, P0123 TP SENSOR ........................... 655
. 655
Wiring Diagram .................................................... 657
DTC P0132 HO2S1 ................................................. 663
. 663
Wiring Diagram .................................................... 665
DTC P0134 HO2S1 ................................................. 670
. 670
Wiring Diagram .................................................... 672
DTC P0222, P0223 TP SENSOR ........................... 677
. 677
Wiring Diagram .................................................... 679
DTC P0327, P0328 KS ........................................... 685
Wiring Diagram .................................................... 686
DTC P0335 CKP SENSOR (POS) .......................... 690

. 690
Wiring Diagram ..................................................... 692
DTC P0340 CMP SENSOR (PHASE) ..................... 698
Wiring Diagram ..................................................... 700
DTC P0500 VSS ...................................................... 706
Description ............................................................ 706
DTC P0550 PSP SENSOR ..................................... 708
. 708
Wiring Diagram ..................................................... 709
DTC P0605 ECM ..................................................... 713
DTC P1065 ECM POWER SUPPLY ....................... 716
Wiring Diagram ..................................................... 717
ACTUATOR ............................................................. 720
FUNCTION .............................................................. 723
Description ............................................................ 723
Wiring Diagram ..................................................... 725
EC-7
http://vnx.su
EC

DTC P1124, P1126 THROTTLE CONTROL MOTOR
RELAY ..................................................................... 734
. 734
Wiring Diagram ..................................................... 736
DTC P1128 THROTTLE CONTROL MOTOR ......... 742
Wiring Diagram ..................................................... 743
DTC P1211 TCS CONTROL UNIT .......................... 750
Description ............................................................ 750
DTC P1212 TCS COMMUNICATION LINE ............ 751
Description ............................................................ 751
DTC P1217 ENGINE OVER TEMPERATURE ........ 752
. 753
Wiring Diagram ..................................................... 756
Main 12 Causes of Overheating ........................... 766
DTC P1225 TP SENSOR ........................................ 768
DTC P1226 TP SENSOR ........................................ 770
DTC P1229 SENSOR POWER SUPPLY ................ 772
Wiring Diagram ..................................................... 773
DTC P1564 ASCD STEERING SWITCH ................ 777

.777
Wiring Diagram ..................................................... 779
DTC P1572 ASCD BRAKE SWITCH ...................... 787
.787
Wiring Diagram ..................................................... 790
DTC P1574 ASCD VEHICLE SPEED SENSOR ..... 797
DTC P1706 PNP SWITCH ....................................... 799
.799
Wiring Diagram ..................................................... 801
DTC P1720 VSS ...................................................... 804
Description ............................................................ 804
.804
DTC P1805 BRAKE SWITCH ................................. 806
Description ............................................................ 806
.806
Wiring Diagram ..................................................... 808
DTC P2122, P2123 APP SENSOR ......................... 812
.812
Wiring Diagram ..................................................... 814
DTC P2127, P2128 APP SENSOR ......................... 819
EC-8
http://vnx.su

. 819
Wiring Diagram .................................................... 821
DTC P2135 TP SENSOR ........................................ 827
. 827
Wiring Diagram .................................................... 829
DTC P2138 APP SENSOR ..................................... 835
. 835
Wiring Diagram .................................................... 837
HO2S1 HEATER ..................................................... 843
Description ........................................................... 843
. 843
Wiring Diagram .................................................... 844
HO2S2 HEATER ..................................................... 848
Description ........................................................... 848
. 848
Wiring Diagram .................................................... 849
IAT SENSOR ........................................................... 853
Wiring Diagram .................................................... 854
HO2S1 .................................................................... 858
. 858
Wiring Diagram .................................................... 859
HO2S2 ..................................................................... 864

. 864
Wiring Diagram ..................................................... 865
IGNITION SIGNAL .................................................. 870
Wiring Diagram ..................................................... 871
EVAP CANISTER PURGE VOLUME CONTROL
SOLENOID VALVE ................................................. 881
Description ............................................................ 881
. 881
Wiring Diagram ..................................................... 882
INJECTOR CIRCUIT ............................................... 888
. 888
Wiring Diagram ..................................................... 889
VIAS ........................................................................ 894
Description ............................................................ 894
. 895
Wiring Diagram ..................................................... 896
FUEL PUMP CIRCUIT ............................................ 903
Description ............................................................ 903
. 903
Wiring Diagram ..................................................... 904
REFRIGERANT PRESSURE SENSOR .................. 911
Wiring Diagram ..................................................... 912
ELECTRICAL LOAD SIGNAL ................................ 917
. 917
Wiring Diagram ..................................................... 918
ASCD BRAKE SWITCH ......................................... 943
Component Description .......................................
EC-9
http://vnx.su
EC

. 943
Wiring Diagram ..................................................... 944
ASCD INDICATOR .................................................. 951
. 951
Wiring Diagram ..................................................... 952
MI & DATA LINK CONNECTORS ........................... 954
Wiring Diagram ..................................................... 954
Wiring Diagram .................................................. 956
EVAPORATIVE EMISSION SYSTEM ..................... 958
Description ............................................................ 958
POSITIVE CRANKCASE VENTILATION ............... 963
Description ............................................................ 963
AUTOMATIC SPEED CONTROL DEVICE (ASCD). 965
Fuel Pressure ....................................................... 967
Idle Speed and Ignition Timing ............................. 967
Mass Air Flow Sensor ........................................... 967
Intake Air Temperature Sensor ............................. 967
Engine Coolant Temperature Sensor ................... 967
Heated Oxygen Sensor 1 Heater ......................... 967
Heated Oxygen sensor 2 Heater .......................... 967
Crankshaft Position Sensor (POS) ....................... 967
Camshaft Position Sensor (PHASE) .................... 968
Throttle Control Motor ........................................... 968
Injector .................................................................. 968
Fuel Pump ............................................................ 968
YD (WITH EURO-OBD)
INDEX FOR DTC ..................................................... 969
Alphabetical Index ................................................ 969
DTC No. Index ...................................................... 972
PRECAUTIONS ....................................................... 975
(SRS) AIR BAG and SEAT BELT PRE-TENSIONER ............................................................... 975
On Board Diagnostic (OBD) System of Engine .... 975
Precautions ........................................................... 975
Wiring Diagrams and Trouble Diagnosis .............. 978
PREPARATION ....................................................... 979
ENGINE CONTROL SYSTEM ................................ 980
System Diagram ................................................... 980
Vacuum Hose Drawing ......................................... 981
System Chart ........................................................ 982
Fuel Injection Control System ............................... 982
Fuel Injection Timing Control System ................... 984
Air Conditioning Cut Control ................................. 984
Fuel Cut Control (At No Load & High Engine Speed).984

Crankcase Ventilation System .............................. 985
CAN Communication ............................................ 985
BASIC SERVICE PROCEDURE ............................. 989
Fuel Filter .............................................................. 989
Fuel Pump Learning Value Clearing ..................... 989
ON BOARD DIAGNOSTIC (OBD) SYSTEM ........... 991
Introduction ........................................................... 991
Three Trip Detection Logic and One Trip Detection
Logic ..................................................................... 991
Emission-related Diagnostic Information .............. 991
NATS (Nissan Anti-theft System) .......................... 996
Malfunction Indicator (MI) ..................................... 996
OBD System Operation Chart ............................... 999
TROUBLE DIAGNOSIS .........................................
1002
Trouble Diagnosis Introduction ............................
1002
DTC Inspection Priority Chart ..............................
1005
Basic Inspection ...................................................
1007
Symptom Matrix Chart .........................................1011
Engine Control Component Parts Location ..........
1015
Circuit Diagram ....................................................
1020
ECM Harness Connector Terminal Layout ...........
1022
ECM Terminals And Reference Value ..................
1022
CONSULT-II Function (ENGINE) .........................
1029
Generic Scan Tool (GST) Function ......................
1035
1037
Mode ....................................................................
1038
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT ......................................................................
1040
Description ...........................................................
1040
Diagnostic Procedure ...........................................
1040
POWER SUPPLY AND GROUND CIRCUIT ..........
1041
Wiring Diagram ....................................................
1041
1042
Component Inspection .........................................
1048
Ground Inspection ................................................
1049
DTC U1000 CAN COMMUNICATION LINE ...........
1050
Description ...........................................................
1050
On Board Diagnosis Logic ...................................
1050
DTC Confirmation Procedure ...............................
1050
Wiring Diagram ....................................................
1051
1052
DTC P0016 CKP - CMP CORRELATION ..............
1053
1053
1053
1053
DTC P0045 TC BOOST CONTROL SOLENOID
VALVE .....................................................................
1055
Description ...........................................................
1055
1055
1055
Wiring Diagram ....................................................
1056
1057
1058
DTC P0088 FUEL SYSTEM ...................................
1060
1060
1060
EC-10
http://vnx.su
Diagnostic Procedure ..........................................1060

Removal and Installation .....................................1061
DTC P0089 FUEL PUMP .......................................1062
On Board Diagnosis Logic ..................................1062
DTC Confirmation Procedure ..............................1062
DTC P0093 FUEL SYSTEM ..................................1065
Component Inspection ........................................1067
DTC P0101 MAF SENSOR ...................................1069
Component Description .......................................1069
1069
Wiring Diagram ...................................................1071
DTC P0102, P0103 MAF SENSOR .......................1077
1077
Wiring Diagram ...................................................1078
DTC P0112, P0113 IAT SENSOR ..........................1082
Wiring Diagram ...................................................1083
DTC P0117, P0118 ECT SENSOR ........................1087
Description ..........................................................1087
Wiring Diagram ...................................................1089
DTC P0122, P0123 APP SENSOR .......................1093
Description ..........................................................1093
1093
Wiring Diagram ...................................................1094
DTC P0182, P0183 FUEL PUMP TEMPERATURE

SENSOR ................................................................1099
Description ...........................................................1099
1099
On Board Diagnosis Logic ...................................1099
Wiring Diagram ....................................................1100
DTC P0192, P0193 FRP SENSOR ........................1103
Description ...........................................................1103
1103
Wiring Diagram ....................................................1104
Component Inspection .........................................1107
DTC P0200 FUEL INJECTOR ...............................1108
DTC P0201 - P0204 FUEL INJECTOR ..................1110
1110
Wiring Diagram ....................................................1112
DTC P0217 ENGINE OVER TEMPERATURE .......1116
System Description ..............................................1116
1116
Overall Function Check .......................................1117
Wiring Diagram ....................................................1119
Main 12 Causes of Overheating ..........................1128
DTC P0222, P0223 APP SENSOR ........................1130
Description ...........................................................1130
1130
Wiring Diagram ....................................................1131
DTC P0234 TC SYSTEM .......................................1136
Description ...........................................................1136
Wiring Diagram ....................................................1137
EC-11
http://vnx.su
EC

DTC P0237, P0238 TC BOOST SENSOR .............1142
1142
Wiring Diagram ....................................................1144
DTC P0335 CKP SENSOR ....................................1148
Description ...........................................................1148
1148
Wiring Diagram ....................................................1149
DTC P0336 CKP SENSOR ....................................1154
Description ...........................................................1154
1154
Wiring Diagram ....................................................1155
DTC P0340 CMP SENSOR ....................................1160
Description ...........................................................1160
Wiring Diagram ....................................................1161
DTC P0341 CMP SENSOR ....................................1166
Description ...........................................................1166
Wiring Diagram ....................................................1167
DTC P0380 GLOW RELAY ....................................1173
Wiring Diagram ....................................................1174
DTC P0401 EGR FUNCTION .................................1177
Description ...........................................................1177
1178
DTC Confirmation Procedure ...............................1178

Wiring Diagram ....................................................1179
Diagnostic Procedure ...........................................1180
Removal and Installation ......................................1183
DTC P0404 EGR VOLUME CONTROL VALVE .....1184
Description ...........................................................1184
1185
Wiring Diagram ....................................................1186
DTC P0501 ASCD VEHICLE SPEED SENSOR ....1191
DTC P0504 ASCD BRAKE SWITCH .....................1197
1197
DTC confirmation Procedure ...............................1198
Wiring Diagram ....................................................1199
1200
1204
DTC P0563 BATTERY VOLTAGE ..........................
1206
1206
1206
1206
DTC P0580, P0581 ASCD STEERING SWITCH ...
1208
1208
1208
1209
1209
Wiring Diagram ....................................................
1210
1213
1215
DTC P0605 ECM ....................................................
1217
Description ...........................................................
1217
1217
1217
1218
DTC P0606 ECM ....................................................
1219
Description ...........................................................
1219
EC-12
http://vnx.su

DTC P0628, P0629 FUEL PUMP ..........................1221
Description ..........................................................1221
1221
Wiring Diagram ...................................................1222
DTC P0642, P0643 SENSOR POWER SUPPLY ..1226
Wiring Diagram ...................................................1227
Wiring Diagram ...................................................1231
DTC P0686 ECM RELAY .......................................1235
Wiring Diagram ...................................................1236
DTC P1211 TCS CONTROL UNIT ........................1239
Description ..........................................................1239
DTC P1212 TCS COMMUNICATION LINE ...........1240
Description ..........................................................1240
DTC P1260 - P1267 FUEL INJECTOR ADJUSTMENT RESISTOR ..................................................1241
Description ..........................................................1241
Wiring Diagram ...................................................1243
DTC P1268 - P1271 FUEL INJECTOR .................1247
1247
Wiring Diagram ...................................................1249
DTC P1272 FUEL PUMP .......................................1253

Description ...........................................................1253
1253
Wiring Diagram ....................................................1254
DTC P1273 FUEL PUMP .......................................1259
Description ...........................................................1259
1259
Wiring Diagram ....................................................1260
DTC P1274 FUEL PUMP .......................................1264
Description ...........................................................1264
1264
Wiring Diagram ....................................................1265
DTC P1275 FUEL PUMP .......................................1269
Description ...........................................................1269
1269
Wiring Diagram ....................................................1270
DTC P2135 APP SENSOR ....................................1274
Description ...........................................................1274
1274
Wiring Diagram ....................................................1275
DTC P2146, P2149 FUEL INJECTOR POWER SUPPLY .........................................................................1280
1280
Wiring Diagram ....................................................1282
EC-13
http://vnx.su
EC
DTC P2147, P2148 FUEL INJECTOR CIRCUIT ...1285

1285
Wiring Diagram ....................................................1286
DTC P2228, P2229 BARO SENSOR .....................1291
Description ...........................................................1291
GLOW CONTROL SYSTEM ..................................1293
Description ...........................................................1293
Wiring Diagram ....................................................1294
BRAKE SWITCH ....................................................1301
Description ...........................................................1301
1301
Wiring Diagram ....................................................1302
PNP SWITCH .........................................................1310
Description ...........................................................1310
1310
Wiring Diagram ....................................................1311
PSP SWITCH .........................................................1314
1314
Wiring Diagram ....................................................1315
FUEL TRANSPORT PUMP ....................................1319
Description ...........................................................1319
Wiring Diagram ....................................................1320
AUTOMATIC SPEED CONTROL DEVICE (ASCD)1327
ASCD INDICATOR .................................................1329
Wiring DiagramLHD Models .............................1330
Wiring DiagramRHD Models ............................1331
START SIGNAL .....................................................1333
Wiring Diagram ....................................................1333
MI & DATA LINK CONNECTORS ..........................

1336
Wiring Diagram ....................................................
1336
SERVICE DATA AND SPECIFICATIONS (SDS) ...
1338
General Specifications .........................................
1338
Mass Air Flow Sensor ..........................................
1338
Engine Coolant Temperature Sensor ...................
1338
Fuel Rail Pressure Sensor ...................................
1338
Glow Plug .............................................................
1338
EGR Volume Control Valve ..................................
1338
Crankshaft Position Sensor .................................1338
Camshaft Position Sensor ...................................
1338
YD (WITHOUT EURO-OBD)
INDEX FOR DTC ....................................................
1339
Alphabetical Index ................................................
1339
DTC No. Index .....................................................
1341
PRECAUTIONS ......................................................
1343
(SRS) AIR BAG and SEAT BELT PRE-TENSIONER ..............................................................
1343
On Board Diagnostic (OBD) System of Engine ...
1343
Precautions ..........................................................
1343
Wiring Diagrams and Trouble Diagnosis ..............
1346
PREPARATION ......................................................
1347
Special Service Tools ...........................................1347
Commercial Service Tools ...................................
1347
ENGINE CONTROL SYSTEM ................................
1348
System Diagram ..................................................
1348
Vacuum Hose Drawing ........................................1349
System Chart .......................................................
1350
Fuel Injection Control System ..............................
1350
Fuel Injection Timing Control System ..................
1352
Air Conditioning Cut Control ................................
1352
Fuel Cut Control (At No Load & High Engine Speed)1352
Crankcase Ventilation System .............................
1353
CAN Communication ...........................................
1353
BASIC SERVICE PROCEDURE ............................
1357
Fuel Filter .............................................................
1357
Fuel Pump Learning Value Clearing ....................
1357
ON BOARD DIAGNOSTIC (OBD) SYSTEM ..........
1359
DTC and MI Detection Logic ................................
1359
Diagnostic Trouble Code (DTC) ...........................
1359
Freeze Frame Data ..............................................
1360
NATS (Nissan Anti-theft System) .........................
1360
Malfunction Indicator (MI) ....................................
1360
Relationship Between MI, DTC, CONSULT-II and
Driving Patterns ...................................................
1363
TROUBLE DIAGNOSIS .........................................
1365
Trouble Diagnosis Introduction ............................
1365
DTC Inspection Priority Chart ..............................
1368
Basic Inspection ...................................................
1369
Symptom Matrix Chart .........................................
1374
Engine Control Component Parts Location ..........
1378
Circuit Diagram ....................................................
1383
ECM Harness Connector Terminal Layout ...........
1385
ECM Terminals And Reference Value ..................
1385
CONSULT-II Function (ENGINE) .........................
1392
EC-14
http://vnx.su
1398
Mode ...................................................................1400
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT .....................................................................1401
Description ..........................................................1401
POWER SUPPLY AND GROUND CIRCUIT .........1402
Wiring Diagram ...................................................1402
Ground Inspection ...............................................1410
DTC U1000 CAN COMMUNICATION LINE ..........1411
Description ..........................................................1411
Wiring Diagram ...................................................1412
DTC P0016 CKP - CMP CORRELATION ..............1414
DTC P0088 FUEL SYSTEM ..................................1416
DTC P0089 FUEL PUMP .......................................1418
DTC P0093 FUEL SYSTEM ..................................1420
DTC P0102, P0103 MAF SENSOR .......................1424
1424
Wiring Diagram ...................................................1425
DTC P0112, P0113 IAT SENSOR ..........................1429
Wiring Diagram ...................................................1431
DTC P0117, P0118 ECT SENSOR ........................1435
Description ..........................................................1435

Wiring Diagram ....................................................1437
DTC P0122, P0123 APP SENSOR ........................1441
Description ...........................................................1441
1441
Wiring Diagram ....................................................1443
DTC P0182, P0183 FUEL PUMP TEMPERATURE
SENSOR ................................................................1448
Description ...........................................................1448
1448
Wiring Diagram ....................................................1449
DTC P0192, P0193 FRP SENSOR ........................1452
Description ...........................................................1452
1452
Wiring Diagram ....................................................1453
DTC P0200 FUEL INJECTOR ...............................1457
DTC P0201 - P0204 FUEL INJECTOR ..................1459
1459
Wiring Diagram ....................................................1461
DTC P0217 ENGINE OVER TEMPERATURE .......1465
1465
Wiring Diagram ....................................................1468
Main 12 Causes of Overheating ..........................1476
EC-15
http://vnx.su
EC
DTC P0222, P0223 APP SENSOR ........................1478

Description ...........................................................1478
1478
Wiring Diagram ....................................................1480
DTC P0234 TC SYSTEM .......................................1485
Description ...........................................................1485
Wiring Diagram ....................................................1486
DTC P0237, P0238 TC BOOST SENSOR .............1491
1491
Wiring Diagram ....................................................1493
DTC P0335 CKP SENSOR ....................................1497
Description ...........................................................1497
1497
Wiring Diagram ....................................................1498
DTC P0336 CKP SENSOR ....................................1503
Description ...........................................................1503
1503
Wiring Diagram ....................................................1504
DTC P0340 CMP SENSOR ....................................1509
Description ...........................................................1509
Wiring Diagram ....................................................1510
DTC P0341 CMP SENSOR ....................................1515
Description ...........................................................1515
Wiring Diagram ....................................................

1516
1517
1521
DTC P0501 ASCD VEHICLE SPEED SENSOR ....
1522
1522
1522
1522
1523
1524
1524
1524
1524
1525
1526
1526
1526
1526
1527
DTC P0504 ASCD BRAKE SWITCH .....................
1528
1528
1528
1528
DTC confirmation Procedure ...............................
1529
Overall Function Check ........................................
1529
Wiring Diagram ....................................................
1531
1532
1536
DTC P0563 BATTERY VOLTAGE ..........................
1538
1538
1538
1538
DTC P0580, P0581 ASCD STEERING SWITCH ...
1540
1540
1540
1541
1541
Wiring Diagram ....................................................
1542
1545
1547
DTC P0605 ECM ....................................................
1549
Description ...........................................................
1549
1549
1549
1550
DTC P0606 ECM ....................................................
1551
Description ...........................................................
1551
1551
1551
1552
DTC P0628, P0629 FUEL PUMP ...........................
1553
Description ...........................................................
1553
1553
1553
1553
Wiring Diagram ....................................................
1554
EC-16
http://vnx.su

Wiring Diagram ...................................................1559
Wiring Diagram ...................................................1563
DTC P0686 ECM RELAY .......................................1567
Wiring Diagram ...................................................1568
DTC P1211 TCS CONTROL UNIT ........................1571
Description ..........................................................1571
DTC P1212 TCS COMMUNICATION LINE ...........1572
Description ..........................................................1572
DTC P1260 - P1267 FUEL INJECTOR ADJUSTMENT RESISTOR ..................................................1573
Description ..........................................................1573
Wiring Diagram ...................................................1575
DTC P1268 - P1271 FUEL INJECTOR .................1579
1579
Wiring Diagram ...................................................1581
DTC P1272 FUEL PUMP .......................................1585
Description ..........................................................1585
1585
Wiring Diagram ...................................................1587
DTC P1273 FUEL PUMP .......................................1592

Description ...........................................................1592
1592
Wiring Diagram ....................................................1593
DTC P1274 FUEL PUMP .......................................1597
Description ...........................................................1597
1597
Wiring Diagram ....................................................1598
DTC P1275 FUEL PUMP .......................................1602
Description ...........................................................1602
1602
Wiring Diagram ....................................................1603
DTC P2135 APP SENSOR ....................................1607
Description ...........................................................1607
1607
Wiring Diagram ....................................................1609
DTC P2146, P2149 FUEL INJECTOR POWER SUPPLY .........................................................................1614
1614
Wiring Diagram ....................................................1615
DTC P2147, P2148 FUEL INJECTOR CIRCUIT ...1618
1618
Wiring Diagram ....................................................1619
EC-17
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EC
DTC P2228, P2229 BARO SENSOR .....................1624

Description ...........................................................1624
GLOW CONTROL SYSTEM ..................................1626
Description ...........................................................1626
Wiring Diagram ....................................................1627
EGR VOLUME CONTROL SYSTEM .....................1634
Description ...........................................................1634
1635
Wiring Diagram ....................................................1636
TC BOOST CONTROL SOLENOID VALVE ..........1642
Description ...........................................................1642
Wiring Diagram ....................................................1643
BRAKE SWITCH ....................................................1647
Description ...........................................................1647
1647
Wiring Diagram ....................................................1648
PNP SWITCH .........................................................1656
Description ...........................................................1656
1656
Wiring Diagram ....................................................1657
PSP SWITCH ..........................................................1660

1660
1660
Wiring Diagram ....................................................
1661
1662
1663
FUEL TRANSPORT PUMP ....................................
1665
Description ...........................................................
1665
Wiring Diagram ....................................................
1666
1668
1672
AUTOMATIC SPEED CONTROL DEVICE (ASCD)1673
System Description ..............................................
1673
1674
ASCD INDICATOR .................................................
1675
1675
Wiring DiagramLHD Models .............................
1676
Wiring DiagramRHD Models ............................
1677
1678
START SIGNAL ......................................................
1679
Wiring Diagram ....................................................
1679
1680
MI & DATA LINK CONNECTORS ..........................
1682
Wiring Diagram ....................................................
1682
SERVICE DATA AND SPECIFICATIONS (SDS) ...
1684
General Specifications .........................................
1684
Mass Air Flow Sensor ..........................................
1684
Engine Coolant Temperature Sensor ...................
1684
Fuel Rail Pressure Sensor ...................................
1684
Glow Plug .............................................................
1684
EGR Volume Control Valve ..................................
1684
Crankshaft Position Sensor .................................1684
Camshaft Position Sensor ...................................
1684
EC-18
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INDEX FOR DTC

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

Alphabetical Index
PFP:00024
A
EBS010KY
Check if the vehicle is a model with Euro-OBD (E-OBD) system or not by the Type approval number on the
identification plate. Refer to GI-46, "IDENTIFICATION PLATE" .
EC
NOTE:
If DTC U1000 or U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC U1000,
U1001. Refer to EC-132, "DTC U1000, U1001 CAN COMMUNICATION LINE" .
C
Items
(CONSULT-II screen terms)
DTC*1
CONSULT-II
GST*2
Trip
ECM*3
MI lighting
up
Reference page
A/T 1ST GR FNCTN
P0731
0731
AT-125
A/T 2ND GR FNCTN
P0732
0732
AT-130
A/T 3RD GR FNCTN
P0733
0733
AT-135
A/T 4TH GR FNCTN
P0734
0734
AT-140
APP SEN 1/CIRC
P2122
2122
EC-408
APP SEN 1/CIRC
P2123
2123
EC-408
APP SEN 2/CIRC
P2127
2127
EC-415
APP SEN 2/CIRC
P2128
2128
EC-415
APP SENSOR
P2138
2138
EC-431
ASCD BRAKE SW*8
P1572
1572
EC-386
ASCD SW *8
P1564
1564
EC-376
P1574
1574
EC-395
ATF TEMP SEN/CIRC
P0710
0710
AT-106
BRAKE SW/CIRCUIT
P1805
1805
EC-404
CAN COMM CIRCUIT
U1000
1000*5
1 (A/T)
2 (M/T)
(A/T)
(M/T)
EC-132
CAN COMM CIRCUIT
U1001
1001*5
EC-132
CKP SEN/CIRCUIT
P0335
0335
EC-249
CMP SEN/CIRC-B1
P0340
0340
EC-256
CTP LEARNING
P1225
1225
EC-367
CTP LEARNING
P1226
1226
EC-369
CYL 1 MISFIRE
P0301
0301
EC-238
CYL 2 MISFIRE
P0302
0302
EC-238
CYL 3 MISFIRE
P0303
0303
EC-238
CYL 4 MISFIRE
P0304
0304
EC-238
ECM
P0605
0605
1 or 2
or
EC-282
ECM BACK UP/CIRCUIT
P1065
1065
EC-285
ECT SEN/CIRC
P0117
0117
EC-164
ECT SEN/CIRC
P0118
0118
EC-164
ENG OVER TEMP
P1217
1217
EC-351
ENGINE SPEED SIG
P0725
0725
AT-119
ETC ACTR
P1121
1121
EC-293
ETC FUNCTION/CIRC
P1122
1122
EC-295
ETC MOT
P1128
1128
EC-313
ETC MOT PWR
P1124
1124
EC-305
ETC MOT PWR
P1126
1126
EC-305
ASCD VHL SPD
SEN*8
EC-19
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INDEX FOR DTC

DTC*1
Items
CONSULT-II
Trip
MI lighting
up
Reference page
GST*2
ECM*
FUEL SYS-LEAN-B1
P0171
0171
EC-218
FUEL SYS-RICH-B1
P0172
0172
EC-224
HO2S1 (B1)
P0132
0132
EC-178
HO2S1 (B1)
P0133
0133
EC-185
HO2S1 (B1)
P0134
0134
EC-195
HO2S1 (B1)
P1143
1143
EC-321
HO2S1 (B1)
P1144
1144
EC-327
HO2S1 HTR (B1)
P0031
0031
EC-138
HO2S1 HTR (B1)
P0032
0032
EC-138
HO2S2 (B1)
P0138
0138
EC-203
HO2S2 (B1)
P0139
0139
EC-210
HO2S2 (B1)
P1146
1146
EC-333
HO2S2 (B1)
P1147
1147
EC-341
HO2S2 HTR (B1)
P0037
0037
EC-144
HO2S2 HTR (B1)
P0038
0038
EC-144
IAT SEN/CIRCUIT
P0112
0112
EC-158
IAT SEN/CIRCUIT
P0113
0113
EC-158
INT/V TIM CONT-B1
P0011
0011
EC-135
INT/V TIM V/CIR-B1
P1111
1111
EC-289
KNOCK SEN/CIRC-B1
P0327
0327
EC-244
KNOCK SEN/CIRC-B1
P0328
0328
EC-244
L/PRESS SOL/CIRC
P0745
0745
AT-154
MAF SEN/CIRCUIT
P0102
0102
EC-150
MAF SEN/CIRCUIT
P0103
0103
EC-150
MULTI CYL MISFIRE
P0300
0300
EC-238
NATS MALFUNCTION
P1610 - P1615
1610 - 1615
BL-108
NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.
No DTC
Flashing*4
Flashing*4
EC-64
NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.
P0000
0000
O/R CLTCH SOL/CIRC
P1760
1760
AT-178
P-N POS SW/CIRCUIT
P1706
1706
EC-397
PNP SW/CIRC
P0705
0705
AT-100
PURG VOLUME CONT/V
P0444
0444
EC-268
PW ST P SEN/CIRC
P0550
0550
EC-277
SENSOR POWER/CIRC
P1229
1229
EC-371
SFT SOL A/CIRC
P0750
0750
AT-161
SFT SOL B/CIRC
P0755
0755
AT-167
P0740
0740
AT-148
P1211
1211
EC-349
P1212
1212
EC-350
TCC SOLENOID/CIRC
TCS C/U FUNCTN*
TCS/CIRC*6
EC-20
http://vnx.su
INDEX FOR DTC

DTC*1
Items
CONSULT-II
Trip
MI lighting
up
Reference page
GST*2
ECM*
TP SEN 1/CIRC
P0222
0222
EC-230
TP SEN 1/CIRC
P0223
0223
EC-230
TP SEN 2/CIRC
P0122
0122
EC-170
TP SEN 2/CIRC
P0123
0123
EC-170
TP SENSOR
P2135
2135
EC-423
TP SEN/CIRC A/T
P1705
1705
AT-173
TW CATALYST SYS-B1
P0420
0420
EC-263
V/SP SEN (A/T OUT)
P1720
1720
EC-402
VEH SPD SEN/CIR AT*7
P0720
0720
AT-112
VEH SPEED SEN/CIRC*7
P0500
0500
EC-275
*1: 1st trip DTC No. is the same as DTC No.

*2: This number is prescribed by ISO 15031-5.
*3: In Diagnostic Test Mode II (Self-diagnostic results), this number is controlled by NISSAN.
*4: When engine is running
*5: The troubleshooting for this DTC needs CONSULT-II.
*6: For models with ESP system
*7: When the fail-safe operation for both self-diagnoses occur, the MI illuminates.
*8: For QR25DE engine models
H
EBS010KZ
NOTE:
DTC*1
GST*2
EC
DTC No. Index
CONSULT-II
ECM*3
Items
NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.
Trip
MI lighting
up
Reference page
Flashing*4
EC-64
Flashing*4
U1000
1000*5
CAN COMM CIRCUIT
1 (A/T)
2 (M/T)
(A/T)
(M/T)
EC-132
U1001
1001*5
CAN COMM CIRCUIT
EC-132
P0000
0000
NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.
P0011
0011
INT/V TIM CONT-B1
EC-135
P0031
0031
HO2S1 HTR (B1)
EC-138
P0032
0032
HO2S1 HTR (B1)
EC-138
P0037
0037
HO2S2 HTR (B1)
EC-144
P0038
0038
HO2S2 HTR (B1)
EC-144
P0102
0102
MAF SEN/CIRCUIT
EC-150
P0103
0103
MAF SEN/CIRCUIT
EC-150
P0112
0112
IAT SEN/CIRCUIT
EC-158
P0113
0113
IAT SEN/CIRCUIT
EC-158
P0117
0117
ECT SEN/CIRC
EC-164
P0118
0118
ECT SEN/CIRC
EC-164
P0122
0122
TP SEN 2/CIRC
EC-170
EC-21
No DTC
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INDEX FOR DTC

DTC*1
CONSULT-II
Items
Trip
MI lighting
up
Reference page
GST*2
ECM*
P0123
0123
TP SEN 2/CIRC
EC-170
P0132
0132
HO2S1 (B1)
EC-178
P0133
0133
HO2S1 (B1)
EC-185
P0134
0134
HO2S1 (B1)
EC-195
P0138
0138
HO2S2 (B1)
EC-203
P0139
0139
HO2S2 (B1)
EC-210
P0171
0171
FUEL SYS-LEAN-B1
EC-218
P0172
0172
FUEL SYS-RICH-B1
EC-224
P0222
0222
TP SEN 1/CIRC
EC-230
P0223
0223
TP SEN 1/CIRC
EC-230
P0300
0300
MULTI CYL MISFIRE
EC-238
P0301
0301
CYL 1 MISFIRE
EC-238
P0302
0302
CYL 2 MISFIRE
EC-238
P0303
0303
CYL 3 MISFIRE
EC-238
P0304
0304
CYL 4 MISFIRE
EC-238
P0327
0327
KNOCK SEN/CIRC-B1
EC-244
P0328
0328
KNOCK SEN/CIRC-B1
EC-244
P0335
0335
CKP SEN/CIRCUIT
EC-249
P0340
0340
CMP SEN/CIRC-B1
EC-256
P0420
0420
TW CATALYST SYS-B1
EC-263
P0444
0444
PURG VOLUME CONT/V
EC-268
P0500
0500
VEH SPEED SEN/CIRC*7
EC-275
P0550
0550
PW ST P SEN/CIRC
P0605
0605
ECM
EC-277
1 or 2
or
EC-282
P0705
0705
PNP SW/CIRC
AT-100
P0710
0710
ATF TEMP SEN/CIRC
AT-106
P0720
0720
VEH SPD SEN/CIR AT*7
AT-112
P0725
0725
ENGINE SPEED SIG
AT-119
P0731
0731
A/T 1ST GR FNCTN
AT-125
P0732
0732
A/T 2ND GR FNCTN
AT-130
P0733
0733
A/T 3RD GR FNCTN
AT-135
P0734
0734
A/T 4TH GR FNCTN
AT-140
P0740
0740
TCC SOLENOID/CIRC
AT-148
P0745
0745
L/PRESS SOL/CIRC
AT-154
P0750
0750
SFT SOL A/CIRC
AT-161
P0755
0755
SFT SOL B/CIRC
AT-167
P1065
1065
ECM BACK UP/CIRCUIT
EC-285
P1111
1111
INT/V TIM V/CIR-B1
EC-289
P1121
1121
ETC ACTR
EC-293
P1122
1122
ETC FUNCTION/CIRC
EC-295
P1124
1124
ETC MOT PWR
EC-305
P1126
1126
ETC MOT PWR
EC-305
EC-22
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INDEX FOR DTC

DTC*1
CONSULT-II
Items
Trip
MI lighting
up
Reference page
GST*2
ECM*
P1128
1128
ETC MOT
EC-313
P1143
1143
HO2S1 (B1)
EC-321
P1144
1144
HO2S1 (B1)
EC-327
P1146
1146
HO2S2 (B1)
EC-333
P1147
1147
HO2S2 (B1)
EC-341
P1211
1211
TCS C/U FUNCTN*6
EC-349
P1212
1212
TCS/CIRC*6
EC-350
P1217
1217
ENG OVER TEMP
EC-351
P1225
1225
CTP LEARNING
EC-367
P1226
1226
CTP LEARNING
EC-369
P1229
1229
SENSOR POWER/CIRC
EC-371
P1564
1564
ASCD SW*
EC-376
P1572
1572
ASCD BRAKE SW*8
EC-386
P1574
1574
ASCD VHL SPD SEN*8
EC-395
P1610 - P1615
1610 - 1615
NATS MALFUNCTION
BL-108
P1705
1705
TP SEN/CIRC A/T
AT-173
P1706
1706
P-N POS SW/CIRCUIT
EC-397
P1720
1720
V/SP SEN (A/T OUT)
EC-402
P1760
1760
O/R CLTCH SOL/CIRC
AT-178
P1805
1805
BRAKE SW/CIRCUIT
EC-404
P2122
2122
APP SEN 1/CIRC
EC-408
P2123
2123
APP SEN 1/CIRC
EC-408
P2127
2127
APP SEN 2/CIRC
EC-415
P2128
2128
APP SEN 2/CIRC
EC-415
P2135
2135
TP SENSOR
EC-423
P2138
2138
APP SENSOR
EC-431

*4: When engine is running
*6: For models with ESP system
*7: When the fail-safe operations for both self-diagnoses occur, the MI illuminates.
EC-23
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EC
PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) AIR BAG and SEAT
BELT PRE-TENSIONER
EBS010L0
The Supplemental Restraint System such as AIR BAG and SEAT BELT PRE-TENSIONER, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
On Board Diagnostic (OBD) System of Engine and A/T
EBS010L1
The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver of
a malfunction causing emission deterioration.
CAUTION:
Be sure to turn the ignition switch OFF and disconnect the battery ground cable before any repair
or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc. will
cause the MI to light up.
Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will
cause the MI to light up due to the open circuit. (Be sure the connector is free from water, grease,
dirt, bent terminals, etc.)
Certain systems and components, especially those related to OBD, may use a new style slidelocking type harness connector. For description and how to disconnect, refer to PG-73, "HARNESS CONNECTOR" .
Be sure to route and secure the harnesses properly after work. The interference of the harness
with a bracket, etc. may cause the MI to light up due to the short circuit.
Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube
may cause the MI to light up due to the malfunction of the fuel injection system, etc.
Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM and
TCM (Transmission control module) before returning the vehicle to the customer.
Precaution
EBS010L2
Always use a 12 volt battery as power source.

Do not attempt to disconnect battery cables while engine is
running.
Before connecting or disconnecting the ECM harness connector, turn ignition switch OFF and disconnect battery
ground cable. Failure to do so may damage the ECM
because battery voltage is applied to ECM even if ignition
switch is turned OFF.
Before removing parts, turn ignition switch OFF and then
disconnect battery ground cable.
SEF289H
EC-24
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PRECAUTIONS
Do not disassemble ECM.

If battery cable is disconnected, the memory will return to
the initial ECM values.
The ECM will now start to self-control at its initial values.
Engine operation can vary slightly when the cable is disconnected. However, this is not an indication of a malfunction. Do not replace parts because of a slight variation.
EC
C
PBIB1164E
When connecting ECM harness connector, fasten it

securely with levers as far as they will go as shown in the
figure.
G
PBIB1512E
When connecting or disconnecting pin connectors into or

from ECM, take care not to damage pin terminals (bend or
break).
Make sure that there are not any bends or breaks on ECM
pin terminal, when connecting pin connectors.
Securely connect ECM harness connectors.
A poor connection can cause an extremely high (surge)
voltage to develop in coil and condenser, thus resulting in
damage to ICs.
Keep engine control system harness at least 10 cm (4 in)
away from adjacent harness, to prevent engine control system malfunctions due to receiving external noise, degraded
operation of ICs, etc.
Keep engine control system parts and harness dry.
Before replacing ECM, perform ECM Terminals and Reference Value inspection and make sure ECM functions properly. Refer to EC-94, "ECM Terminals and Reference Value" .
Handle mass air flow sensor carefully to avoid damage.
Do not disassemble mass air flow sensor.
Do not clean mass air flow sensor with any type of detergent.
Do not disassemble electric throttle control actuator.
Even a slight leak in the air intake system can cause serious incidents.
Do not shock or jar the camshaft position sensor (PHASE),
crankshaft position sensor (POS).
EC-25
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K
PBIB0090E
MEF040D
PRECAUTIONS
After performing each TROUBLE DIAGNOSIS, perform DTC

Confirmation Procedure or Overall Function Check.
The DTC should not be displayed in the DTC Confirmation
Procedure if the repair is completed. The Overall Function
Check should be a good result if the repair is completed.
SAT652J
When measuring ECM signals with a circuit tester, connect

a break-out box (SST) and Y-cable adapter (SST) between
the ECM and ECM harness connector.
When measuring ECM signals with a circuit tester, never
allow the two tester probes to contact.
Accidental contact of probes will cause a short circuit and
damage the ECM power transistor.
Do not use ECM ground terminals when measuring input/
output voltage. Doing so may result in damage to the ECM's
transistor. Use a ground other than ECM terminals, such as
the ground.
SEF348N
Do not operate fuel pump when there is no fuel in lines.

Tighten fuel hose clamps to the specified torque.
PBIB0513E
EC-26
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PRECAUTIONS
Do not depress accelerator pedal when starting.

Immediately after starting, do not rev up engine unnecessarily.
Do not rev up engine just prior to shutdown.
EC
C
SEF709Y
When installing C.B. ham radio or a mobile phone, be sure

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

When you read wiring diagrams, refer to the following:
GI-14, "How to Read Wiring Diagrams"
PG-2, "POWER SUPPLY ROUTING" for power distribution circuit

When you perform trouble diagnosis, refer to the following:
GI-10, "HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES"
GI-23, "How to Perform Efficient Diagnosis for an Electrical Incident"
G
SEF708Y
EBS010L3
EC-27
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PREPARATION
PREPARATION
PFP:00002
EBS010L4
Tool number
Tool name
Description
KV10117100
Heated oxygen
sensor wrench
Loosening or tightening heated oxygen sensor

with 22 mm (0.87 in) hexagon nut
S-NT379
KV10114400
Heated oxygen
sensor wrench

a: 22 mm (0.87 in)
S-NT636
EG17650301
Radiator cap tester
adapter
Adapting radiator cap tester to radiator cap and

radiator filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
S-NT564
KV109E0010
Break-out box
Measuring ECM signals with a circuit tester
NT825
KV109E0080
Y-cable adapter
NT826
EC-28
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PREPARATION
EBS010L5
A
Tool name
Description
Quick connector
release
Removing fuel tube quick connectors in engine

room
(Available in SEC. 164 of PARTS CATALOG: Part
No. 16441 6N210)
EC
C
PBIC0198E
Fuel filler cap adapter
Checking fuel tank vacuum relief valve opening

pressure
S-NT653
Socket wrench
Removing and installing engine coolant

temperature sensor
S-NT705
Oxygen sensor thread

cleaner

before installing a new oxygen sensor. Use with
anti-seize lubricant shown below.
a: 18 mm diameter with pitch 1.5 mm for
Zirconia Oxygen Sensor
b: 12 mm diameter with pitch 1.25 mm for
Titania Oxygen Sensor
Lubricating oxygen sensor thread cleaning tool

when reconditioning exhaust system threads.
AEM488
Anti-seize lubricant
i.e.: (PermatexTM
133AR or equivalent
meeting MIL
specification MIL-A907)
L
S-NT779
EC-29
http://vnx.su


System Diagram
PFP:23710
EBS010L6
QR20DE ENGINE MODELS
PBIB2455E
EC-30
http://vnx.su

A
EC
PBIB2456E
EC-31
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Vacuum Hose Drawing
EBS010L7
PBIB0489E
Refer to EC-30, "QR20DE ENGINE MODELS" for Vacuum Control System.
EC-32
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A
EC
PBIB1445E
EC-33
http://vnx.su

System Chart
Input (Sensor)
EBS010L8
ECM Function
Output (Actuator)
Fuel injection & mixture ratio control
Fuel injector
Electronic ignition system
Power transistor
Fuel pump control
Fuel pump relay
On board diagnostic system
MI (On the instrument panel)*3
Throttle position sensor
Heated oxygen sensor 1 heater control
Heated oxygen sensor 1 heater
Accelerator pedal position sensor
Park/neutral position (PNP) switch
EVAP canister purge flow control
Intake air temperature sensor

solenoid valve
Power steering pressure sensor
Air conditioning cut control
Air conditioner relay
Ignition switch
Power valve control*6
VIAS control solenoid valve
Battery voltage
ASCD vehicle speed control*6
Knock sensor
Refrigerant pressure sensor
Stop lamp switch
Heated oxygen sensor 2*1
TCM (Transmission control module)*2
ESP/TCS/ABS control unit*2 *4

Cooling fan control
Cooling fan relay
ABS actuator and electric unit

(control unit)*2 *5
Air conditioner switch
Wheel sensor*2
Electrical load signal
ASCD steering switch*6
ASCD brake switch*6
ASCD clutch switch*6
Stop lamp switch
*1: This sensor is not used to control the engine system under normal conditions.
*2: This input signal is sent to the ECM through CAN communication line.
*3: This output signal is sent from the ECM through CAN communication line.
*4: For models with ESP
*5: For models without ESP
EC-34
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Multiport Fuel Injection (MFI) System
EBS010L9
INPUT/OUTPUT SIGNAL CHART

Sensor
Input Signal to ECM

Engine speed*3 and piston position
Amount of intake air
Engine coolant temperature
Density of oxygen in exhaust gas
Throttle position
Accelerator pedal position
Gear position
Knock sensor
Engine knocking condition
Battery
Battery voltage*3
Heated oxygen sensor
2*1
Actuator
EC

ECM
function
D
Fuel injection & mixture ratio
control
Fuel injector
Power steering operation
Wheel sensor*2
Vehicle speed
Air conditioner operation
*2: This signal is sent to the ECM through CAN communication line.
*3: ECM determines the start signal status by the signals of engine speed and battery voltage.
SYSTEM DESCRIPTION
The amount of fuel injected from the fuel injector is determined by the ECM. The ECM controls the length of
time the valve remains open (injection pulse duration). The amount of fuel injected is a program value in the
ECM memory. The program value is preset by engine operating conditions. These conditions are determined
by input signals (for engine speed and intake air) from both the crankshaft position sensor and the mass air
flow sensor.
VARIOUS FUEL INJECTION INCREASE/DECREASE COMPENSATION

In addition, the amount of fuel injected is compensated to improve engine performance under various operating conditions as listed below.
<Fuel increase>
During warm-up
When starting the engine
During acceleration
Hot-engine operation
When selector lever is changed from N to D (A/T models)
High-load, high-speed operation

<Fuel decrease>
During deceleration
During high engine speed operation
EC-35
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MIXTURE RATIO FEEDBACK CONTROL (CLOSED LOOP CONTROL)
PBIB0121E
The mixture ratio feedback system provides the best air-fuel mixture ratio for driveability and emission control.
The three way catalyst (manifold) can then better reduce CO, HC and NOx emissions. This system uses
heated oxygen sensor 1 in the exhaust manifold to monitor whether the engine operation is rich or lean. The
ECM adjusts the injection pulse width according to the sensor voltage signal. For more information about
heated oxygen sensor 1, refer to EC-178, "DTC P0132 HO2S1" . This maintains the mixture ratio within the
range of stoichiometric (ideal air-fuel mixture).
This stage is referred to as the closed loop control condition.
Heated oxygen sensor 2 is located downstream of the three way catalyst (manifold). Even if the switching
characteristics of heated oxygen sensor 1 shift, the air-fuel ratio is controlled to stoichiometric by the signal
from heated oxygen sensor 2.
Open Loop Control

The open loop system condition refers to when the ECM detects any of the following conditions. Feedback
control stops in order to maintain stabilized fuel combustion.
Deceleration and acceleration
Malfunction of heated oxygen sensor 1 or its circuit
Insufficient activation of heated oxygen sensor 1 at low engine coolant temperature
High engine coolant temperature
During warm-up
After shifting from N to D (A/T models)
MIXTURE RATIO SELF-LEARNING CONTROL

The mixture ratio feedback control system monitors the mixture ratio signal transmitted from heated oxygen
sensor 1. This feedback signal is then sent to the ECM. The ECM controls the basic mixture ratio as close to
the theoretical mixture ratio as possible. However, the basic mixture ratio is not necessarily controlled as originally designed. Both manufacturing differences (i.e., mass air flow sensor hot wire) and characteristic
changes during operation (i.e., injector clogging) directly affect mixture ratio.
Accordingly, the difference between the basic and theoretical mixture ratios is monitored in this system. This is
then computed in terms of injection pulse duration to automatically compensate for the difference between
the two ratios.
Fuel trim refers to the feedback compensation value compared against the basic injection duration. Fuel trim
includes short term fuel trim and long term fuel trim.
Short term fuel trim is the short-term fuel compensation used to maintain the mixture ratio at its theoretical
value. The signal from heated oxygen sensor 1 indicates whether the mixture ratio is RICH or LEAN compared
to the theoretical value. The signal then triggers a reduction in fuel volume if the mixture ratio is rich, and an
increase in fuel volume if it is lean.
Long term fuel trim is overall fuel compensation carried out long-term to compensate for continual deviation
of the short term fuel trim from the central value. Such deviation will occur due to individual engine differences,
wear over time and changes in the usage environment.
EC-36
http://vnx.su

FUEL INJECTION TIMING
A
EC
SEF337W
Two types of systems are used.
Sequential Multiport Fuel Injection System

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

Fuel is injected simultaneously into all four cylinders twice each engine cycle. In other words, pulse signals of
the same width are simultaneously transmitted from the ECM.
The four injectors will then receive the signals two times for each engine cycle.
This system is used when the engine is being started and/or if the fail-safe system (CPU) is operating.
FUEL SHUT-OFF
Fuel to each cylinder is cut off during deceleration or operation of the engine at excessively high speeds.
Electronic Ignition (EI) System
EBS010LA

Sensor
Input Signal to ECM
Throttle position
Knock sensor
Engine knocking
Gear position
Battery
Battery voltage*2
Wheel sensor*
I
Actuator
Engine speed*2
piston position
ECM function
K
Ignition
timing control
Power transistor
Vehicle speed
SYSTEM DESCRIPTION
The ignition timing is controlled by the ECM to maintain the best airfuel ratio for every running condition of the engine. The ignition timing data is stored in the ECM. This data forms the map shown.
The ECM receives information such as the injection pulse width and
camshaft position sensor signal. Computing this information, ignition
signals are transmitted to the power transistor.
e.g., N: 1,800 rpm, Tp: 1.50 msec
A BTDC
During the following conditions, the ignition timing is revised by the
ECM according to the other data stored in the ECM.
At starting
During warm-up
EC-37
http://vnx.su
SEF742M

At idle
At low battery voltage
During acceleration
The knock sensor retard system is designed only for emergencies. The basic ignition timing is programmed
within the anti-knocking zone, if recommended fuel is used under dry conditions. The retard system does not
operate under normal driving conditions. If engine knocking occurs, the knock sensor monitors the condition.
The signal is transmitted to the ECM. The ECM retards the ignition timing to eliminate the knocking condition.
Air Conditioning Cut Control
EBS010LB

Sensor
Input Signal to ECM
Air conditioner ON signal
Throttle valve opening angle

Engine speed*2
Battery
Battery voltage*2
Refrigerant pressure
Wheel sensor*1
Vehicle speed
ECM function
Air conditioner
cut control
Actuator
SYSTEM DESCRIPTION
This system improves engine operation when the air conditioner is used.
Under the following conditions, the air conditioner is turned off.
When the accelerator pedal is fully depressed.
When cranking the engine.
At high engine speeds.
When the engine coolant temperature becomes excessively high.
When operating power steering during low engine speed or low vehicle speed.
When engine speed is excessively low.
When refrigerant pressure is excessively low or high.
Fuel Cut Control (at No Load and High Engine Speed)
EBS010LC

Sensor
Input Signal to ECM
Neutral position

Engine speed
Wheel sensor*
Vehicle speed
ECM function
Fuel cut control
Actuator
Fuel injector
*: This signal is sent to the ECM through CAN communication line.
SYSTEM DESCRIPTION
If the engine speed is above 1,800 rpm under no load (for example, the shift position is neutral and engine
speed is over 1,800 rpm) fuel will be cut off after some time. The exact time when the fuel is cut off varies
based on engine speed.
Fuel cut will be operated until the engine speed reaches 1,500 rpm, then fuel cut will be cancelled.
NOTE:
This function is different from deceleration control listed under EC-35, "Multiport Fuel Injection (MFI) System" .
EC-38
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CAN Communication Unit
EBS010LD
SYSTEM DESCRIPTION
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other EC
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.
C
M/T MODELS WITHOUT ESP

System Diagram
D
I
PKIA6458E
Input/output Signal Chart
J
T: Transmit R: Receive
Signals
ECM
ABS actuator and

electric unit
(control unit)
4WD mode indicator lamp signal

4WD warning lamp signal
A/C compressor feedback signal
4WD control unit
Combination meter
T
T
T
Engine coolant temperature signal
Engine speed signal
MI signal
ABS warning lamp signal

Accelerator pedal position signal
R
R
R
R
R
Parking brake switch signal
Stop lamp switch signal

Vehicle speed signal
ASCD SET lamp signal
ASCD CRUISE lamp signal
EC-39
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A/T MODELS WITHOUT ESP
System Diagram
PKIA6457E

ABS actuator
and electric unit
(control unit)
4WD control
unit
Combination
meter
Signals
ECM
A/T position indicator lamp signal

A/T self-diagnosis signal
TCM
R
T
Closed throttle position signal
Engine A/T integrated control signal

Engine speed signal
MI signal
O/D OFF indicator signal

Output shaft revolution signal
R
R
R
R
R
T
Overdrive control switch signal
PN range signal
R
R

R
Wide open throttle position signal
T
T
R
T
EC-40
http://vnx.su

Signals
ECM
TCM
ABS actuator
and electric unit
(control unit)
4WD control
unit
Combination
meter
M/T MODELS WITH ESP

System Diagram
EC
PKIA6459E
4WD control
unit
Combination
meter
Signals
ECM
Engine speed signal
ESP OFF indicator lamp signal
R
R
R
T
R
SLIP indicator lamp signal
R
T
Steering angle sensor signal
R
R
R
T
R
T
Brake warning lamp signal
MI signal
Steering angle
sensor

ESP/TCS/ABS
control unit
EC-41
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A/T MODELS WITH ESP
System Diagram
PKIA6460E

ESP/TCS/
ABS control
unit
4WD control
unit
Combination
meter
Signals
ECM
R
T
Engine and A/T integrated
Engine speed signal
R
T
R
R
PN range signal
T
T
MI signal


Steering
angle sensor

TCM
R
T
T
T
EC-42
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Signals
ECM
TCM
ESP/TCS/
ABS control
unit
T
Steering
angle sensor
4WD control
unit
Combination
meter
EC
EC-43
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BASIC SERVICE PROCEDURE


Idle Speed and Ignition Timing Check
PFP:00018
EBS010LE
IDLE SPEED
With CONSULT-II
Check idle speed in DATA MONITOR mode with CONSULT-II.
SEF058Y
With GST
Check idle speed with GST.
IGNITION TIMING
Any of following two methods may be used.
Method A
1.
2.
Slide the harness protector of ignition coil No.1 to clear the

wires.
Attach timing light to the wire as shown in the figure.
PBIB1975E
3.
Check ignition timing.
PBIB0514E
EC-44
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Method B
1.
Remove No. 1 ignition coil.
EC
PBIB1982E
2.
Connect No. 1 ignition coil and No. 1 spark plug with suitable
high-tension wire as shown, and attach timing light clamp to this
wire.
PBIB1976E
K
SEF166Y
3.
PBIB0514E
Accelerator Pedal Released Position Learning
EBS010LF
DESCRIPTION
Accelerator Pedal Released Position Learning is an operation to learn the fully released position of the accelerator pedal by monitoring the accelerator pedal position sensor output signal. It must be performed each time
harness connector of accelerator pedal position sensor or ECM is disconnected.
OPERATION PROCEDURE
1.
2.
Make sure that accelerator pedal is fully released.

Turn ignition switch ON and wait at least 2 seconds.
EC-45
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3.
4.
5.
Turn ignition switch OFF and wait at least 10 seconds.

Throttle Valve Closed Position Learning
EBS010LG
DESCRIPTION
Throttle Valve Closed Position Learning is an operation to learn the fully closed position of the throttle valve by
monitoring the throttle position sensor output signal. It must be performed each time harness connector of
electric throttle control actuator or ECM is disconnected.
OPERATION PROCEDURE
1.
2.
3.

Turn ignition switch ON.
Make sure that throttle valve moves during above 10 seconds by confirming the operating sound.
Idle Air Volume Learning
EBS010LH
DESCRIPTION
Idle Air Volume Learning is an operation to learn the idle air volume that keeps each engine within the specific
range. It must be performed under any of the following conditions:
Each time electric throttle control actuator or ECM is replaced.
Idle speed or ignition timing is out of specification.
PREPARATION
Before performing Idle Air Volume Learning, make sure that all of the following conditions are satisfied.
Learning will be cancelled if any of the following conditions are missed for even a moment.
Battery voltage: More than 12.9V (At idle)
Engine coolant temperature: 70 - 95C (158 - 203F)
PNP switch: ON
Electric load switch: OFF

(Air conditioner, headlamp, rear window defogger)
On vehicles equipped with daytime light systems, set lighting switch to the 1st position to light
only small lamps.
Steering wheel: Neutral (Straight-ahead position)
Vehicle speed: Stopped
Transmission: Warmed-up
For A/T models with CONSULT-II, drive vehicle until FLUID TEMP SE in DATA MONITOR mode of A/
T system indicates less than 0.9V.
For A/T models without CONSULT-II and M/T models, drive vehicle for 10 minutes.
OPERATION PROCEDURE
With CONSULT-II
1.
2.
3.
4.
5.
Perform EC-45, "Accelerator Pedal Released Position Learning" .

Perform EC-46, "Throttle Valve Closed Position Learning" .
Check that all items listed under the topic PREPARATION (previously mentioned) are in good order.
Select IDLE AIR VOL LEARN in WORK SUPPORT mode.
SEF217Z
EC-46
http://vnx.su

6.
Touch START and wait 20 seconds.
EC
SEF454Y
7.
8.
Make sure that CMPLT is displayed on CONSULT-II screen. If

CMPLT is not displayed, Idle Air Volume Learning will not be
carried out successfully. In this case, find the cause of the incident by referring to the DIAGNOSTIC PROCEDURE below.
Rev up the engine two or three times and make sure that idle
speed and ignition timing are within the specifications.
ITEM
SPECIFICATION
Idle speed
QR20DE with M/T models: 650 50 rpm (in Neutral position)

Except above: 700 50 rpm [in P or N (A/T), Neutral (M/T) position]
Ignition timing
M/T: 15 5 BTDC (in Neutral position)

A/T: 15 5 BTDC (in P or N position)
G
MBIB0238E
Without CONSULT-II
NOTE:
It is better to count the time accurately with a clock.
It is impossible to switch the diagnostic mode when an accelerator pedal position sensor circuit
has a malfunction.
1. Perform EC-45, "Accelerator Pedal Released Position Learning" .
2. Perform EC-46, "Throttle Valve Closed Position Learning" .
3. Start engine and warm it up to normal operating temperature.
4. Check that all items listed under the topic PREPARATION (previously mentioned) are in good order.
5. Turn ignition switch OFF and wait at least 10 seconds.
6. Confirm that accelerator pedal is fully released, turn ignition switch ON and wait 3 seconds.
7. Repeat the following procedure quickly 5 times within 5 seconds.
a. Fully depress the accelerator pedal.
b. Fully release the accelerator pedal.
8. Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 20 seconds until the MI stops
blinking and turned ON.
9. Fully release the accelerator pedal within 3 seconds after the MI turned ON.
10. Start engine and let it idle.
11. Wait 20 seconds.
PBIB0665E
EC-47
http://vnx.su

12. Rev up the engine two or three times and make sure that idle speed and ignition timing are within the
specifications.
ITEM
SPECIFICATION
Idle speed

Ignition timing

13. If idle speed and ignition timing are not within the specification, Idle Air Volume Learning will not be carried
out successfully. In this case, find the cause of the incident by referring to the DIAGNOSTIC PROCEDURE below.
DIAGNOSTIC PROCEDURE
If idle air volume learning cannot be performed successfully, proceed as follows:
1. Check that throttle valve is fully closed.
2. Check PCV valve operation.
3. Check that downstream of throttle valve is free from air leakage.
4. When the above three items check out OK, engine component parts and their installation condition are questionable. Check and eliminate the cause of the incident.
It is useful to perform EC-119, "TROUBLE DIAGNOSIS - SPECIFICATION VALUE" .
5. If any of the following conditions occur after the engine has started, eliminate the cause of the
incident and perform Idle Air Volume Learning all over again:
Engine stalls.
Erroneous idle.
Fuel Pressure Check
EBS010LI
FUEL PRESSURE RELEASE

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

Perform FUEL PRESSURE RELEASE in WORK SUPPORT
mode with CONSULT-II.
Start engine.
After engine stalls, crank it two or three times to release all fuel
pressure.
Turn ignition switch OFF.
SEF214Y
Without CONSULT-II
1.
2.
3.
4.
5.
Remove fuel pump fuse located in fuse box.

Start engine.
pressure.
Reinstall fuel pump fuse after servicing fuel system.
PBIB0508E
FUEL PRESSURE CHECK

CAUTION:
Before disconnecting fuel line, release fuel pressure from fuel line to eliminate danger.
EC-48
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NOTE:
Prepare pans or saucers under the disconnected fuel line because the fuel may spill out. The fuel pres- A
sure cannot be completely released because T30 models do not have fuel return system.
CAUTION:
The fuel hose connection method used when taking fuel pressure check must not be used for EC
other purposes.
Be careful not to scratch or put debris around connection area when servicing, so that the quick
connector maintains sealability with O-rings inside.
C
When installing fuel hose quick connector, refer to EM-18, "INTAKE MANIFOLD" .
1. Release fuel pressure to zero. Refer to EC-48, "FUEL PRESSURE RELEASE" .
2. Prepare fuel hose and fuel hose clamp for fuel pressure check, and connect fuel pressure gauge.
D
Use suitable fuel hose for fuel pressure check (genuine NISSAN fuel hose without quick connector).
To avoid unnecessary force or tension to hose, use moderately long fuel hose for fuel pressure check.
E
Do not use the fuel hose for checking fuel pressure with damage or cracks on it.
Use Pressure Gauge to check fuel pressure.
3. Remove fuel hose. Refer to EM-18, "INTAKE MANIFOLD" .
F
Do not twist or kink fuel hose because it is plastic hose.
Do not remove fuel hose from quick connector.
Keep the original fuel hose to be free from intrusion of dust or foreign substances with a suitable cover.
G
4. Install the fuel pressure gauge as shown in the figure.
Wipe off oil or dirt from hose insertion part using cloth moistened with gasoline.
H
Apply proper amount of gasoline between top of the fuel tube
and No.1 spool.
Insert fuel hose for fuel pressure check until it touches the
I
No.1 spool on fuel tube.
Use NISSAN genuine hose clamp (part number: 16439
N4710 or 16439 40U00).
J
When reconnecting fuel line, always use new clamps.
PBIB0669E
When reconnecting fuel hose, check the original fuel hose for
damage and abnormality.
K
Use a torque driver to tighten clamps.
Install hose clamp to the position within 1 - 2 mm (0.04 - 0.08
in).
L
Tightening
torque:
1 - 1.5 Nm (0.1 - 0.15 kg-m, 9 - 13 in-lb)
Make sure that clamp screw does not contact adjacent parts.
After connecting fuel hose for fuel pressure check, pull the hose
with a force of approximately 98 N (10 kg, 22 lb) to confirm fuel
tube does not come off.
Turn ignition switch ON, and check for fuel leakage.
PBIB1977E
Start engine and check for fuel leakage.
Read the indication of fuel pressure gauge.
Do not perform fuel pressure check with system operating. Fuel pressure gauge may indicate false
readings.
During fuel pressure check, confirm for fuel leakage from fuel connection every 3 minutes.
5.
6.
7.
8.
At idling:
Approximately 350 kPa (3.5 bar, 3.57 kg/cm2 , 51 psi)
9. If result is unsatisfactory, go to next step.

10. Check the following.
Fuel hoses and fuel tubes for clogging
EC-49
http://vnx.su

Fuel filter for clogging
Fuel pump
Fuel pressure regulator for clogging
If OK, replace fuel pressure regulator.
If NG, repair or replace.
EC-50
http://vnx.su
ON BOARD DIAGNOSTIC (OBD) SYSTEM


Introduction
PFP:00028
A
EBS01FF0
The ECM has an on board diagnostic system, which detects malfunctions related to engine sensors or actuators. The ECM also records various emission-related diagnostic information including:
EC
Emission-related diagnostic information
ISO Standard
Diagnostic Trouble Code (DTC)
Service $03 of ISO 15031-5
Freeze Frame data
System Readiness Test (SRT) code
1st Trip Diagnostic Trouble Code (1st Trip DTC)
1st Trip Freeze Frame data

Test values and Test limits
Calibration ID
The above information can be checked using procedures listed in the table below.
: Applicable
: Not applicable
DTC
1st trip DTC
Freeze Frame
data
1st trip Freeze

Frame data
SRT code
Test value
CONSULT-II
GST
ECM
*: When DTC and 1st trip DTC simultaneously appear on the display, they cannot be clearly distinguished from each other.
The malfunction indicator (MI) on the instrument panel lights up when the same malfunction is detected in two
consecutive trips (Two trip detection logic), or when the ECM enters fail-safe mode. (Refer to EC-77, "Fail-safe
Chart" .)
Two Trip Detection Logic
EBS010LK
When a malfunction is detected for the first time, 1st trip DTC and 1st trip Freeze Frame data are stored in the
ECM memory. The MI will not light up at this stage. <1st trip>
If the same malfunction is detected again during the next drive, the DTC and Freeze Frame data are stored in
the ECM memory, and the MI lights up. The MI lights up at the same time when the DTC is stored. <2nd trip>
The trip in the Two Trip Detection Logic means a driving mode in which self-diagnosis is performed during
vehicle operation. Specific on board diagnostic items will cause the ECM to light up or blink the MI, and store
DTC and Freeze Frame data, even in the 1st trip, as shown below.
: Applicable
MI
DTC
1st trip
Items
2nd trip
: Not applicable
2nd trip
displaying
1st trip
displaying
2nd trip
displaying
Blinking
Blinking
Lighting
up
Misfire (Possible three way catalyst

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

damage) DTC: P0300 - P0304 is
being detected
One trip detection diagnoses

(Refer to EC-19 )
Except above
When there is an open circuit on MI circuit, the ECM can not warn the driver by lighting up MI when there is
trouble on engine control system.
Therefore, when electrical controlled throttle and part of ECM related diagnoses are continuously detected as
NG for 5 trips, ECM warns the driver that engine control system has trouble and MI circuit is open by means of
operating fail-safe function.
EC-51
http://vnx.su
1st trip DTC
1st trip
displaying
Lighting
up

The fail-safe function also operates when above diagnoses except MI circuit are detected and demands the
driver to repair the trouble.
Engine operating condition in fail-safe mode
Engine speed will not rise more than 2,500 rpm due to the fuel cut
Emission-related Diagnostic Information
EBS010LL
EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS

DTC*1
Items
CONSULT-II
SRT code
Test Valve/
Test Limit
(GST only)
1st trip DTC
Reference page
ECM*3
CAN COMM CIRCUIT
U1000
1000*4
(A/T)
(M/T)
EC-132
CAN COMM CIRCUIT
U1001
1001*4
EC-132
NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.
P0000
0000
GST*
INT/V TIM CONT-B1
P0011
0011
EC-135
HO2S1 HTR (B1)
P0031
0031
EC-138
HO2S1 HTR (B1)
P0032
0032
EC-138
HO2S2 HTR (B1)
P0037
0037
EC-144
HO2S2 HTR (B1)
P0038
0038
EC-144
MAF SEN/CIRCUIT
P0102
0102
EC-150
MAF SEN/CIRCUIT
P0103
0103
EC-150
IAT SEN/CIRCUIT
P0112
0112
EC-158
IAT SEN/CIRCUIT
P0113
0113
EC-158
ECT SEN/CIRCU
P0117
0117
EC-164
ECT SEN/CIRCU
P0118
0118
EC-164
TP SEN 2/CIRC
P0122
0122
EC-170
TP SEN 2/CIRC
P0123
0123
EC-170
HO2S1 (B1)
P0132
0132
EC-178
HO2S1 (B1)
P0133
0133
EC-185
HO2S1 (B1)
P0134
0134
EC-195
HO2S2 (B1)
P0138
0138
EC-203
HO2S2 (B1)
P0139
0139
EC-210
FUEL SYS-LEAN-B1
P0171
0171
EC-218
FUEL SYS-RICH-B1
P0172
0172
EC-224
TP SEN 1/CIRC
P0222
0222
EC-230
TP SEN 1/CIRC
P0223
0223
EC-230
MULTI CYL MISFIRE
P0300
0300
EC-238
CYL 1 MISFIRE
P0301
0301
EC-238
CYL 2 MISFIRE
P0302
0302
EC-238
CYL 3 MISFIRE
P0303
0303
EC-238
CYL 4 MISFIRE
P0304
0304
EC-238
KNOCK SEN/CIRC-B1
P0327
0327
EC-244
KNOCK SEN/CIRC-B1
P0328
0328
EC-244
CKP SEN/CIRCUIT
P0335
0335
EC-249
CMP SEN/CIRC-B1
P0340
0340
EC-256
TW CATALYST SYS-B1
P0420
0420
EC-263
EC-52
http://vnx.su

DTC*1
Items
CONSULT-II
SRT code
Test Valve/
Test Limit
(GST only)
1st trip DTC
Reference page
GST*2
ECM*
PURG VOLUME CONT/V
P0444
0444
EC-268
SEN/CIRC*7
P0500
0500
EC-275
PW ST P SEN/CIRC
P0550
0550
EC-277
ECM
P0605
0605
or
EC-282
PNP SW/CIRC
P0705
0705
AT-100
P0710
0710
AT-106
P0720
P0720
AT-112
ENGINE SPEED SIG
P0725
0725
AT-119
A/T 1ST GR FNCTN
P0731
0731
AT-125
A/T 2ND GR FNCTN
P0732
0732
AT-130
A/T 3RD GR FNCTN
P0733
P0733
AT-135
A/T 4TH GR FNCTN
P0734
P0734
AT-140
TCC SOLENOID/CIRC
P0740
0740
AT-148
L/PRESS SOL/CIRC
P0745
0745
AT-154
SFT SOL A/CIRC
P0750
0750
AT-161
SFT SOL B/CIRC
P0755
0755
AT-167
ECM BACK UP/CIRC
P1065
1065
EC-285
INT/V TIM V/CIR-B1
P1111
1111
EC-289
ETC ACTR
P1121
1121
EC-293
ETC FUNCTION/CIRC
P1122
1122
EC-295
ETC MOT PWR
P1124
1124
EC-305
ETC MOT PWR
P1126
1126
EC-305
ETC MOT
P1128
1128
EC-313
HO2S1 (B1)
P1143
1143
EC-321
HO2S1 (B1)
P1144
1144
EC-327
HO2S2 (B1)
P1146
1146
EC-333
HO2S2 (B1)
P1147
1147
EC-341
TCS CU FUNCTN*5
P1211
1211
EC-349
TCS/CIRC*5
P1212
1212
EC-350
ENG OVER TEMP
P1217
1217
EC-351
CTP LEARNING
P1225
1225
EC-367
CTP LEARNING
P1226
1226
EC-369
SENSOR POWER/CIRC
P1229
1229
EC-371
ASCD SW*6
P1564
1564
EC-376
P1572
1572
EC-386
P1574
1574
EC-395
P1610 P1615
1610 - 1615
BL-108
VEH SPEED
ATF TEMP SEN/CIRC

VEH SPD SEN/CIR
AT*7
ASCD BRAKE SW*6

ASCD VHL SPD
SEN*6
NATS MALFUNCTION
TP SEN/CIRC A/T
P1705
1705
AT-173
P-N POS SW/CIRCUIT
P1706
1706
EC-397
V/SP SEN (A/T OUT)
P1720
1720
EC-402
O/R CLTCH SOL/CIRC
P1760
1760
AT-178
EC-53
http://vnx.su
EC

DTC*1
Items
CONSULT-II
GST*2
SRT code
Test Valve/
Test Limit
(GST only)
1st trip DTC
Reference page
ECM*3
BRAKE SW/CIRCUIT
P1805
1805
EC-404
APP SEN 1/CIRC
P2122
2122
EC-408
APP SEN 1/CIRC
P2123
2123
EC-408
APP SEN 2/CIRC
P2127
2127
EC-415
APP SEN 2/CIRC
P2128
2128
EC-415
TP SENSOR
P2135
2135
EC-423
APP SENSOR
P2138
2138
EC-431

*5: For models with ESP
*7: When the fail-safe operation for both self-diagnoses occur at the same time, the MI illuminates.
DTC AND 1ST TRIP DTC

The 1st trip DTC (whose number is the same as the DTC number) is displayed for the latest self-diagnostic
result obtained. If the ECM memory was cleared previously, and the 1st trip DTC did not reoccur, the 1st trip
DTC will not be displayed.
If a malfunction is detected during the 1st trip, the 1st trip DTC is stored in the ECM memory. The MI will not
light up (two trip detection logic). If the same malfunction is not detected in the 2nd trip (meeting the required
driving pattern), the 1st trip DTC is cleared from the ECM memory. If the same malfunction is detected in the
2nd trip, both the 1st trip DTC and DTC are stored in the ECM memory and the MI lights up. In other words,
the DTC is stored in the ECM memory and the MI lights up when the same malfunction occurs in two consecutive trips. If a 1st trip DTC is stored and a non-diagnostic operation is performed between the 1st and 2nd
trips, only the 1st trip DTC will continue to be stored. For malfunctions that blink or light up the MI during the
1st trip, the DTC and 1st trip DTC are stored in the ECM memory.
Procedures for clearing the DTC and the 1st trip DTC from the ECM memory are described in EC-62, "HOW
TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" .
For malfunctions in which 1st trip DTCs are displayed, refer to EC-52, "EMISSION-RELATED DIAGNOSTIC
INFORMATION ITEMS" . These items are required by legal regulations to continuously monitor the system/
component. In addition, the items monitored non-continuously are also displayed on CONSULT-II.
1st trip DTC is specified in Service $07 of ISO 15031-5. 1st trip DTC detection occurs without lighting up the
MI and therefore does not warn the driver of a malfunction. However, 1st trip DTC detection will not prevent
the vehicle from being tested, for example during Inspection/Maintenance (I/M) tests.
When a 1st trip DTC is detected, check, print out or write down and erase (1st trip) DTC and Freeze Frame
data as specified in Work Flow procedure Step II, refer to EC-73, "WORK FLOW" . Then perform DTC Confirmation Procedure or Overall Function Check to try to duplicate the malfunction. If the malfunction is duplicated, the item requires repair.
How to Read DTC and 1st Trip DTC

DTC and 1st trip DTC can be read by the following methods.
With CONSULT-II
With GST
CONSULT-II or GST (Generic Scan Tool) Examples: P0340, P0740, P0745, etc.
This DTC is prescribed by ISO 15031-5.
(CONSULT-II also displays the malfunctioning component or system.)
No Tools
The number of blinks of the MI in the Diagnostic Test Mode II (Self-Diagnostic Results) indicates the DTC.
Example: 0102, 0340 etc.
This DTC is controlled by NISSAN.
1st trip DTC No. is the same as DTC No.
Output of a DTC indicates a malfunction. However, GST or the Diagnostic Test Mode II do not indicate whether the malfunction is still occurring or has occurred in the past and has returned to nor-
EC-54
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mal. CONSULT-II can identify malfunction status as shown below. Therefore, using CONSULT-II (if
available) is recommended.
A
A sample of CONSULT-II display for DTC and 1st trip DTC is shown below. DTC or 1st trip DTC of a malfunction is displayed in SELF-DIAGNOSTIC RESULTS mode of CONSULT-II. Time data indicates how many
times the vehicle was driven after the last detection of a DTC.
EC
If the DTC is being detected currently, the time data will be [0].
If a 1st trip DTC is stored in the ECM, the time data will be [1t].
C
PBIB0911E
FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA

The ECM records the driving conditions such as fuel system status, calculated load value, engine coolant temperature, short term fuel trim, long term fuel trim, engine speed, vehicle speed, base fuel schedule and intake
air temperature at the moment a malfunction is detected.
Data which are stored in the ECM memory, along with the 1st trip DTC, are called 1st trip freeze frame data.
The data, stored together with the DTC data, are called freeze frame data and displayed on CONSULT-II or
GST. The 1st trip freeze frame data can only be displayed on the CONSULT-II screen, not on the GST. For
details, see EC-105, "Freeze Frame Data and 1st Trip Freeze Frame Data" .
Only one set of freeze frame data (either 1st trip freeze frame data or freeze frame data) can be stored in the
ECM. 1st trip freeze frame data is stored in the ECM memory along with the 1st trip DTC. There is no priority
for 1st trip freeze frame data and it is updated each time a different 1st trip DTC is detected. However, once
freeze frame data (2nd trip detection/MI on) is stored in the ECM memory, 1st trip freeze frame data is no
longer stored. Remember, only one set of freeze frame data can be stored in the ECM. The ECM has the following priorities to update the data.
Priority
1
2
3
Items
Freeze frame data
Misfire DTC: P0300 - P0304

Fuel Injection System Function DTC: P0171, P0172
Except the above items (Includes A/T related items)
1st trip freeze frame data
For example, the EGR malfunction (Priority: 2) was detected and the freeze frame data was stored in the 2nd
trip. After that when the misfire (Priority: 1) is detected in another trip, the freeze frame data will be updated
from the EGR malfunction to the misfire. The 1st trip freeze frame data is updated each time a different malfunction is detected. There is no priority for 1st trip freeze frame data. However, once freeze frame data is
stored in the ECM memory, 1st trip freeze data is no longer stored (because only one freeze frame data or 1st
trip freeze frame data can be stored in the ECM). If freeze frame data is stored in the ECM memory and freeze
frame data with the same priority occurs later, the first (original) freeze frame data remains unchanged in the
ECM memory.
Both 1st trip freeze frame data and freeze frame data (along with the DTCs) are cleared when the ECM memory is erased. Procedures for clearing the ECM memory are described in EC-62, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" .
SYSTEM READINESS TEST (SRT) CODE

System Readiness Test (SRT) code is specified in Service $01 of ISO 15031-5.
As part of an enhanced emissions test for Inspection & Maintenance (I/M), certain states require the status of
SRT be used to indicate whether the ECM has completed self-diagnosis of major emission systems and components. Completion must be verified in order for the emissions inspection to proceed.
If a vehicle is rejected for a State emissions inspection due to one or more SRT items indicating INCMP, use
the information in this Service Manual to set the SRT to CMPLT.
EC-55
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In most cases the ECM will automatically complete its self-diagnosis cycle during normal usage, and the SRT
status will indicate CMPLT for each application system. Once set as CMPLT, the SRT status remains
CMPLT until the self-diagnosis memory is erased.
Occasionally, certain portions of the self-diagnostic test may not be completed as a result of the customer's
normal driving pattern; the SRT will indicate INCMP for these items.
NOTE:
The SRT will also indicate INCMP if the self-diagnosis memory is erased for any reason or if the ECM memory power supply is interrupted for several hours.
If, during the state emissions inspection, the SRT indicates CMPLT for all test items, the inspector will continue with the emissions test. However, if the SRT indicates INCMP for one or more of the SRT items the
vehicle is returned to the customer untested.
NOTE:
If MI is ON during the state emissions inspection, the vehicle is also returned to the customer untested even
though the SRT indicates CMPLT for all test items. Therefore, it is important to check SRT (CMPLT) and
DTC (No DTCs) before the inspection.
SRT Item
The table below shows required self-diagnostic items to set the SRT to CMPLT.
SRT item
(CONSULT-II
indication)
Performance
Priority*
Required self-diagnostic items to set the SRT to CMPLT
Corresponding DTC No.
CATALYST
Three way catalyst function
P0420
HO2S
P0133
P1143
P1144
P0139
P1146
P1147
P0031, P0032
P0037, P0038
HO2S HTR
*: If completion of several SRTs is required, perform driving patterns (DTC confirmation procedure), one by one based on the priority for
models with CONSULT-II.
SRT Set Timing

SRT is set as CMPLT after self-diagnosis has been performed one or more times. Completion of SRT is
done regardless of whether the result is OK or NG. The set timing is different between OK and NG results and
is shown in the table below.
Example
Self-diagnosis result
All OK
Case 1
Case 2
Ignition cycle
ON OFF ON
Diagnosis
ON
P0400
OK (1)
(1)
OK (2)
(2)
P0402
OK (1)
(1)
(1)
OK (2)
OFF
OFF
ON
P1402
OK (1)
OK (2)
(2)
(2)
SRT of EGR
CMPLT
CMPLT
CMPLT
CMPLT
P0400
OK (1)
(1)
(1)
(1)
P0402
(0)
(0)
OK (1)
(1)
P1402
OK (1)
OK (2)
(2)
(2)
SRT of EGR
INCMP
INCMP
CMPLT
CMPLT
EC-56
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Example
Self-diagnosis result
NG exists
Case 3
Ignition cycle
ON OFF ON
Diagnosis
ON
P0400
OK
OK
P0402
P1402
NG
NG
NG
(Consecutive
NG)
(1st trip)
DTC
1st trip DTC
1st trip DTC
DTC
(= MI ON)
SRT of EGR
INCMP
INCMP
INCMP
CMPLT
OFF
OFF
ON
OK: Self-diagnosis is carried out and the result is OK.

NG: Self-diagnosis is carried out and the result is NG.
: Self-diagnosis is not carried out.
EC
When all SRT related self-diagnoses showed OK results in a single cycle (Ignition OFF-ON-OFF), the SRT will
indicate CMPLT. Case 1 above
When all SRT related self-diagnoses showed OK results through several different cycles, the SRT will indicate
CMPLT at the time the respective self-diagnoses have at least one OK result. Case 2 above
If one or more SRT related self-diagnoses showed NG results in 2 consecutive cycles, the SRT will also indicate CMPLT. Case 3 above
The table above shows that the minimum number of cycles for setting SRT as INCMP is one (1) for each
self-diagnosis (Case 1 & 2) or two (2) for one of self-diagnoses (Case 3). However, in preparation for the state
emissions inspection, it is unnecessary for each self-diagnosis to be executed twice (Case 3) for the following
reasons:
The SRT will indicate CMPLT at the time the respective self-diagnoses have one (1) OK result.
The emissions inspection requires CMPLT of the SRT only with OK self-diagnosis results.
When, during SRT driving pattern, 1st trip DTC (NG) is detected prior to CMPLT of SRT, the self-diagnosis memory must be erased from ECM after repair.
If the 1st trip DTC is erased, all the SRT will indicate INCMP.
NOTE:
SRT can be set as CMPLT together with the DTC(s). Therefore, DTC check must always be carried out
prior to the state emission inspection even though the SRT indicates CMPLT.
SRT Service Procedure

If a vehicle has failed the state emissions inspection due to one or more SRT items indicating INCMP, review
the flowchart diagnostic sequence on the next page.
EC-57
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SEF573XB
*1
EC-54, "How to Read DTC and 1st

Trip DTC"
*2
EC-58, "How to Display SRT Code"
*3
EC-59, "How to Set SRT Code"
How to Display SRT Code

WITH CONSULT-II
Selecting SRT STATUS in DTC CONFIRMATION mode with
CONSULT-II.
For items whose SRT codes are set, a CMPLT is displayed on the
CONSULT-II screen; for items whose SRT codes are not set,
INCMP is displayed.
A sample of CONSULT-II display for SRT code is shown at right.
INCMP means the self-diagnosis is incomplete and SRT is not set.
CMPLT means the self-diagnosis is complete and SRT is set.
WITH GST
Selecting Service $01 with GST (Generic Scan Tool)
EC-58
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PBIB0666E

How to Set SRT Code
To set all SRT codes, self-diagnosis for the items indicated above must be performed one or more times. Each A
diagnosis may require a long period of actual driving under various conditions.
WITH CONSULT-II
Perform corresponding DTC Confirmation Procedure one by one based on Performance Priority in the table EC
on EC-56, "SRT Item" .
WITHOUT CONSULT-II
The most efficient driving pattern in which SRT codes can be properly set is explained on the next page. The C
driving pattern should be performed one or more times to set all SRT codes.
D
EC-59
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Driving Pattern
PBIB2451E
EC-60
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The time required for each diagnosis varies with road surface conditions, weather, altitude, individual driving habits, etc.
A
Zone A refers to the range where the time, required for the diagnosis under normal conditions*, is the
shortest.
Zone B refers to the range where the diagnosis can still be performed if the diagnosis is not completed
EC
within zone A.
*: Normal conditions refer to the following:
Sea level
C
Flat road
Ambient air temperature: 20 - 30C (68 - 86F)
Diagnosis is performed as quickly as possible under normal conditions.

D
Under different conditions [For example: ambient air temperature other than 20 - 30C (68 - 86F)], diagnosis may also be performed.
Pattern 1:
E
The engine is started at the engine coolant temperature of 10 to 35C (14 to 95F)
(where the voltage between the ECM terminal 72 and ground is 3.0 - 4.3V).
The engine must be operated at idle speed until the engine coolant temperature is greater than F
70C (158F) (where the voltage between the ECM terminal 72 and ground is lower than 1.4V).
Pattern 2:
When steady-state driving is performed again even after it is interrupted, each diagnosis can be con- G
ducted. In this case, the time required for diagnosis may be extended.
*1: Depress the accelerator pedal until vehicle speed is 90 km/h (56 MPH), then release the accelerator pedal
and keep it released for more than 10 seconds. Depress the accelerator pedal until vehicle speed is 90 km/h H
(56 MPH) again.
*2: Checking the vehicle speed with GST is advised.
TEST VALUE AND TEST LIMIT (GST ONLY NOT APPLICABLE TO CONSULT-II)
The following is the information specified in Service $06 of ISO 15031-5.

The test value is a parameter used to determine whether a system/circuit diagnostic test is OK or NG while
being monitored by the ECM during self-diagnosis. The test limit is a reference value which is specified as the
maximum or minimum value and is compared with the test value being monitored.
These data (test value and test limit) are specified by Test ID (TID) and Component ID (CID) and can be displayed on the GST screen.
SRT item
CATALYST
Self-diagnostic test item
Three way catalyst function
HO2S

HO2S HTR
Test value
(GST display)
DTC
K
Test limit
TID
CID
P0420
01H
01H
Max.
P0420
02H
81H
Min.
P0133
09H
04H
Max.
P1143
0AH
84H
Min.
P1144
0BH
04H
Max.
P0132
0CH
04H
Max.
P0134
0DH
04H
Max.
P0139
19H
86H
Min.
P1147
1AH
86H
Min.
P1146
1BH
06H
Max.
P0138
1CH
06H
Max.
P0032
29H
08H
Max.
P0031
2AH
88H
Min.
P0038
2DH
0AH
Max.
P0037
2EH
8AH
Min.
EC-61
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HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION
How to Erase DTC
With CONSULT-II
The emission related diagnostic information in the ECM can be erased by selecting ERASE in the SELFDIAG RESULTS mode with CONSULT-II.
If DTCs are displayed for both ECM and TCM (Transmission control module), they need to be erased individually from the ECM and TCM (Transmission control module).
NOTE:
If the DTC is not for A/T related items (see EC-19, "INDEX FOR DTC" ), skip steps 2 through 4.
1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once.
Wait at least 10 seconds and then turn it ON (engine stopped) again.
2. Turn CONSULT-II ON and touch A/T.
3. Touch SELF-DIAG RESULTS.
4. Touch ERASE. [The DTC in the TCM (Transmission control module) will be erased.] Then touch BACK
twice.
5. Touch ENGINE.
7. Touch ERASE. (The DTC in the ECM will be erased.)
SCIA5680E
With GST
The emission related diagnostic information in the ECM can be erased by selecting Service $04 with GST.
NOTE:
If the DTC is not for A/T related items (see EC-19, "INDEX FOR DTC" ), skip step 2.
EC-62
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2.
3.
Perform AT-43, "HOW TO ERASE DTC (WITH GST)" . (The DTC in the TCM will be erased.)
Select Service $04 with GST (Generic Scan Tool).
No Tools
NOTE:
EC
If the DTC is not for A/T related items (see EC-19, "INDEX FOR DTC" ), skip step 2.
C
2. Perform AT-43, "HOW TO ERASE DTC (NO TOOLS)" . (The DTC in TCM will be erased.)
3. Change the diagnostic test mode from Mode II to Mode I by depressing the accelerator pedal. Refer to
EC-65, "HOW TO SWITCH DIAGNOSTIC TEST MODE" .
D
If the battery is disconnected, the emission-related diagnostic information will be lost within 24
hours.
The following data are cleared when the ECM memory is erased.
E
Diagnostic trouble codes
1st trip diagnostic trouble codes
Freeze frame data

F
System readiness test (SRT) codes
Test values
G
Actual work procedures are explained using a DTC as an example. Be careful so that not only the DTC, but all
of the data listed above, are cleared from the ECM memory during work procedures.
H
NATS (Nissan Anti-theft System)
EBS010LM
If the security indicator lights up with the ignition switch in

the ON position or NATS MALFUNCTION is displayed on
SELF-DIAG RESULTS screen, perform self-diagnostic
results mode with CONSULT-II using NATS program card.
Refer to BL-108, "NATS (NISSAN ANTI-THEFT SYSTEM)" .
Confirm no self-diagnostic results of NATS is displayed
before touching ERASE in SELF-DIAG RESULTS mode
with CONSULT-II.
When replacing ECM, initialization of NATS system and registration of all NATS ignition key IDs must be carried out
SEF515Y
with CONSULT-II using NATS program card.
Therefore, be sure to receive all keys from vehicle owner.
Regarding the procedures of NATS initialization and all NATS ignition key ID registration, refer to
CONSULT-II Operation Manual, NATS.
Malfunction Indicator (MI)
EBS010LN
DESCRIPTION
The MI is located on the instrument panel.
1. The MI will light up when the ignition switch is turned ON without
the engine running. This is a bulb check.
If the MI does not light up, refer to DI-33, "WARNING LAMPS"
or see EC-516, "MI & DATA LINK CONNECTORS" .
2. When the engine is started, the MI should go off.
If the MI remains on, the on board diagnostic system has
detected an engine system malfunction.
SAT652J
ON BOARD DIAGNOSTIC SYSTEM FUNCTION

The on board diagnostic system has the following four functions.
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Diagnostic Test
Mode
KEY and ENG.

Status
Function
Explanation of Function
Mode I
Ignition switch in
ON position
BULB CHECK
This function checks the MI bulb for damage (blown, open

circuit, etc.).
If the MI does not come on, check MI circuit.
MALFUNCTION
WARNING
This is a usual driving condition. When a malfunction is

detected twice in two consecutive driving cycles (two trip
detection logic), the MI will light up to inform the driver that
a malfunction has been detected.
The following malfunctions will light up or blink the MI in
the 1st trip.
Engine stopped
Engine running
Mode II
Ignition switch in
ON position
Misfire (Possible three way catalyst damage)
SELF-DIAGNOSTIC
RESULTS
This function allows DTCs and 1st trip DTCs to be read.
HEATED OXYGEN SENSOR 1

MONITOR
This function allows the fuel mixture condition (lean or

rich), monitored by heated oxygen sensor 1, to be read.
Engine stopped
Engine running
MI Flashing without DTC

If the ECM is in Diagnostic Test Mode II, MI may flash when engine is running. In this case, check ECM diagnostic test mode. EC-65, "HOW TO SWITCH DIAGNOSTIC TEST MODE" .
How to switch the diagnostic test (function) modes, and details of the above functions are described later, EC65, "HOW TO SWITCH DIAGNOSTIC TEST MODE" .
The following emission-related diagnostic information is cleared when the ECM memory is erased.
Freeze frame data
Test values
EC-64
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HOW TO SWITCH DIAGNOSTIC TEST MODE
A
NOTE:
EC
has a malfunction.
Always ECM returns to Diagnostic Test Mode I after ignition switch is turned OFF.
How to Set Diagnostic Test Mode II (Self-diagnostic Results)

1.
2.
a.
b.
3.
4.
Confirm that accelerator pedal is fully released, turn ignition switch ON and wait 3 seconds.
Repeat the following procedure quickly five times within 5 seconds.
Fully depress the accelerator pedal.
Fully release the accelerator pedal.
Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 10 seconds until the MI starts
blinking.
ECM has entered to Diagnostic Test Mode II (Self-diagnostic results).
PBIB0092E
How to Set Diagnostic Test Mode II (Heated Oxygen Sensor 1 Monitor)

1.
2.
Set the ECM in Diagnostic Test Mode II (Self-diagnostic results). Refer to EC-65, "How to Set Diagnostic
Test Mode II (Self-diagnostic Results)" .
Start Engine.
ECM has entered to Diagnostic Test Mode II (Heated oxygen sensor 1 monitor).
How to Erase Diagnostic Test Mode II (Self-diagnostic Results)

1.
2.
3.
Set ECM in Diagnostic Test Mode II (Self-diagnostic results). Refer to EC-65, "How to Set Diagnostic Test
Mode II (Self-diagnostic Results)" .
Fully depress the accelerator pedal and keep it for more than 10 seconds.
The emission-related diagnostic information has been erased from the backup memory in the ECM.
Fully release the accelerator pedal, and confirm the DTC 0000 is displayed.
In this mode, the MI on the instrument panel should stay ON. If it remains OFF, check the bulb. Refer to DI-33,
"WARNING LAMPS" or see EC-516, "MI & DATA LINK CONNECTORS" .
DIAGNOSTIC TEST MODE I MALFUNCTION WARNING
Condition
ON
When the malfunction is detected.
OFF
No malfunction.
These DTC numbers are clarified in Diagnostic Test Mode II (SELF-DIAGNOSTIC RESULTS)
DIAGNOSTIC TEST MODE II SELF-DIAGNOSTIC RESULTS

In this mode, the DTC and 1st trip DTC are indicated by the number of blinks of the MI as shown below.
The DTC and 1st trip DTC are displayed at the same time. If the MI does not illuminate in diagnostic test mode
I (Malfunction warning), all displayed items are 1st trip DTCs. If only one code is displayed when the MI illuminates in diagnostic test mode II (SELF-DIAGNOSTIC RESULTS), it is a DTC; if two or more codes are displayed, they may be either DTCs or 1st trip DTCs. DTC No. is same as that of 1st trip DTC. These unidentified
EC-65
http://vnx.su
DIAGNOSTIC TEST MODE I BULB CHECK
MI

codes can be identified by using the CONSULT-II or GST. A DTC will be used as an example for how to read a
code.
PBIA3905E
A particular trouble code can be identified by the number of four-digit numeral flashes. The zero is indicated
by the number of ten flashes. The length of time the 1,000th-digit numeral flashes on and off is 1.2 seconds
consisting of an ON (0.6-second) - OFF (0.6-second) cycle.
The 100th-digit numeral and lower digit numerals consist of a 0.3-second ON and 0.3-second OFF cycle.
A change from one digit numeral to another occurs at an interval of 1.0-second OFF. In other words, the later
numeral appears on the display 1.3 seconds after the former numeral has disappeared.
A change from one trouble code to another occurs at an interval of 1.8-second OFF.
In this way, all the detected malfunctions are classified by their DTC numbers. The DTC 0000 refers to no malfunction. (See EC-19, "INDEX FOR DTC" )

The DTC can be erased from the back up memory in the ECM by depressing accelerator pedal. Refer to EC65, "HOW TO SWITCH DIAGNOSTIC TEST MODE" .
If the battery is disconnected, the DTC will be lost from the backup memory within 24 hours.
Be careful not to erase the stored memory before starting trouble diagnoses.
DIAGNOSTIC TEST MODE II HEATED OXYGEN SENSOR 1 MONITOR

In this mode, the MI displays the condition of the fuel mixture (lean or rich) which is monitored by the heated
oxygen sensor 1.
MI
Fuel mixture condition in the exhaust gas
ON
Lean
OFF
Rich
*Remains ON or OFF
Any condition
Air fuel ratio feedback control condition

Closed loop system
Open loop system
*: Maintains conditions just before switching to open loop.
To check the heated oxygen sensor 1 function, start engine in the Diagnostic Test Mode II and warm it up until
engine coolant temperature indicator points to the middle of the gauge.
Next run engine at about 2,000 rpm for about 2 minutes under no-load conditions. Then make sure that the MI
comes ON more than 5 times within 10 seconds with engine running at 2,000 rpm under no-load.
OBD System Operation Chart
EBS010LO
RELATIONSHIP BETWEEN MI, 1ST TRIP DTC, DTC, AND DETECTABLE ITEMS
When a malfunction is detected for the first time, the 1st trip DTC and the 1st trip freeze frame data are
stored in the ECM memory.
When the same malfunction is detected in two consecutive trips, the DTC and the freeze frame data are
stored in the ECM memory, and the MI will come on. For details, refer to EC-51, "Two Trip Detection
Logic" .
EC-66
http://vnx.su

The MI will go off after the vehicle is driven 3 times (driving pattern B) with no malfunction. The drive is
counted only when the recorded driving pattern is met (as stored in the ECM). If another malfunction A
occurs while counting, the counter will reset.
The DTC and the freeze frame data will be stored until the vehicle is driven 40 times (driving pattern A)
without the same malfunction recurring (except for Misfire and Fuel Injection System). For Misfire and EC
Fuel Injection System, the DTC and freeze frame data will be stored until the vehicle is driven 80 times
(driving pattern C) without the same malfunction recurring. The TIME in SELF-DIAGNOSTIC
RESULTS mode of CONSULT-II will count the number of times the vehicle is driven.
C
The 1st trip DTC is not displayed when the self-diagnosis results in OK for the 2nd trip.
SUMMARY CHART
Items
MI (goes off)
DTC, Freeze Frame Data (no
display)
1st Trip DTC (clear)
1st Trip Freeze Frame Data
(clear)
Fuel Injection System
Misfire
Other
3 (pattern B)
3 (pattern B)
3 (pattern B)
80 (pattern C)
80 (pattern C)
40 (pattern A)
1 (pattern C), *1
1 (pattern C), *1
1 (pattern B)
*1 , *2
*1 , *2
1 (pattern B)
For details about patterns B and C under Fuel Injection System and Misfire, see EC-69, "EXPLANATION FOR DRIVING PATTERNS
FOR MISFIRE <EXHAUST QUALITY DETERIORATION>, FUEL INJECTION SYSTEM" .
For details about patterns A and B under Other, see EC-71, "EXPLANATION FOR DRIVING PATTERNS EXCEPT FOR MISFIRE
<EXHAUST QUALITY DETERIORATION>, FUEL INJECTION SYSTEM" .
*1: Clear timing is at the moment OK is detected.
*2: Clear timing is when the same malfunction is detected in the 2nd trip.
EC-67
http://vnx.su

RELATIONSHIP BETWEEN MI, DTC, 1ST TRIP DTC AND DRIVING PATTERNS FOR MISFIRE
<EXHAUST QUALITY DETERIORATION>, FUEL INJECTION SYSTEM
SEF392SA
*1: When the same malfunction is

detected in two consecutive trips, MI
will light up.
*2: MI will go off after vehicle is driven 3

times (pattern B) without any malfunctions.
*4: The DTC and the freeze frame data *5: When a malfunction is detected for
will not be displayed any longer after
the first time, the 1st trip DTC and
vehicle is driven 80 times (pattern C)
the 1st trip freeze frame data will be
without the same malfunction. (The
stored in ECM.
DTC and the freeze frame data still
remain in ECM.)
detected in the 2nd trip, the 1st trip
freeze frame data will be cleared.
*8: 1st trip DTC will be cleared when

vehicle is driven once (pattern C)
without the same malfunction after
DTC is stored in ECM.
EC-68
http://vnx.su

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

EXPLANATION FOR DRIVING PATTERNS FOR MISFIRE <EXHAUST QUALITY DETERIORATION>, FUEL INJECTION SYSTEM
<Driving Pattern B>
Driving pattern B means the vehicle operation as follows:
All components and systems should be monitored at least once by the OBD system.
The B counter will be cleared when the malfunction is detected once regardless of the driving pattern.
The B counter will be counted up when driving pattern B is satisfied without any malfunction.
The MI will go off when the B counter reaches 3. (*2 in OBD SYSTEM OPERATION CHART)
EC
<Driving Pattern C>

Driving pattern C means the vehicle operation as follows:
The following conditions should be satisfied at the same time:
Engine speed: (Engine speed in the freeze frame data) 375 rpm
Calculated load value: (Calculated load value in the freeze frame data) x (10.1) [%]
Engine coolant temperature (T) condition:
When the freeze frame data shows lower than 70C (158F), T should be lower than 70C (158F).
When the freeze frame data shows higher than or equal to 70C (158F), T should be higher than or equal
to 70C (158F).
Example:
If the stored freeze frame data is as follows:
Engine speed: 850 rpm, Calculated load value: 30%, Engine coolant temperature: 80C (176F)
To be satisfied with driving pattern C, the vehicle should run under the following conditions:
Engine speed: 475 - 1,225 rpm, Calculated load value: 27 - 33%, Engine coolant temperature: more than 70C
(158F)
The C counter will be cleared when the malfunction is detected regardless of vehicle conditions above.
The C counter will be counted up when vehicle conditions above is satisfied without the same malfunction.
The DTC will not be displayed after C counter reaches 80.
The 1st trip DTC will be cleared when C counter is counted once without the same malfunction after DTC
is stored in ECM.
EC-69
http://vnx.su

RELATIONSHIP BETWEEN MI, DTC, 1ST TRIP DTC AND DRIVING PATTERNS EXCEPT FOR
MISFIRE <EXHAUST QUALITY DETERIORATION>, FUEL INJECTION SYSTEM
PBIB2551E

detected in two consecutive trips, MI
will light up.

times (pattern B) without any malfunctions.

detected in two consecutive trips, the
DTC and the freeze frame data will
be stored in ECM.
*4: The DTC and the freeze frame data

vehicle is driven 40 times (pattern A)
without the same malfunction.
(The DTC and the freeze frame data
still remain in ECM.)
*5: When a malfunction is detected for

the first time, the 1st trip DTC and
the 1st trip freeze frame data will be
stored in ECM.
*6: 1st trip DTC will be cleared after

vehicle is driven once (pattern B)

detected in the 2nd trip, the 1st trip
freeze frame data will be cleared.
EC-70
http://vnx.su

EXPLANATION FOR DRIVING PATTERNS EXCEPT FOR MISFIRE <EXHAUST QUALITY
DETERIORATION>, FUEL INJECTION SYSTEM
<Driving Pattern A>
EC
G
AEC574
The A counter will be cleared when the malfunction is detected regardless of (1) - (4).
The A counter will be counted up when (1) - (4) are satisfied without the same malfunction.
The DTC will not be displayed after the A counter reaches 40.
<Driving Pattern B>

All components and systems should be monitored at least once by the OBD system.
The B counter will be cleared when the malfunction is detected once regardless of the driving pattern.
The B counter will be counted up when driving pattern B is satisfied without any malfunctions.
The MI will go off when the B counter reaches 3 (*2 in OBD SYSTEM OPERATION CHART).
EC-71
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TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS
Trouble Diagnosis Introduction
PFP:00004
EBS010LP
INTRODUCTION
The engine has an ECM to control major systems such as fuel control, ignition control, idle air control system, etc. The ECM accepts
input signals from sensors and instantly drives actuators. It is essential that both input and output signals are proper and stable. At the
same time, it is important that there are no malfunctions such as vacuum leaks, fouled spark plugs, or other malfunctions with the engine.
It is much more difficult to diagnose an incident that occurs intermittently rather than continuously. Most intermittent incidents are
caused by poor electric connections or improper wiring. In this case,
careful checking of suspected circuits may help prevent the replacement of good parts.
A visual check only may not find the cause of the incidents. A road
test with CONSULT-II (or GST) or a circuit tester connected should
be performed. Follow EC-73, "WORK FLOW" .
Before undertaking actual checks, take a few minutes to talk with a
customer who approaches with a driveability complaint. The customer can supply good information about such incidents, especially
intermittent ones. Find out what symptoms are present and under
what conditions they occur. A Diagnostic Worksheet like the example
on EC-75, "Worksheet Sample" should be used.
Start your diagnosis by looking for conventional malfunctions first.
This will help troubleshoot driveability malfunctions on an electronically controlled engine vehicle.
MEF036D
SEF233G
SEF234G
EC-72
http://vnx.su
TROUBLE DIAGNOSIS
WORK FLOW
Flow Chart
EC
MBIB0159E
*1
If time data of SELF-DIAG

RESULTS is other than [0] or [1t],
perform EC-123, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
*2
If the incident cannot be verified, per- *3

form EC-123, "TROUBLE DIAGNOSIS FOR INTERMITTENT
INCIDENT" .
If the on board diagnostic system

cannot be performed, check main
power supply and ground circuit.
Refer to EC-124, "POWER SUPPLY
AND GROUND CIRCUIT" .
*4
If malfunctioning part cannot be

detected, perform EC-123, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
*5
EC-60, "Driving Pattern"
EC-119, "TROUBLE DIAGNOSIS SPECIFICATION VALUE"
EC-73
http://vnx.su
*6
TROUBLE DIAGNOSIS
Description for Work Flow
STEP
DESCRIPTION
STEP I
Get detailed information about the conditions and the environment when the incident/symptom occurred using EC-75,
"DIAGNOSTIC WORKSHEET" .
STEP II
Before confirming the concern, check and write down (print out using CONSULT-II or GST) the (1st trip) DTC and the
(1st trip) freeze frame data, then erase the DTC and the data. (Refer to EC-62, "HOW TO ERASE EMISSIONRELATED DIAGNOSTIC INFORMATION" .) The (1st trip) DTC and the (1st trip) freeze frame data can be used when
duplicating the incident at STEP III & IV.
If the incident cannot be verified, perform EC-123, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
Study the relationship between the cause, specified by (1st trip) DTC, and the symptom described by the customer.
(The Symptom Matrix Chart will be useful. See EC-83, "Symptom Matrix Chart" .)
Also check related service bulletins for information.
STEP III
Try to confirm the symptom and under what conditions the incident occurs.
The DIAGNOSTIC WORK SHEET and the freeze frame data are useful to verify the incident. Connect CONSULT-II
to the vehicle in DATA MONITOR (AUTO TRIG) mode and check real time diagnosis results.
If the malfunction code is detected, skip STEP IV and perform STEP V.
STEP IV
Try to detect the (1st trip) DTC by driving in (or performing) the DTC Confirmation Procedure. Check and read the (1st
trip) DTC and (1st trip) freeze frame data by using CONSULT-II or GST.
During the (1st trip) DTC verification, be sure to connect CONSULT-II to the vehicle in DATA MONITOR (AUTO
TRIG) mode and check real time diagnosis results.
In case the DTC Confirmation Procedure is not available, perform the Overall Function Check instead. The (1st trip)
DTC cannot be displayed by this check, however, this simplified check is an effective alternative.
The NG result of the Overall Function Check is the same as the (1st trip) DTC detection.
STEP V
Take the appropriate action based on the results of STEP I through IV.
If the malfunction code is indicated, proceed to TROUBLE DIAGNOSIS FOR DTC PXXXX.
If the normal code is indicated, proceed to the BASIC INSPECTION. (Refer to EC-78, "Basic Inspection" .)Then perform inspections according to the Symptom Matrix Chart. (Refer to EC-83, "Symptom Matrix Chart" .)
STEP VI
Identify where to begin diagnosis based on the relationship study between symptom and possible causes. Inspect the
system for mechanical binding, loose connectors or wiring damage using (tracing) Harness Layouts.
Gently shake the related connectors, components or wiring harness with CONSULT-II set in DATA MONITOR
(AUTO TRIG) mode.
Check the voltage of the related ECM terminals or monitor the output data from the related sensors with CONSULT-II.
Refer to EC-94, "ECM Terminals and Reference Value" , EC-114, "CONSULT-II Reference Value in Data Monitor
Mode" .
The Diagnostic Procedure in EC section contains a description based on open circuit inspection. A short circuit
inspection is also required for the circuit check in the Diagnostic Procedure. For details, refer to Circuit Inspection in
GI-23, "How to Perform Efficient Diagnosis for an Electrical Incident" .
Repair or replace the malfunction parts.
If malfunctioning part cannot be detected, perform EC-123, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
STEP VII
Once you have repaired the circuit or replaced a component, you need to run the engine in the same conditions and
circumstances which resulted in the customer's initial complaint.
Perform the DTC Confirmation Procedure and confirm the normal code [DTC No. P0000] is detected. If the incident is
still detected in the final check, perform STEP VI by using a method different from the previous one.
Before returning the vehicle to the customer, be sure to erase the unnecessary (already fixed) (1st trip) DTC in ECM
and TCM (Transmission control module). (Refer to EC-62, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC
INFORMATION" and AT-42, "HOW TO ERASE DTC" .)
EC-74
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TROUBLE DIAGNOSIS
DIAGNOSTIC WORKSHEET
Description
There are many operating conditions that lead to the malfunction of

engine components. A good grasp of such conditions can make troubleshooting faster and more accurate.
In general, each customer feels differently about a incident. It is
important to fully understand the symptoms or conditions for a customer complaint.
Utilize a diagnostic worksheet like the one on the next page in order
to organize all the information for troubleshooting.
Some conditions may cause the MI to come on steady or blink and
DTC to be detected. Examples:
Vehicle ran out of fuel, which caused the engine to misfire.
EC
D
SEF907L
Worksheet Sample
MTBL0017
EC-75
http://vnx.su
TROUBLE DIAGNOSIS
DTC Inspection Priority Chart
EBS010LQ
If some DTCs are displayed at the same time, perform inspections one by one based on the following priority
chart.
NOTE:
If DTC U1000 and/or U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC
U1000 and U1001. Refer to EC-132, "DTC U1000, U1001 CAN COMMUNICATION LINE" .
Priority
1
Detected items (DTC)
U1000 U1001 CAN communication line
P0102 P0103 Mass air flow sensor
P0112 P0113 Intake air temperature sensor
P0117 P0118 Engine coolant temperature sensor
P0122 P0123 P0222 P0223 P1225 P1226 P2135 Throttle position sensor
P0327 P0328 Knock sensor
P0335 Crankshaft position sensor (POS)
P0340 Camshaft position sensor (PHASE)
P0500 Vehicle speed sensor
P0605 ECM
P0705 Park/Neutral position (PNP) sensor
P1229 Sensor power supply
P1610-P1615 NATS
P1706 Park/Neutral position (PNP) switch
P2122 P2123 P2127 P2128 P2138 Accelerator pedal position sensor
P0031 P0032 Heated oxygen sensor 1 heater
P0037 P0038 Heated oxygen sensor 2 heater
P0132 P0133 P0134 P1143 P1144 Heated oxygen sensor 1
P0138 P0139 P1146 P1147 Heated oxygen sensor 2
P0444 EVAP canister purge volume control solenoid valve
P0550 Power steering pressure sensor
P0710 P0720 P725 P0740 P0745 P0750 P0755 P1705 P1760 A/T related sensors and solenoid valves
P1065 ECM power supply
P1111 Intake valve timing control solenoid valve
P1122 Electric throttle control function
P1124 P1126 Throttle control motor relay
P1128 Throttle control mother
P1211 TCS control unit
P1212 TCS communication line
P1805 Brake switch
P0011 Intake valve timing control
P0171 P0172 Fuel injection system function
P0300 - P0304 Misfire
P0420 Three way catalyst function
P0731 - P0734 A/T function
P1121 Electric throttle control actuator
P1217 Engine over temperature (OVERHEAT)
P1564 ASCD steering switch*
P1572 ASCD brake switch*
P1574 ASCD vehicle speed sensor*
*: For QR25DE engine models
EC-76
http://vnx.su
TROUBLE DIAGNOSIS
Fail-safe Chart
EBS010LR
When the DTC listed bellow is detected, the ECM enters fail-safe mode and the MI lights up.
DTC No.
Detected items
P0102
P0103
Mass air flow sensor circuit
Engine speed will not rise more than 2,400 rpm due to the fuel cut.
P0117
P0118
Engine coolant temperature sensor circuit
Engine coolant temperature will be determined by ECM based on the time after turning
ignition switch ON or START.
CONSULT-II displays the engine coolant temperature decided by ECM.
Condition
Just as ignition switch is turned ON or START
40C (104F)
More than approx. 4 minutes after ignition ON

or START
80C (176F)
Except as shown above
P0122
P0123
P0221
P0222
P2135
P1121
Electric throttle control

actuator
Engine coolant temperature decided

(CONSULT-II display)
EC
E
40 - 80C (104 - 176F)
(Depends on the time)
When the fail-safe system for engine coolant temperature sensor is activated, the cooling
fan operates while engine is running.
The ECM controls the electric throttle control actuator in regulating the throttle opening in
order for the idle position to be within +10 degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal
condition.
So, the acceleration will be poor.
(When electric throttle control actuator does not function properly due to the return spring
malfunction:)
ECM controls the electric throttle actuator by regulating the throttle opening around the
idle position. The engine speed will not rise more than 2,000 rpm.
(When throttle valve opening angle in fail-safe mode is not in specified range:)
ECM controls the electric throttle control actuator by regulating the throttle opening to 20
degrees or less.
(ECM detect the throttle valve is stuck open:)
While the vehicle is driving, it slows down gradually by fuel cut. After the vehicle stops, the
engine stalls.
The engine can restart in N or P position (A/T), neutral position (M/T) and engine speed
will not exceed 1,000 rpm or more.
P1122

function
ECM stops the electric throttle control actuator control, throttle valve is maintained at a
fixed opening (approx. 5 degrees) by the return spring.
P1124
P1126
Throttle control motor relay
P1128
Throttle control motor
P1229
Sensor power supply
P2122
P2123
P2127
P2128
P2138

sensor
condition.
EC-77
http://vnx.su
TROUBLE DIAGNOSIS
Basic Inspection
EBS010LS
1. INSPECTION START
1.
2.
3.
4.
Check service records for any recent repairs that may indicate a related malfunction, or a current need for
scheduled maintenance.
Open engine hood and check the following:
Harness connectors for improper connections
Wiring harness for improper connections, pinches and cut
Vacuum hoses for splits, kinks and improper connections
Hoses and ducts for leaks
Air cleaner clogging
Gasket
Confirm that electrical or mechanical loads are not applied.
Headlamp switch is OFF.
SEF983U
Air conditioner switch is OFF.
Rear window defogger switch is OFF.
Steering wheel is in the straight-ahead position, etc.
Start engine and warm it up until engine coolant temperature
indicator points the middle of gauge.
Ensure engine stays below 1,000 rpm.
SEF976U
5.
Run engine at about 2,000 rpm for about 2 minutes under no

load.
6. Make sure that no DTC is displayed with CONSULT-II or GST.
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
SEF977U
2. REPAIR OR REPLACE
Repair or replace components as necessary according to corresponding Diagnostic Procedure.
>> GO TO 3
EC-78
http://vnx.su
TROUBLE DIAGNOSIS
3. CHECK TARGET IDLE SPEED

1.
2.
With CONSULT-II
Run engine at about 2,000 rpm for about 2 minutes under no load.
Rev engine (2,000 to 3,000 rpm) two or three times under no
load, then run engine at idle speed for about 1 minute.
EC
E
PBIA8513J
3.
Read idle speed in DATA MONITOR mode with CONSULT-II.

F
QR20DE with M/T models

: 650 50 rpm (in Neutral position)
Except above
: 700 50 rpm [in P or N (A/T), Neutral (M/T) position]
H
SEF058Y
Without CONSULT-II
1. Run engine at about 2,000 rpm for about 2 minutes under no load.
2. Rev engine (2,000 to 3,000 rpm) two or three times under no load, then run engine at idle speed for about
1 minute.
3. Check idle speed.
Except above
OK or NG
OK
>> GO TO 10.
NG
>> GO TO 4.
4. PERFORM ACCELERATOR PEDAL RELEASED POSITION LEARNING

1.
2.
Stop engine.
>> GO TO 5.
5. PERFORM THROTTLE VALVE CLOSED POSITION LEARNING

>> GO TO 6.
EC-79
http://vnx.su
TROUBLE DIAGNOSIS
6. PERFORM IDLE AIR VOLUME LEARNING

Refer to EC-46, "Idle Air Volume Learning" .
Is Idle Air Volume Learning carried out successfully?
Yes or No
Yes
>> GO TO 7.
No
>> 1. Follow the instruction of Idle Air Volume Learning.
2. GO TO 4.
7. CHECK TARGET IDLE SPEED AGAIN

With CONSULT-II
2. Read idle speed in DATA MONITOR mode with CONSULT-II.
Except above
Without CONSULT-II
SEF058Y

Except above
OK or NG
OK
>> GO TO 10.
NG
>> GO TO 8.
8. DETECT MALFUNCTIONING PART

Check the Following.
Check camshaft position sensor (PHASE) and circuit. Refer to EC-256, "DTC P0340 CMP SENSOR
(PHASE)" .
Check crankshaft position sensor (POS) and circuit. Refer to EC-249, "DTC P0335 CKP SENSOR (POS)"
.
OK or NG
OK
>> GO TO 9.
NG
>> 1. Repair or replace.
2. GO TO 4.
9. CHECK ECM FUNCTION

1.
2.
Substitute another known-good ECM to check ECM function. (ECM may be the cause of an incident, but
this is a rare case.)
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-108,
"NATS (NISSAN ANTI-THEFT SYSTEM)" .
>> GO TO 4.
EC-80
http://vnx.su
TROUBLE DIAGNOSIS
10. CHECK IGNITION TIMING

1.
2.
Run engine at idle.

Check ignition timing with a timing light.
EC
PBIB0514E

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 11.

1.
2.
Stop engine.
>> GO TO 12.

K
>> GO TO 13.

L

Yes or No
Yes
>> GO TO 14.
No
2. GO TO 4.
EC-81
http://vnx.su
TROUBLE DIAGNOSIS

1.
2.
With CONSULT-II
Except above
Without CONSULT-II
SEF058Y

Except above
OK or NG
OK
>> GO TO 15.
NG
>> GO TO 17.
15. CHECK IGNITION TIMING AGAIN

1.
2.
Run engine at idle.

PBIB0514E

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 16.
16. CHECK TIMING CHAIN INSTALLATION

Check timing chain installation. Refer to EM-46, "TIMING CHAIN" .
OK or NG
OK
>> GO TO 17.
NG
>> 1. Repair the timing chain installation.
2. GO TO 4.
EC-82
http://vnx.su
TROUBLE DIAGNOSIS
A
Check the following.
EC
(PHASE)" .
.
C
OK or NG
OK
>> GO TO 18.
NG
D
2. GO TO 4.

1.
2.
>> GO TO 4.
Symptom Matrix Chart
EBS010LT
SYSTEM BASIC ENGINE CONTROL SYSTEM

H
Fuel pressure regulator system
Injector circuit
Evaporative emission system
Air
Positive crankcase ventilation system
Incorrect idle speed adjustment
Ignition
Incorrect ignition timing adjustment
Ignition circuit
Main power supply and ground circuit
EC-83
BATTERY DEAD (UNDER CHARGE)
Fuel pump circuit
EXCESSIVE OIL CONSUMPTION
Fuel
EXCESSIVE FUEL CONSUMPTION
AE
OVERHEATS/WATER TEMPERATURE HIGH
LACK OF POWER/POOR ACCELERATION
AD
SLOW/NO RETURN TO IDLE
SPARK KNOCK/DETONATION
AC
IDLING VIBRATION
HESITATION/SURGING/FLAT SPOT
AB
ROUGH IDLE/HUNTING
ENGINE STALL
AA
Warranty symptom code
HIGH IDLE/LOW IDLE
HARD/NO START/RESTART (EXCP. HA)
SYMPTOM
AF
AG
AH
AJ
AK
AL
AM
HA
3
4
J
Reference
page
M
EC-465
EC-48
EC-450
EC-520
EC-78
EC-293,
EC-295 ,
EC-305 ,
EC-313
EC-525
EC-78
EC-439
EC-124
http://vnx.su
TROUBLE DIAGNOSIS
ENGINE STALL
HIGH IDLE/LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SYMPTOM
AA
AB
AC
AD
AE
AF
AG
AH
AJ
AK
AL
AM
HA
Throttle position sensor circuit
Accelerator pedal position sensor circuit
Heated oxygen sensor 1 circuit
Knock sensor circuit
EC-150
EC-164
EC-170,
EC-230 ,
EC-367 ,
EC-369 ,
EC-423
EC-371,
EC-408 ,
EC-415 ,
EC-431
Reference
page
EC-178,
EC-185 ,
EC-195 ,
EC-321 ,
EC-327
EC-244
Crankshaft position sensor (POS) circuit
EC-249
Camshaft position sensor (PHASE) circuit
EC-256
Vehicle speed signal circuit
Power steering pressure sensor circuit
3
3
3
3
EC-289
EC-397
EC-473
Intake valve timing control solenoid valve circuit
Electrical load signal circuit

Air conditioner circuit
ESP/TCS/ABS CONTROL UNIT

(models with ESP)
ABS actuator and electric unit (control unit)
(models without ESP)
1 - 6: The numbers refer to the order of inspection.

(continued on next page)
EC-84
http://vnx.su
EC-277
EC-282,
EC-285
Refrigerant pressure sensor circuit
EC-275
ECM
PNP switch circuit
EC-479
3
ATC-34,
MTC-3
BRC-11,
BRC-58
TROUBLE DIAGNOSIS
SYSTEM ENGINE MECHANICAL & OTHER
A
Fuel
ENGINE STALL
HIGH IDLE/LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SYMPTOM
AA
AB
AC
AD
AE
AF
AG
AH
AJ
AK
AL
AM
HA
EC
Fuel tank
Fuel piping
Vapor lock
FL-3, EM34
Valve deposit
Air
Reference
page
FL-11
5
Poor fuel (Heavy weight gasoline, Low octane)
Air duct
Air cleaner
EM-16
Air leakage from air duct

(Mass air flow sensor electric
throttle control actuator)
5
5
5
5
EM-18
Air leakage from intake manifold/

Collector/Gasket
Cranking
Battery
Alternator circuit
Engine
SC-3
SC-12
Starter circuit
SC-22
Signal plate/Flywheel/Drive plate
EM-86
MT-13 or
AT-100
PNP switch
Cylinder head
5
4
EM-70
3
Cylinder block
Piston
Piston ring
4
6
Connecting rod
Bearing
Crankshaft
EC-85
http://vnx.su
EM-86
TROUBLE DIAGNOSIS
Valve
mechanism
ENGINE STALL
HIGH IDLE/LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SYMPTOM
AA
AB
AC
AD
AE
AF
AG
AH
AJ
AK
AL
AM
HA
Reference
page
Timing chain
EM-46
Camshaft
EM-56
Intake valve timing control
EM-46
Intake valve
3
Exhaust valve
Exhaust
Exhaust manifold/Tube/Muffler/
Gasket
EM-25, EX2
Three way catalyst

Lubrication
Cooling
Oil pan/Oil strainer/Oil pump/Oil

filter/Oil gallery
EM-70
EM-27, LU13 , LU-10 ,

LU-5
Oil level (Low)/Filthy oil
LU-7
Radiator/Hose/Radiator filler cap
CO-12
Thermostat
CO-23
Water pump
Water gallery
CO-21
5
Cooling fan
2
5
Coolant level (low)/Contaminated

coolant
CO-7
CO-19
CO-9
EC-63 or
BL-108
EC-86
http://vnx.su
TROUBLE DIAGNOSIS
Engine Control Component Parts Location
EBS010LU
EC
EC-87
http://vnx.su
TROUBLE DIAGNOSIS
EC-88
http://vnx.su
TROUBLE DIAGNOSIS
A
EC
PBIB1980E
EC-89
http://vnx.su
TROUBLE DIAGNOSIS
EC-90
http://vnx.su
TROUBLE DIAGNOSIS
A
EC
EC-91
http://vnx.su
TROUBLE DIAGNOSIS
Circuit Diagram
EBS010LV
TBWA0592E
EC-92
http://vnx.su
TROUBLE DIAGNOSIS
A
EC
TBWB0462E
EC-93
http://vnx.su
TROUBLE DIAGNOSIS
ECM Harness Connector Terminal Layout
EBS010LW
MBIB0045E
ECM Terminals and Reference Value
EBS010LX
PREPARATION
1.
2.
ECM is located behind the glove box. For this inspection,

remove glove box.
Remove ECM harness protector.
PBIB1973E
3.
4.
When disconnecting ECM harness connector, loosen it with

levers as far as they will go as shown at right.
Connect a break-out box (SST) and Y-cable adapter (SST)
between the ECM and ECM harness connector.
Use extreme care not to touch 2 pins at one time.
Data is for comparison and may not be exact.
PBIB1512E
ECM INSPECTION TABLE

Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
1
WIRE
COLOR
B
ITEM
ECM ground
CONDITION
[Engine is running]
Idle speed
EC-94
http://vnx.su
DATA (DC Voltage)
Body ground
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running]
Warm-up condition
Engine speed is below 3,600 rpm after the following conditions are met
PU/R

heater
EC
0 - 1.0V
Keeping the engine speed between 3,500

and 4,000 rpm for 1 minute and at idle for 1
minute under no load
[Ignition switch: ON]
Engine stopped
[Engine is running]
W/B

relay power supply
D
BATTERY VOLTAGE
(11 - 14V)
Engine speed is above 3,600 rpm
BATTERY VOLTAGE
(11 - 14V)
0 - 14V
4

(Close)
Engine stopped
Shift lever: D (A/T), 1st (M/T)
Accelerator pedal: Fully released
PBIB1104E
0 - 14V

5

(Open)
Engine stopped
Accelerator pedal: Fully depressed
J
PBIB1105E
[Engine is running]
6*1
VIAS control solenoid

valve
Idle speed
[Engine is running]
[Engine is running]
12
Power steering pressure

sensor
Steering wheel is being turned
[Engine is running]
Steering wheel is not being turned
EC-95
http://vnx.su
BATTERY VOLTAGE
(11 - 14V)
0 - 1.0V
0.5 - 4.0V
M
0.4 - 0.8V
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
[Engine is running]
Warm-up condition
Idle speed
DATA (DC Voltage)
1.0 - 4.0V
NOTE:
The pulse cycle changes depending on rpm
at idle
13
L/W
PBIB0525E

(PHASE)
1.0 - 4.0V
[Engine is running]
Engine speed is 2,000 rpm
PBIB0526E
[Engine is running]
Warm-up condition
Idle speed
Approximately 3.0V
NOTE:
at idle
14
PU/R
PBIB0527E
Crankshaft position
sensor (POS)
Approximately 3.0V
[Engine is running]
PBIB0528E
15
Knock sensor
[Engine is running]
Idle speed
Approximately 2.5V
[Engine is running]
16
OR/B
Warm-up condition
Revving engine from idle to 3,000 rpm quickly

after the following conditions are met

and 4,000 rpm for 1 minute and at idle for 1
EC-96
http://vnx.su
0 - Approximately 1.0V
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
BATTERY VOLTAGE
EC
(11 - 14V)
[Engine is running]
19
Idle speed
PBIB0050E
Approximately 10V
[Engine is running]
Engine speed is about 2,000 rpm (More than

100 seconds after starting engine)
F
PBIB0520E
BATTERY VOLTAGE
[Engine is running]
22
23
41
42
G/B
R/B
L/B
Y/B
Warm-up condition
Idle speed
(11 - 14V)
NOTE:
at idle
Injector No. 3
Injector No. 1
Injector No. 4
Injector No. 2
I
PBIB0529E
BATTERY VOLTAGE
(11 - 14V)
[Engine is running]
Warm-up condition
PBIB0530E
Approximately 7.0V
[Engine is running]
24
G/W

heater
Warm-up condition
Engine speed is below 3,600 rpm
PBIB0519E
[Engine is running]
29
30
34
Y/G
Sensor ground
(Camshaft position sensor)
[Engine is running]
Sensor ground
(Crankshaft position sensor)
[Engine is running]
Intake air temperature

sensor
Warm-up condition
Idle speed
Warm-up condition
Idle speed
[Engine is running]
EC-97
http://vnx.su
BATTERY VOLTAGE
(11 - 14V)
Approximately 0V
Approximately 0V
Approximately 0 - 4.8V
Output voltage varies with intake
air temperature.
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running]
35
P/L
Warm-up condition
(Periodically change)
46
Sensor power supply

(Refrigerant pressure sensor)
Approximately 5V
47
Sensor power supply

(Throttle position sensor)
Approximately 5V
49
Engine stopped
Throttle position sensor 1
More than 0.36V
Engine stopped
Less than 4.75V
Approximately 0.4V
[Engine is running]
50
OR
Warm-up condition
Idle speed

[Engine is running]
Warm-up condition
Engine is revving from idle to about 4,000 rpm
0.7 - 1.1V (QR20DE)

0.8 - 1.2V (QR25DE)
0.7 - 1.1 to Approximately 4.0V
(QR20DE)
(QR25DE)
(Check for liner voltage rise in
response to engine being
increased to about 4,000 rpm.)
[Engine is running]
54
Sensor ground
(Knock sensor)
Warm-up condition
Idle speed
Approximately 0V
[Engine is running]
57
Sensor ground
Warm-up condition
Idle speed
[Engine is running]
60
61
79
80
L/R
BR
GY/R
PU
Warm-up condition
Idle speed
Approximately 0V
0 - 0.1V
NOTE:
at idle
Ignition signal No. 3

PBIB0521E
0 - 0.2V
[Engine is running]
Warm-up condition
PBIB0522E
EC-98
http://vnx.su
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running]
Warm-up condition
Idle speed
BATTERY VOLTAGE
(11 - 14V)
EC
Approximately 4V - BATTERY
62
Intake valve timing

control solenoid valve
VOLTAGE (11 - 14V)

[Engine is running]
Warm-up condition
PBIB1790E
65
Sensor power supply

(Power steering pressure
sensor)
Approximately 5V
F
[Engine is running]
66
Sensor ground
Warm-up condition
Idle speed
Approximately 0V
[Engine is running]
67
B/P
Sensor ground
(Mass air flow sensor)
Warm-up condition
Idle speed
Approximately 0V
68
Engine stopped
Less than 4.75V
Engine stopped
More than 0.36V
[Engine is running]
69
Warm-up condition
Both A/C switch and blower switch: ON
1.0 - 4.0V
(Compressor operates)
72
BR/Y
[Engine is running]
73
Sensor ground
(Engine coolant temperature sensor)
Warm-up condition
Idle speed
Output voltage varies with
engine coolant temperature.
[Engine is running]
Approximately 0V
[Engine is running]
74
82
83
RY
Sensor ground
(Heated oxygen sensor)
Warm-up condition
Idle speed
Sensor ground
(Accelerator pedal position
sensor 1)
[Engine is running]
Sensor ground
sensor 2)
[Engine is running]
Warm-up condition
Idle speed
Warm-up condition
Idle speed
EC-99
http://vnx.su
Approximately 0V
Approximately 0V
Approximately 0V
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
84
L/Y

(Headlamp signal)
Lighting switch: 2ND position (placed in LOW

position for models with Xenon headlamp)
85
LG
DATA link connector
86
GY/R
CAN communication line
CONSULT-II or GST is disconnected
BATTERY VOLTAGE
(11 - 14V)
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
1.0 - 2.5V
[Engine is running]
BATTERY VOLTAGE
(11 - 14V)
89
Lighting switch: OFF
DATA (DC Voltage)
Cooling fan relay (High)
Cooling fan is not operating
[Engine is running]
Cooling fan is high speed operating
0 - 1.0V
90
Sensor power supply

sensor 1)
Approximately 5V
91
BR/Y
Sensor power supply

sensor 2)
Approximately 5V
BATTERY VOLTAGE
(11 - 14V)
BR

(Rear window defogger
signal)
93
94
G/R
Rear window defogger switch: ON
Rear window defogger switch: OFF

[Engine is running]
96
LG/B
Heater fan switch
Heater fan switch: ON
[Engine is running]
Heater fan switch: OFF
97
PU
Cooling fan relay (Low)
Cooling fan is operating
Approximately 0V
2.5 - 4.0V
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
BATTERY VOLTAGE
(11 - 14V)
0 - 1.0V
98
B/W

sensor 2
Engine stopped
Engine stopped
ASCD steering switch: OFF
99*1
W/R
ASCD steering switch
0.15 - 0.6V
MAIN switch: Pressed
CANCEL switch: Pressed
RESUME/ACCELERATE switch: Pressed
SET/COAST switch: Pressed
EC-100
http://vnx.su
1.95 - 2.4V
Approximately 4V
Approximately 0V
Approximately 1V
Approximately 3V
Approximately 2V
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
[Ignition switch: OFF]
101
Stop lamp switch
Brake pedal: Fully released
Brake pedal: Slightly depressed
102
G/OR
PNP switch
104
W/B

relay
Shift lever: P or N (A/T), Neutral (M/T)
Except above position
DATA (DC Voltage)
Approximately 0V
EC
BATTERY VOLTAGE
(11 - 14V)
C
Approximately 0V
A/T models
BATTERY VOLTAGE
(11 - 14V)
M/T models
Approximately 5V
BATTERY VOLTAGE
(11 - 14V)
0 - 1.0V
106

sensor 1
Engine stopped
0.5 - 1.0V
Engine stopped
3.9 - 4.7V
108*1
109
GY/L
Clutch pedal: Slightly depressed (M/T)
ASCD brake switch
B/R
Ignition switch
Clutch pedal: Fully released (M/T)
G/W
ECM relay
(Self shut-off)
BATTERY VOLTAGE
(11 - 14V)
0V
BATTERY VOLTAGE
(11 - 14V)
For a few seconds after turning ignition switch

OFF
More than a few seconds after turning ignition

switch OFF
0 - 1.0V
BATTERY VOLTAGE
(11 - 14V)
114
[Engine is running]
111
Approximately 0V
B/OR
Fuel pump relay
For 1 second after turning ignition switch ON
0 - 1.0V
[Engine is running]
More than 1 second after turning ignition

switch ON
[Engine is running]
BATTERY VOLTAGE
(11 - 14V)
115
116
B
B
ECM ground
119
120
SB
GY
Power supply for ECM
BATTERY VOLTAGE
(11 - 14V)
121
W/L

(Back-up)
BATTERY VOLTAGE
(11 - 14V)
Idle speed
: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)
EC-101
http://vnx.su
Body ground
TROUBLE DIAGNOSIS
CONSULT-II Function (ENGINE)
EBS010LY
FUNCTION
Diagnostic test mode
Function
Work support
This mode enables a technician to adjust some devices faster and more accurately by following the
indications on the CONSULT-II unit.
Self-diagnostic results
Self-diagnostic results such as 1st trip DTC, DTCs and 1st trip freeze frame data or freeze frame data
can be read and erased quickly.*
Data monitor
Input/Output data in the ECM can be read.
Data monitor (SPEC)
Input/Output of the specification for Basic fuel schedule, AFM, A/F feedback control value and the
other data monitor items can be read.
CAN diagnostic support

monitor
The results of transmit/receive diagnosis of CAN communication can be read.
Active test
Diagnostic Test Mode in which CONSULT-II drives some actuators apart from the ECMs and also
shifts some parameters in a specified range.
Function test
This mode is used to inform customers when their vehicle condition requires periodic maintenance.
DTC & SRT confirmation
The status of system monitoring tests and the self-diagnosis status/result can be confirmed.
ECM part number
ECM part number can be read.
*: The following emission-related diagnostic information is cleared when the ECM memory is erased.
Freeze frame data
Test values
EC-102
http://vnx.su
TROUBLE DIAGNOSIS
ENGINE CONTROL COMPONENT PARTS/CONTROL SYSTEMS APPLICATION
A
DIAGNOSTIC TEST MODE

SELF-DIAGNOSTIC RESULTS
WORK
SUPPORT
Item
DTC*1
FREEZE
FRAME
INPUT
ENGINE CONTROL COMPONENT PARTS
DATA*
ACTIVE
TEST
SRT
STATUS
DTC
WORK
SUPPORT
Knock sensor
Closed throttle position switch

(accelerator pedal position sensor
signal)
Stop lamp switch
Battery voltage
ASCD brake switch*3
Fuel injector
Power transistor (Ignition timing)

solenoid valve

Fuel pump relay
EC
OUTPUT
DTC & SRT

CONFIRMATION
ASCD clutch switch*
DATA
MONITOR
DATA
MONITOR
(SPEC)
Cooling fan relay

valve
Calculated load value

X: Applicable
EC-103
http://vnx.su
TROUBLE DIAGNOSIS
*1: This item includes 1st trip DTCs.
*2: This mode includes 1st trip freeze frame data or freeze frame data. The items appear on CONSULT-II screen in freeze frame data
mode only if a 1st trip DTC or DTC is detected. For details, refer to EC-55, "FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME
DATA" .
INSPECTION PROCEDURE
1.
2.
3.

Connect CONSULT-II and CONSULT-II CONVERTER to data
link connector, which is located under driver side dash panel.
PBIB0376E
4.
Touch START(NISSAN BASED VHCL).
BCIA0029E
5.
Touch ENGINE.
If ENGINE is not indicated, go to GI-35, "CONSULT-II Data
Link Connector (DLC) Circuit" .
BCIA0030E
6.
Perform each diagnostic test mode according to each service

procedure.
For further information, see the CONSULT-II Operation Manual.
BCIA0031E
EC-104
http://vnx.su
TROUBLE DIAGNOSIS
WORK SUPPORT MODE
Work Item
WORK ITEM
CONDITION
USAGE
FUEL PUMP WILL STOP BY TOUCHING START DURING IDLING.

CRANK A FEW TIMES AFTER ENGINE STALLS.
When releasing fuel pressure

from fuel line
IDLE AIR VOL LEARN
THE IDLE AIR VOLUME THAT KEEPS THE ENGINE

WITHIN THE SPECIFIED RANGE IS MEMORIZED IN
ECM.
When learning the idle air volume
SELF-LEARNING CONT
THE COEFFICIENT OF SELF-LEARNING CONTROL

MIXTURE RATIO RETURNS TO THE ORIGINAL COEFFICIENT.
When clearing the coefficient of

self-learning control value
TARGET IDLE RPM ADJ*
IDLE CONDITION
When setting target idle speed
TARGET IGN TIM ADJ*
IDLE CONDITION
When adjusting target ignition timing
EC
*: This function is not necessary in the usual service procedure.
SELF-DIAG RESULTS MODE

Self Diagnostic Item
Regarding items of DTC and 1st trip DTC, refer to EC-19, "INDEX FOR DTC" .
Freeze Frame Data and 1st Trip Freeze Frame Data

Freeze frame data
item*
DIAG TROUBLE
CODE
[PXXXX]
Description
The engine control component part/control system has a trouble code, it is displayed as PXXXX. (Refer to
EC-19, "INDEX FOR DTC" .)
Fuel injection system status at the moment a malfunction is detected is displayed.
One mode in the following is displayed.

Mode2: Open loop due to detected system malfunction
Mode3: Open loop due to driving conditions (power enrichment, deceleration enleanment)
Mode4: Closed loop - using oxygen sensor(s) as feedback for fuel control
Mode5: Open loop - has not yet satisfied condition to go to closed loop
FUEL SYS-B1
CAL/LD VALUE [%]
The calculated load value at the moment a malfunction is detected is displayed.
COOLANT TEMP
[C] or [F]
The engine coolant temperature at the moment a malfunction is detected is displayed.
Long-term fuel trim at the moment a malfunction is detected is displayed.
The long-term fuel trim indicates much more gradual feedback compensation to the base fuel schedule
than short-term fuel trim.
Short-term fuel trim at the moment a malfunction is detected is displayed.
S-FUEL TRM-B1 [%]
The short-term fuel trim indicates dynamic or instantaneous feedback compensation to the base fuel
schedule.
ENGINE SPEED
[rpm]
The engine speed at the moment a malfunction is detected is displayed.
VEHICL SPEED
[km/h] or [mph]
The vehicle speed at the moment a malfunction is detected is displayed.
B/FUEL SCHDL
[msec]
The base fuel schedule at the moment a malfunction is detected is displayed.
INT/A TEMP SE
[C] or [F]
The intake air temperature at the moment a malfunction is detected is displayed.
L-FUEL TRM-B1 [%]
*: The items are the same as those of 1st trip freeze frame data.
EC-105
http://vnx.su
TROUBLE DIAGNOSIS
DATA MONITOR MODE
Monitored Item
Monitored item
[Unit]
ECM
INPUT
SIGNALS
: Applicable
MAIN
SIGNALS
Description
ENG SPEED [rpm]
MAS A/F SE-B1 [V]
B/FUEL SCHDL
[msec]
COOLAN TEMP/S
[C] or [F]
HO2S1 (B1) [V]
HO2S2 (B1) [V]
HO2S1 MNTR (B1)

[RICH/LEAN]
The signal voltage of the mass air flow sensor

is displayed.
Base fuel schedule indicates the fuel injection pulse width programmed into ECM, prior
to any learned on board correction.
A/F ALPHA-B1 [%]
Indicates the engine speed computed from the

signals of the crankshaft position sensor
(POS) and camshaft position sensor (PHASE).
The mean value of the air-fuel ratio feedback

correction factor per cycle is indicated.
The engine coolant temperature (determined

by the signal voltage of the engine coolant
temperature sensor) is displayed.
The signal voltage of the heated oxygen sensor 1 is displayed.
Display of heated oxygen sensor 1 signal during air-fuel ratio feedback control:
RICH: means the mixture became rich, and
control is being affected toward a leaner mixture.
LEAN: means the mixture became lean, and
control is being affected toward a rich mixture.
Display of heated oxygen sensor 2 signal:

RICH: means the amount of oxygen after three
way catalyst is relatively small.
LEAN: means the amount of oxygen after
three way catalyst is relatively large.
HO2S2 MNTR (B1)

[RICH/LEAN]
VHCL SPEED SE
[km/h] or [mph]
The vehicle speed computed from the vehicle

speed signal is displayed.
BATTERY VOLT [V]
The power supply voltage of ECM is displayed.
ACCEL SEN 1 [V]
The accelerator pedal position sensor signal

voltage is displayed.
The throttle position sensor signal voltage is

displayed.
ACCEL SEN 2 [V]
THRTL SEN 1 [V]
THRTL SEN 2 [V]
EC-106
http://vnx.su
Remarks
Accuracy becomes poor if engine

speed drops below the idle rpm.
If the signal is interrupted while

the engine is running, an abnormal value may be indicated.
When the engine is stopped, a

certain value is indicated.

This data also includes the data

for the air-fuel ratio learning control.
When the engine coolant temperature sensor is open or short-circuited, ECM enters fail-safe
mode. The engine coolant temperature determined by the ECM
is displayed.
After turning ON the ignition

switch, RICH is displayed until
air-fuel mixture ratio feedback
control begins.
When the air-fuel ratio feedback

is clamped, the value just before
the clamping is displayed continuously.

ACCEL SEN 2 signal is converted by ECM internally. Thus, it

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

differs from ECM terminal voltage
signal.
TROUBLE DIAGNOSIS
Monitored item
[Unit]
ECM
INPUT
SIGNALS
MAIN
SIGNALS
INT/A TEMP SE [C]

or [F]
START SIGNAL
[ON/OFF]
CLSD THL POS

[ON/OFF]
AIR COND SIG

[ON/OFF]
P/N POSI SW
[ON/OFF]
PW/ST SIGNAL
[ON/OFF]
LOAD SIGNAL [ON/

OFF]
Description
The intake air temperature (determined by the

signal voltage of the intake air temperature
sensor) is indicated.
Indicates start signal status [ON/OFF] computed by the ECM according to the signals of
engine speed and battery voltage.
Indicates [ON/OFF] condition from the park/

neutral position (PNP) switch signal.
[ON/OFF] condition of the power steering

pressure sensor as determined by the power
steering pressure sensor is indicated.
Indicates [ON/OFF] condition from the electrical load signal.

ON: Rear window defogger switch is ON and/
or lighting switch is in 2nd position (placed in
LOW position for models with Xenon headlamp).
OFF: Both rear window defogger switch and
lighting switch are OFF.
Indicates [ON/OFF] condition from ignition
switch.
HEATER FAN SW
[ON/OFF]
Indicates [ON/OFF] condition from the heater

fan switch signal.
BRAKE SW
[ON/OFF]
Indicates [ON/OFF] condition from the stop

lamp switch signal.
CAL/LD VALUE [%]

MASS AIRFLOW
[gm/s]
Indicates the actual fuel injection pulse width

compensated by ECM according to the input
signals.

certain computed value is indicated.
Indicates the ignition timing computed by ECM

according to the input signals.

Calculated load value indicates the value of

the current airflow divided by peak airflow.
Indicates the mass airflow computed by ECM

according to the signal voltage of the mass air
flow sensor.
Indicates the EVAP canister purge volume

control solenoid valve control value computed
by the ECM according to the input signals.
The opening becomes larger as the value

increases.
Indicates [CA] of intake camshaft advanced

angle.
The control value of the intake valve timing

control solenoid valve (determined by ECM
according to the input signal) is indicated.
The advance angle becomes larger as the

value increases
INT/V SOL (B1) [%]
PURG VOL C/V [%]
INT/V TIM (B1)

[CA]
After starting the engine, [OFF] is

displayed regardless of the
starter signal.
Indicates [ON/OFF] condition of the air conditioner switch as determined by the air conditioner signal.
IGN TIMING [BTDC]
EC
IGNITION SW
[ON/OFF]
INJ PULSE-B1
[msec]
Indicates idle position [ON/OFF] computed by

the ECM according to the accelerator pedal
position sensor signal.
Remarks
EC-107
http://vnx.su
TROUBLE DIAGNOSIS
Monitored item
[Unit]
ECM
INPUT
SIGNALS
MAIN
SIGNALS
Description
The control condition of the VIAS control solenoid valve (determined by ECM according to
the input signals) is indicated.
ON: VIAS control solenoid valve is operating.
OFF: VIAS control solenoid valve is not operating.
The air conditioner relay control condition

(determined by ECM according to the input
signals) is indicated.
Indicates the fuel pump relay control condition

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

signals).
HI: High speed operation
LOW: Low speed operation
OFF: Stop
Indicates [ON/OFF] condition of heated oxygen sensor 1 heater determined by ECM


Display the condition of idle air volume learning

YET: Idle Air Volume Learning has not been
performed yet.
CMPLT: Idle Air Volume Learning has already
been performed successfully.
Distance traveled while MI is activated.
The signal voltage from the refrigerant pressure sensor is displayed.

speed signal sent from TCM is displayed.
The preset vehicle speed is displayed.
MAIN SW*
[ON/OFF]
Indicates [ON/OFF] condition from MAIN

switch signal.
CANCEL SW*
[ON/OFF]
Indicates [ON/OFF] condition from CANCEL

switch signal.
RESUME/ACC SW*
[ON/OFF]
Indicates [ON/OFF] condition from RESUME/

ACCELERATE switch signal.
SET SW*
[ON/OFF]
Indicates [ON/OFF] condition from SET/

COAST switch signal.
BRAKE SW1*
[ON/OFF]
Indicates [ON/OFF] condition from ASCD

brake switch signal.
BRAKE SW2*
[ON/OFF]
Indicates [ON/OFF] condition of stop lamp

switch signal.
VIAS S/V*
[ON/OFF]
AIR COND RLY

[ON/OFF]
FUEL PUMP RLY

[ON/OFF]
THRTL RELAY [ON/

OFF]
COOLING FAN
[HI/LOW/OFF]
HO2S1 HTR (B1)

[ON/OFF]
HO2S2 HTR (B1)
[ON/OFF]
IDL A/V LEARN

[YET/CMPLT]
TRVL AFTER MIL

[km] or [mile]
AC PRESS SEN [V]
VHCL SPEED SE*
[km/h] or [mph]
SET VHCL SPD*
[km/h] or [mph]
EC-108
http://vnx.su
Remarks
TROUBLE DIAGNOSIS
Monitored item
[Unit]
ECM
INPUT
SIGNALS
MAIN
SIGNALS
Description
VHCL SPD CUT*

[NON/CUT]
LO SPEED CUT*
[NON/CUT]
Remarks
Indicates the vehicle cruise condition.

NON: Vehicle speed is maintained at the
ASCD set speed.
CUT: Vehicle speed increased to excessively
high compared with the ASCD set speed, and
ASCD operation is cut off.
EC

ASCD set speed.
CUT: Vehicle speed decreased to excessively
low compared with the ASCD set speed, and
AT OD MONITOR
[ON/OFF]
Indicates [ON/OFF] condition of A/T O/D

according to the input signal from the TCM.
For M/T models, always OFF is

displayed.
AT OD CANCEL
[ON/OFF]
Indicates [ON/OFF] condition of A/T O/D cancel signal sent from the TCM.

displayed.
Indicates [ON/OFF] condition of CRUISE lamp

determined by the ECM according to the input
signals.
Indicates [ON/OFF] condition of SET lamp

signals.
CRUISE LAMP*
[ON/OFF]
SET LAMP*
[ON/OFF]
Voltage [V]
Frequency
[msec], [Hz] or [%]
DUTY-HI
DUTY-LOW
Voltage, frequency, duty cycle or pulse width

measured by the probe.
PLS WIDTH-HI
Only # is displayed if item is

unable to be measured.
Figures with #s are temporary

ones. They are the same figures
as an actual piece of data which
was just previously measured.
PLS WIDTH-LOW

NOTE:
Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.
DATA MONITOR (SPEC) MODE

Monitored Item
Monitored item [Unit]
ECM
input
signals
ENG SPEED [rpm]
MAS A/F SE-B1 [V]
Main
signals
Description
Indicates the engine speed computed

from the signals of the crankshaft position sensor (POS) and camshaft position
sensor (PHASE).
The signal voltage of the mass air flow

sensor specification is displayed.
Base fuel schedule indicates the fuel

injection pulse width programmed into
ECM, prior to any learned on board correction.
B/FUEL SCHDL
[msec]
A/F ALPHA-B1 [%]
The mean value of the air-fuel ratio feedback correction factor per cycle is indicated.
EC-109
http://vnx.su
Remarks
When engine is running specification

range is indicated.

range is indicated.

range is indicated.
This data also includes the data for the

air-fuel ratio learning control.
TROUBLE DIAGNOSIS
NOTE:
ACTIVE TEST MODE

Test Item
TEST ITEM
CONDITION
FUEL INJECTION
IGNITION TIMING
COOLING FAN*
Engine: Return to the original

trouble condition
Timing light: Set
Retard the ignition timing using

CONSULT-II.
Engine: After warming up, idle

the engine.
FUEL PUMP RELAY
VIAS SOL VALVE*2
PURG VOL CONT/V
If trouble symptom disappears,

see CHECK ITEM.

see CHECK ITEM.
CHECK ITEM (REMEDY)
Harness and connectors
Fuel injector
Perform Idle Air Volume Learning.
Compression
Fuel injector
Power transistor
Air conditioner switch: OFF
Shift lever: N (A/T), Neutral (M/T)
Cut off each injector signal one at

a time using CONSULT-II.
Spark plug
Ignition coil
Ignition switch: ON
Turn the cooling fan LOW, HI,

OFF with CONSULT-II.
Cooling fan relay
Cooling fan motor
Fuel injector
Fuel pump relay makes the operating sound.
Fuel pump relay
Solenoid valve makes an operating sound.
Solenoid valve
Engine speed changes according

to the opening percent.
Solenoid valve
ENG COOLANT
TEMP
Change the amount of fuel injection using CONSULT-II.
POWER BALANCE

trouble condition
JUDGEMENT

trouble condition
Change the engine coolant temperature using CONSULT-II.
Ignition switch: ON (Engine

stopped)
Turn the fuel pump relay ON and

OFF using CONSULT-II and listen to operating sound.
Ignition switch: ON
Turn solenoid valve ON and OFF

with CONSULT-II and listen for
operating sound.
Engine: After warming up, run

engine at 1,500 rpm.
Change the EVAP canister purge

volume control solenoid valve
opening percent using CONSULT-II.
V/T ASSIGN ANGLE

trouble condition
Change intake valve timing using
CONSULT-II.
Engine runs rough or dies.
Cooling fan moves and stops.

see CHECK ITEM.

see CHECK ITEM.
*1:Leaving cooling fan OFF with CONSULT-II while engine is running may cause the engine to overheat.
DTC & SRT CONFIRMATION MODE

SRT STATUS Mode
For details, refer to EC-55, "SYSTEM READINESS TEST (SRT) CODE" .
SRT WORK SUPPORT Mode

This mode enables a technician to drive a vehicle to set the SRT while monitoring the SRT status.
EC-110
http://vnx.su
TROUBLE DIAGNOSIS
DTC WORK SUPPORT Mode
Test mode
HO2S1
Test item
Condition
HO2S1 (B1) P0133
EC-185
HO2S1 (B1) P0134
EC-195
HO2S1 (B1) P1143
EC-321
Refer to corresponding
trouble diagnosis for
DTC.
HO2S1 (B1) P1144

HO2S2 (B1) P0139
H02S2
Reference page
EC
EC-327
EC-210
HO2S2 (B1) P1146
EC-333
HO2S2 (B1) P1147
EC-341
REAL TIME DIAGNOSIS IN DATA MONITOR MODE (RECORDING VEHICLE DATA)

Description
CONSULT-II has two kinds of triggers and they can be selected by touching SETTING in DATA MONITOR
mode.
1. AUTO TRIG (Automatic trigger):
The malfunction will be identified on the CONSULT-II screen
in real time.
In other words, DTC/1st trip DTC and malfunction item will be
displayed if the malfunction is detected by ECM.
At the moment a malfunction is detected by ECM, MONITOR in DATA MONITOR screen is changed to Recording
Data ... xx% as shown at right, and the data after the malfunction detection is recorded. Then when the percentage
reached 100%, REAL-TIME DIAG screen is displayed. If
STOP is touched on the screen during Recording Data ...
xx%, REAL-TIME DIAG screen is also displayed.
SEF705Y
The recording time after the malfunction detection and the
recording speed can be changed by TRIGGER POINT and
Recording Speed. Refer to CONSULT-II Operation Manual.
2. MANU TRIG (Manual trigger):
DTC/1st trip DTC and malfunction item will not be displayed
automatically on CONSULT-II screen even though a malfunction is detected by ECM.
DATA MONITOR can be performed continuously even though
a malfunction is detected.
SEF707X
Operation
1.
2.
AUTO TRIG
While trying to detect the DTC/1st trip DTC by performing the DTC Confirmation Procedure, be sure to
select to DATA MONITOR (AUTO TRIG) mode. You can confirm the malfunction at the moment it is
detected.
While narrowing down the possible causes, CONSULT-II should be set in DATA MONITOR (AUTO
TRIG) mode, especially in case the incident is intermittent.
When you are inspecting the circuit by gently shaking (or twisting) the suspicious connectors, components and harness in the DTC Confirmation Procedure, the moment a malfunction is found the DTC/
1st trip DTC will be displayed. (Refer to Incident Simulation Tests in GI-23, "How to Perform Efficient
Diagnosis for an Electrical Incident" .)
MANU TRIG
If the malfunction is displayed as soon as DATA MONITOR is selected, reset CONSULT-II to MANU
TRIG. By selecting MANU TRIG you can monitor and store the data. The data can be utilized for further diagnosis, such as a comparison with the value for the normal operating condition.
EC-111
http://vnx.su
TROUBLE DIAGNOSIS
PBIB0197E
Generic Scan Tool (GST) Function
EBS010LZ
DESCRIPTION
Generic Scan Tool (OBDII scan tool) complying with ISO 15031-4
has 8 different functions explained below.
ISO9141 is used as the protocol.
The name GST or Generic Scan Tool is used in this service manual.
SEF139P
FUNCTION
Function
Service $01
READINESS TESTS
This diagnostic service gains access to current emission-related data values, including
analog inputs and outputs, digital inputs and outputs, and system status information.
Service $02
(FREEZE DATA)
This diagnostic service gains access to emission-related data value which were stored by
ECM during the freeze frame. For details, refer to EC-55, "FREEZE FRAME DATA AND
1ST TRIP FREEZE FRAME DATA" .
Service $03
DTCs
This diagnostic service gains access to emission-related power train trouble codes which
were stored by ECM.
EC-112
http://vnx.su
TROUBLE DIAGNOSIS
Function
This diagnostic service can clear all emission-related diagnostic information. This
includes:
Service $04
CLEAR DIAG INFO
Clear number of diagnostic trouble codes (Service $01)
Clear diagnostic trouble codes (Service $03)
Clear trouble code for freeze frame data (Service $01)
Clear freeze frame data (Service $02)
Reset status of system monitoring test (Service $01)
Clear on board monitoring test results (Service $06 and $07)
EC
Service $06
(ON BOARD TESTS)
This diagnostic service accesses the results of on board diagnostic monitoring tests of
specific components/systems that are not continuously monitored.
Service $07
(ON BOARD TESTS)
This diagnostic service enables the off board test drive to obtain test results for emissionrelated powertrain components/systems that are continuously monitored during normal
driving conditions.
Service $08
Service $09
(CALIBRATION ID)
This diagnostic service is not applicable on this vehicle.

This diagnostic service enables the off-board test device to request specific vehicle information such as Vehicle Identification Number (VIN) and Calibration IDs.
1.
2.
3.

Connect GST to data link connector, which is located under
driver side dash panel near the fuse box cover.
J
PBIB0376E
4.
Enter the program according to instruction on the screen or in

the operation manual.
(*: Regarding GST screens in this section, sample screens are
shown.)
SEF398S
5.
Perform each diagnostic mode according to each service procedure.

For further information, see the GST Operation Manual of the
tool maker.
SEF416S
EC-113
http://vnx.su
TROUBLE DIAGNOSIS
EBS010M0
Remarks:
Specification data are reference values.
Specification data are output/input values which are detected or supplied by the ECM at the connector.
* Specification data may not be directly related to their components signals/values/operations.
i.e. Adjust ignition timing with a timing light before monitoring IGN TIMING, because the monitor may show the specification data in
spite of the ignition timing not being adjusted to the specification data. This IGN TIMING monitors the data calculated by the ECM
according to the signals input from the camshaft position sensor and other ignition timing related sensors.
MONITOR ITEM
CONDITION
SPECIFICATION
ENG SPEED
Run engine and compare CONSULT-II value with the tachometer indication.
MAS A/F SE-B1
See EC-119, "TROUBLE DIAGNOSIS - SPECIFICATION VALUE" .
B/FUEL SCHDL
A/F ALPHA-B1
COOLAN TEMP/S
Engine: After warming up
HO2S1 (B1)
Keeping the engine speed

between 3,800 and 4,000 rpm
for 1 minute and at idle for 1
minute under no load.
HO2S2 (B1)
HO2S1 MNTR (B1)

HO2S2 MNTR (B1)
VEH SPEED SE
BATTERY VOLT
ACCEL SEN 1
ACCEL SEN 2*1
THRTL SEN 1
THRTL SEN 2*
CLSD THL POS
AIR COND SIG
P/N POSI SW
PW/ST SIGNAL

Maintaining engine speed at 2,000
rpm
0 - 0.3V Approx. 0.6 - 1.0V
Revving engine from idle to 3,000 rpm

quickly.
0 - 0.3V Approx. 0.6 - 1.0V

rpm
LEAN RICH
Changes more than 5 times
during 10 seconds.

quickly.
LEAN RICH
Turn drive wheels and compare CONSULT-II value with the speedometer indication.
Almost the same speed as the

speedometer indication.
Ignition switch: ON (Engine stopped)
11 - 14V
Ignition switch: ON
(Engine stopped)
0.5 - 1.0V
4.0 - 4.7V
Ignition switch: ON
(Engine stopped)
0.3 - 1.2V
3.9 - 4.8V
Ignition switch: ON
(Engine stopped)
More than 0.36V
Less than 4.75V
Ignition switch: ON START ON
START SIGNAL

tachometer indication.
Ignition switch: ON

the engine
Ignition switch: ON
the engine
OFF ON OFF
ON
Accelerator pedal: Slightly depressed
OFF
OFF
Air conditioner switch: ON

(Compressor operates.)
ON
ON
Shift lever: Except above
OFF
Steering wheel is not turned.
OFF
Steering wheel is turned.
ON
EC-114
http://vnx.su
TROUBLE DIAGNOSIS
MONITOR ITEM
LOAD SIGNAL
IGNITION SW
HEATER FAN SW
BRAKE SW
INJ PULSE-B1
IGN TIMING
CAL/LD VALUE
MASS AIRFLOW
PURG VOL C/V
INT/V TIM (B1)
INT/V SOL (B1)
VIAS S/V*2
CONDITION
Ignition switch: ON
Ignition switch: ON
Shift lever: P or N (A/T), Neutral

(M/T)
No load

(M/T)
No load

(M/T)
No load

(M/T)
No load

(M/T)
No load

(M/T)
No load

(M/T)
No load
Rear window defogger switch is ON

and/or lighting switch is in 2nd (placed
in LOW position for models with
Xenon headlamp).
ON
Rear window defogger switch is OFF

and lighting switch is OFF.
OFF
Ignition switch: ON OFF ON

Ignition switch: ON
SPECIFICATION
EC
ON OFF ON
Heater fan is operating.
ON
Heater fan is not operating
OFF
OFF
ON
Idle
2.0 - 3.0 msec
2,000 rpm
1.9 - 2.9 msec
Idle
13 - 17 BTDC
G
2,000 rpm
25 - 45 BTDC
H
Idle
10% - 35%
2,500 rpm
10% - 35%
Idle
1.0 - 4.0 gm/s
2,500 rpm
4.0 - 10.0 gm/s
Idle
0%
2,000 rpm
20 - 30%
M
Idle
5 - 5CA
2,000 rpm
Approx. 0 - 20CA
Idle
0% - 2%
2,000 rpm
Approx. 0% - 50%
Idle
OFF
More than 5,000 rpm
ON
EC-115
http://vnx.su
TROUBLE DIAGNOSIS
MONITOR ITEM
CONDITION
AIR COND RLY
FUEL PUMP RLY
THRTL RELAY
HO2S2 HTR (B1)
TRVL AFTER MIL
OFF

ON
Engine running or cranking
Except above conditions
OFF
Ignition switch: ON
ON

the engine
COOLING FAN
HO2S1 HTR (B1)

the engine
SPECIFICATION
ON
Engine coolant temperature is 94C

(201F) or less
OFF
Engine coolant temperature is

between 95C (203F) and 99C
(210F)
LOW

(212F) or more
HIGH
Engine speed: Below 3,600 rpm
Engine speed: Above 3,600 rpm
Engine speed is below 3,600 rpm after the following conditions are met.
Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute
and at idle for 1 minute under no load.
ON
OFF
ON
OFF
Vehicle has traveled after MI has
turned ON.
0 - 65,535 km
(0 - 40,723 mile)
Ignition switch: ON
Engine coolant temperature when engine started: More than 80C

(176F)
Engine speed: below 3,600 rpm
Engine: Idle
Air conditioner switch: ON (Compressor operates)

speedometer indication
SET VHCL SPD*2
Engine: Running
MAIN SW*2
Ignition switch: ON
CANCEL SW*2
O2SEN HTR DTY
AC PRESS SEN
VEH SPEED SE
RESUME/ACC SW*
SET SW*2
BRAKE SW1*
BRAKE SW2*2
Ignition switch: ON
Ignition switch: ON
Ignition switch: ON
Ignition switch: ON
Ignition switch: ON
ASCD: Operating.
Approx. 50%
1.0 - 4.0V
ON
MAIN switch: Released
OFF
ON
CANCEL switch: Released
OFF
RESUME/ACCELERATE switch:
Pressed
ON
Released
OFF
ON
SET/COAST switch: Released
OFF
Both clutch pedal (M/T) and brake

pedal: Fully released
ON
Clutch pedal (M/T) and/or brake

pedal: Slightly depressed
OFF
OFF
ON
EC-116
http://vnx.su
TROUBLE DIAGNOSIS
MONITOR ITEM
CRUISE LAMP*2
SET LAMP*2
CONDITION
SPECIFICATION
Ignition switch: ON
MAIN switch: Pressed at the 1st time

at the 2nd time
ON OFF
MAIN switch: ON
ASCD: Operating
ON
Vehicle speed: Between 40 km/

h (25 MPH) and 144 km/h (89
MPH)
ASCD: Not operating
OFF
EC
*1: Accelerator pedal position sensor 2 signal and throttle position sensor 2 signal are converted by ECM internally. Thus, they differ
from ECM terminals voltage signal.
Major Sensor Reference Graph in Data Monitor Mode
D
EBS010M1
The following are the major sensor reference graphs in DATA MONITOR mode.
CLSD THL POS, ACCEL SEN 1, THRTL SEN 1
Below is the data for CLSD THL POS, ACCEL SEN 1 and THRTL SEN 1 when depressing the accelerator pedal with the ignition switch ON and with selector lever in D position (A/T models) or with shift lever in 1st
position (M/T models).
The signal of ACCEL SEN 1 and THRTL SEN 1 should rise gradually without any intermittent drop or rise
after CLSD THL POS is changed from ON to OFF.
PBIB0198E
ENG SPEED, MAS A/F SE-B1, THRTL SEN 1, HO2S2 (B1), HO2S1 (B1), INJ PULSE-B1
Below is the data for ENG SPEED, MAS A/F SE-B1, THRTL SEN 1, HO2S2 (B1), HO2S1 (B1) and
INJ PULSE-B1 when revving engine quickly up to 4,800 rpm under no load after warming up engine sufficiently.
Each value is for reference, the exact value may vary.
PBIB2445E
EC-117
http://vnx.su
TROUBLE DIAGNOSIS
PBIB0668E
EC-118
http://vnx.su
TROUBLE DIAGNOSIS - SPECIFICATION VALUE


Description
PFP:00031
A
EBS010M2
The specification (SP) value indicates the tolerance of the value that is displayed in DATA MONITOR (SPEC)
mode of CONSULT-II during normal operation of the Engine Control System. When the value in DATA MONI- EC
TOR (SPEC) mode is within the SP value, the Engine Control System is confirmed OK. When the value in
DATA MONITOR (SPEC) mode is NOT within the SP value, the Engine Control System may have one or
more malfunctions.
The SP value is used to detect malfunctions that may affect the Engine Control System, but will not light the C
MIL.
The SP value will be displayed for the following three items:
B/FUEL SCHDL (The fuel injection pulse width programmed into ECM prior to any learned on board cor- D
rection)
A/F ALPHA-B1 (The mean value of air-fuel ratio feedback correction factor per cycle)
E
MAS A/F SE-B1 (The signal voltage of the mass air flow sensor)
Testing Condition
EBS010M3
Vehicle driven distance: More than 5,000 km (3,017 miles)
F
2
Barometric pressure: 98.3 - 104.3 kPa (0.983 - 1.043 bar, 1.003 - 1.064 kg/cm , 14.25 - 15.12 psi)
Atmospheric temperature: 20 - 30C (68 - 86F)
Transmission: Warmed-up*1
Electrical load: Not applied*2
Engine speed: Idle

*1: For A/T models, after the engine is warmed up to normal operating temperature, drive vehicle until FLUID
TEMP SE (A/T fluid temperature sensor signal) indicates more than 60C (140F).
For M/T models, after the engine is warmed up to normal operating temperature, drive vehicle for 5 minutes.
*2: Rear window defogger switch, air conditioner switch, lighting switch are OFF. Steering wheel is straight
ahead.
Inspection Procedure
EBS010M4
NOTE:
Perform DATA MONITOR (SPEC) mode in maximum scale display.
1. Perform EC-78, "Basic Inspection" .
2. Confirm that the testing conditions indicated above are met.
3. Select B/FUEL SCHDL, A/F ALPHA-B1 and MAS A/F SEB1 in DATA MONITOR (SPEC) mode with CONSULT-II.
4. Make sure that monitor items are within the SP value.
5. If NG, go to EC-120, "Diagnostic Procedure" .
SEF601Z
EC-119
http://vnx.su

Diagnostic Procedure
EBS010M5
SEF613ZD
EC-120
http://vnx.su

A
EC
SEF768Z
EC-121
http://vnx.su

SEF615ZA
EC-122
http://vnx.su
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT


Description
PFP:00006
A
EBS010M6
Intermittent incidents may occur. In many cases, the malfunction resolves itself (the part or circuit function
returns to normal without intervention). It is important to realize that the symptoms described in the customer's EC
complaint often do not recur on (1st trip) DTC visits. Realize also that the most frequent cause of intermittent
incident occurrences is poor electrical connections. Because of this, the conditions under which the incident
occurred may not be clear. Therefore, circuit checks made as part of the standard diagnostic procedure may
C
not indicate the specific malfunctioning area.
Common Intermittent Incident Report Situations
STEP in Work Flow
Situation
II
The CONSULT-II is used. The SELF-DIAG RESULTS screen shows time data other than [0] or [1t].
III
The symptom described by the customer does not recur.
IV
(1st trip) DTC does not appear during the DTC Confirmation Procedure.
VI
The Diagnostic Procedure for PXXXX does not indicate the malfunctioning area.
EBS010M7
1. INSPECTION START
Erase (1st trip) DTCs. Refer to EC-62, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" .
H
>> GO TO 2.
2. CHECK GROUND TERMINALS
Check ground terminals for corroding or loose connection.

Refer to EC-131, "Ground Inspection" .
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace.
3. SEARCH FOR ELECTRICAL INCIDENT

Perform GI-23, "How to Perform Efficient Diagnosis for an Electrical Incident" , Incident Simulation Tests.
OK or NG
OK
>> INSPECTION END
NG
EC-123
http://vnx.su
POWER SUPPLY AND GROUND CIRCUIT


Wiring Diagram
PFP:24110
EBS010M8
TBWA0594E
EC-124
http://vnx.su

CAUTION:
TERMINAL
NO.
1
EC
WIRE
COLOR
B
ITEM
ECM ground
CONDITION
[Engine is running]
109
B/R
Idle speed
BATTERY VOLTAGE
(11 - 14V)
Ignition switch
ECM relay
(Self shut-off)
115
116
B
B
ECM ground
119
120
SB
GY
Power supply for

ECM

OFF
More than a few seconds passed turning ignition

switch OFF
[Engine is running]
Idle speed
Body ground
0V
G/W
DATA (DC Voltage)
[Engine is running]
111
0 - 1.0V
BATTERY VOLTAGE
(11 - 14V)
Body ground
BATTERY VOLTAGE
(11 - 14V)
H
EBS010M9
1. INSPECTION START
Start engine.
Is engine running?
Yes or No
Yes
>> GO TO 11.
No
>> GO TO 2.
2. CHECK ECM POWER SUPPLY CIRCUIT-I

1.
2.
Turn ignition switch OFF and then ON.

Check voltage between ECM terminal 109 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.
MBIB0015E

Fuse block (J/B) connector M1
10A fuse
Harness for open or short between ECM and fuse

>> Repair open circuit or short to ground or short to power in harness or connectors.
EC-125
http://vnx.su

4. CHECK GROUND CONNECTIONS

1.
2.

Loosen and retighten three ground screws on the body.
PBIB2021E
OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace ground connections.
5. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-I

1.
2.
3.

Disconnect ECM harness connector.
Check harness continuity between ECM terminals 1, 115, 116 and ground.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to power.

OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to power in harness or connectors.
EC-126
http://vnx.su

6. CHECK ECM POWER SUPPLY CIRCUIT-II

1.
Disconnect ECM relay.

EC
D
PBIB1973E
2.
Check voltage between ECM relay terminals 1, 6 and ground

with CONSULT-II or tester.
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.
SEF420X

Harness connectors E61, F38
20A fuse
Harness for open or short between ECM relay and battery

8. CHECK OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1.
Check harness continuity between ECM terminal 111 and ECM relay terminal 2.
2. Also check harness for short to ground and short to power.

OK or NG
OK
>> GO TO 10.
NG
>> GO TO 9.

Harness connectors F41, M61
Harness for open or short between ECM relay and ECM

EC-127
http://vnx.su

10. CHECK ECM RELAY

Refer to EC-131, "Component Inspection" .
OK or NG
OK
>> Go to EC-439, "IGNITION SIGNAL" .
NG
>> Replace ECM relay.
11. CHECK ECM POWER SUPPLY CIRCUIT-III

1.
2.
3.

Turn ignition switch ON and then OFF.
Check voltage between ECM terminals 119, 120 and ground
Voltage:
After turning ignition switch OFF, battery

voltage will exist for a few seconds, then
drop approximately 0V.
PBIB1630E
OK or NG
OK
>> GO TO 17.
NG (Battery voltage does not exist.)>>GO TO 12.
NG (Battery voltage exists for more than a few seconds.)>>GO TO 14.
12. CHECK ECM POWER SUPPLY CIRCUIT-IV

1.
PBIB1973E
2.
Check voltage between ECM relay terminal 3 and ground with

OK or NG
OK
>> GO TO 14.
NG
>> GO TO 13.
SEF860T
EC-128
http://vnx.su

10A fuse

14. CHECK ECM POWER SUPPLY CIRCUIT-V

1.
2.

Check harness continuity between ECM terminals 119, 120 and ECM relay terminal 5.
EC

OK or NG
OK
>> GO TO 16.
NG
>> GO TO 15.

16. CHECK ECM RELAY

OK or NG
OK
>> GO TO 17.
NG
EC-129
http://vnx.su


PBIB2021E
OK or NG
OK
>> GO TO 18.
NG
18. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-II

1.
2.


OK or NG
OK
>> GO TO 19.
NG
19. CHECK INTERMITTENT INCIDENT

Refer to EC-123, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
>> INSPECTION END
EC-130
http://vnx.su

Component Inspection
EBS010MA
ECM RELAY
1.
2.
Apply 12V direct current between ECM relay terminals 1 and 2.

Check continuity between relay terminals 3 and 5, 6 and 7.
EC
Condition
Continuity
12V direct current supply between

terminals 1 and 2
Yes
OFF
No
3.
If NG, replace ECM relay.

D
PBIB0077E
Ground Inspection
EBS011V6
Ground connections are very important to the proper operation of electrical and electronic circuits. Ground
connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can
become an unwanted resistance. This unwanted resistance can change the way a circuit works.
Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit. Even
when the ground connection looks clean, there can be a thin film of rust on the surface.
When inspecting a ground connection follow these rules:
Remove the ground bolt or screw.
Inspect all mating surfaces for tarnish, dirt, rust, etc.
Clean as required to assure good contact.
Reinstall bolt or screw securely.
Inspect for add-on accessories which may be interfering with the ground circuit.
If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the
wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one
eyelet make sure no ground wires have excess wire insulation.
For detailed ground distribution information, refer to PG-13, "Ground Distribution" .
PBIB1870E
EC-131
http://vnx.su
DTC U1000, U1001 CAN COMMUNICATION LINE


Description
PFP:23710
EBS010MB
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
On Board Diagnosis Logic

DTC No.
U1000
1000
U1001*1
1001*1
Trouble diagnosis
name
DTC detecting condition
CAN communication
line
EBS010MC
ECM cannot communicate to other control

units.
ECM cannot communicate for more than the
specified time.
Possible cause
Harness or connectors
(CAN communication line is open or
shorted.)
*1: The MI will not light up for this self-diagnosis.
DTC Confirmation Procedure

1.
2.
3.
EBS010MD

Select DATA MONITOR mode with CONSULT-II.
If 1st trip DTC is detected, go to EC-134, "Diagnostic Procedure" .
EC-132
http://vnx.su

Wiring Diagram
EBS010ME
EC
TBWA0595E
EC-133
http://vnx.su

EBS010MF
Go to LAN-4, "CAN Communication Unit" .
EC-134
http://vnx.su
DTC P0011 IVT CONTROL


Description
PFP:23796
A
EBS010MG
SYSTEM DESCRIPTION
Sensor
Input signal to ECM

Engine speed and piston position
Wheel sensor*
Vehicle speed
ECM function
Intake valve
timing control
Actuator
EC

solenoid valve
I
PBIB0540E
This mechanism hydraulically controls cam phases continuously with the fixed operating angle of the intake
valve.
The ECM receives signals such as crankshaft position, camshaft position, engine speed, and engine coolant
temperature. Then, the ECM sends ON/OFF pulse duty signals to the intake valve timing control solenoid
valve depending on driving status. This makes it possible to control the shut/open timing of the intake valve to
increase engine torque in low/mid speed range and output in high-speed range.
EBS010MH

MONITOR ITEM
INT/V TIM (B1)
INT/V SOL (B1)
CONDITION

(M/T)
No load

(M/T)
No load
SPECIFICATION
Idle
5 - 5CA
2,000 rpm
Approx. 0 - 20CA
Idle
0% - 2%
2,000 rpm
Approx. 0% - 50%
EC-135
http://vnx.su

EBS010MI
The MI will not light up for this diagnosis.

Trouble diagnosis
name
DTC No.
P0011
0011
Intake valve timing

control performance
Detecting condition
There is a gap between angle of target and

phase-control angle degree.
Possible cause
Accumulation of debris to the signal pick-up

portion of the camshaft
FAIL-SAFE MODE
ECM enters in fail-safe mode when the malfunction is detected.
Detected items
The signal is not energized to the solenoid valve and the valve control does not function
EBS010MJ
CAUTION:
Always drive at a safe speed.
NOTE:
If DTC P0011 is displayed with DTC P1111, first perform trouble diagnosis for DTC P1111. See EC289, "DTC P1111 IVT CONTROL SOLENOID VALVE" .
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait
at least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is between 10V and 16V at
idle.
WITH CONSULT-II
1.
2.
3.
Turn ignition switch ON and select DATA MONITOR mode with

CONSULT-II.
Start engine and warm it up to the normal operating temperature.
Maintain the following conditions for at least 6 consecutive seconds.
Hold the accelerator pedal as steady as possible.
ENG SPEED
1,200 - 2,000 rpm (A constant rotation is maintained.)
COOLANT TEMPS
60 - 120C (176 - 194F)
Shift lever
A/T: P or N position
M/T: Neutral position
4.
5.
6.
SEF174Y
Let engine idle for 10 seconds.

If the 1st trip DTC is detected, go to EC-137, "Diagnostic Procedure" .
If the 1st trip DTC is not detected, go to next step.
ENG SPEED
COOLANT TEMPS
70 - 105C (176 - 194F)
Shift lever
1st or 2nd position
Driving location uphill
Driving vehicle uphill

(Increased engine load will help maintain the driving
conditions required for this test.)
7.
WITH GST
Follow the procedure WITH CONSULT-II above.
EC-136
http://vnx.su

EBS010MK
1. CHECK CRANKSHAFT POSITION SENSOR (POS)

OK or NG
OK
>> GO TO 2.
NG
>> Replace crankshaft position sensor (POS).
EC
2. CHECK CAMSHAFT POSITION SENSOR (PHASE)

OK or NG
OK
>> GO TO 3.
NG
>> Replace camshaft position sensor (PHASE).
3. CHECK CAMSHAFT (INTAKE)

Accumulation of debris to the signal plate of camshaft rear end
Chipping signal plate of camshaft rear end

OK or NG
OK
>> GO TO 4.
NG
>> Remove debris and clean the signal plate of camshaft
rear end or replace camshaft.
PBIB0565E

For wiring diagram, refer to EC-250, "Wiring Diagram" for CKP sensor (POS) and EC-257, "Wiring Diagram"
for CMP sensor (PHASE).
>> INSPECTION END

L
EC-137
http://vnx.su
DTC P0031, P0032 HO2S1 HEATER


Description
PFP:22690
EBS010ML
SYSTEM DESCRIPTION
Sensor
Input Signal to ECM

Engine speed
ECM function
Actuator

heater control

heater
The ECM performs ON/OFF duty control of the heated oxygen sensor 1 heater corresponding to the engine
speed and engine coolant temperature. The duty percent varies with engine coolant temperature when engine
is started.
OPERATION
Engine speed rpm
Above 3,600
OFF
Below 3,600
ON
EBS010MM

MONITOR ITEM
HO2S1 HTR (B1)
CONDITION
SPECIFICATION
ON
OFF

DTC No.
P0031
0031
P0032
0032
Trouble diagnosis
name
Heated oxygen
sensor 1 heater
control circuit low
Heated oxygen
sensor 1 heater
control circuit high
EBS010MN

The current amperage in the heated oxygen
sensor 1 heater circuit is out of the normal
range.
(An excessively low voltage signal is sent to
ECM through the heated oxygen sensor 1
heater.)
The current amperage in the heated oxygen
sensor 1 heater circuit is out of the normal
range.
(An excessively high voltage signal is sent to
heater.)
Possible cause
(The heated oxygen sensor 1 heater circuit is
open or shorted.)
Heater oxygen sensor 1 heater
shorted.)
EBS010MO
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is between 10.5V and 16V at
idle.
WITH CONSULT-II
1.
2.

EC-138
http://vnx.su

3.
4.
5.

CONSULT-II.
Start engine and run it for at least 6 seconds at idle speed.
If 1st trip DTC is detected, go to EC-141, "Diagnostic Procedure"
.
EC
C
SEF174Y
WITH GST
EC-139
http://vnx.su

Wiring Diagram
EBS010MP
TBWA0596E
EC-140
http://vnx.su

A
CAUTION:
EC
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
C
Approximately 7.0V
[Engine is running]
24
G/W
Warm-up condition.
E
PBIB0519E
[Engine is running]
BATTERY VOLTAGE
(11 - 14V)
EBS010MQ

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-141
http://vnx.su

2. CHECK HO2S1 POWER SUPPLY CIRCUIT

1.
2.
Disconnect heated oxygen sensor 1 harness connector.

PBIB0500E
3.
Check voltage between HO2S1 terminal 4 and ground with

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.
PBIB0541E

Fuse block (J/B) connector E103
10A fuse
Harness for open or short between heated oxygen sensor 1 and fuse
4. CHECK HO2S1 OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1.
2.
3.

Check harness continuity between ECM terminal 24 and HO2S1 terminal 1.

OK or NG
OK
>> GO TO 5.
NG
5. CHECK HEATED OXYGEN SENSOR 1 HEATER

OK or NG
OK
>> GO TO 6.
NG
>> Replace heated oxygen sensor 1.
EC-142
http://vnx.su


EC
>> INSPECTION END
EBS010MR
HEATED OXYGEN SENSOR 1 HEATER

1.
Check resistance between HO2S1 terminals as follows.

Terminal No.
Resistance
1 and 4
3.3 - 4.0 [at 25C (77F)]
2 and 1, 3, 4
(Continuity should not exist)
3 and 1, 2, 4
2. If NG, replace heated oxygen sensor 1.

CAUTION:
Discard any heated oxygen sensor which has been dropped

from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one.
Before installing new oxygen sensor, clean exhaust system

threads using Oxygen Sensor Thread Cleaner tool and
approved anti-seize lubricant.
I
PBIB0542E
EBS010MS

Refer to EM-25, "EXHAUST MANIFOLD AND THREE WAY CATALYST" .
EC-143
http://vnx.su


Description
PFP:226A0
EBS010MT
SYSTEM DESCRIPTION
Sensor
Input Signal to ECM

Engine speed
ECM function
Actuator

heater control
The ECM performs ON/OFF control of the heated oxygen sensor 2 heater corresponding to the engine speed,
amount of intake air and engine coolant temperature.
OPERATION
Engine speed rpm
Above 3,600
OFF
Below 3,600 rpm after the following conditions are met.
Keeping the engine speed between 3,500 and 4,000 rpm for 1
minute and at idle for 1 minute under no load
ON
EBS010MU

MONITOR ITEM
HO2S2 HTR (B1)
CONDITION
SPECIFICATION
Warm-up condition
and at idle for 1 minute under no load
ON
OFF

DTC No.
P0037
0037
P0038
0038
Trouble diagnosis
name
Heated oxygen
sensor 2 heater
control circuit low
Heated oxygen
sensor 2 heater
control circuit high
EBS010MV

The current amperage in the heated oxygen sensor 2 heater circuit is out of the normal range.
(An excessively low voltage signal is sent to ECM
through the heated oxygen sensor 2 heater.)
The current amperage in the heated oxygen sensor 2 heater circuit is out of the normal range.
(An excessively high voltage signal is sent to
heater.)
Possible cause
open or shorted.)
shorted.)

EBS010MW
NOTE:
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is between 10.5V and 16V at
idle.
EC-144
http://vnx.su

WITH CONSULT-II
1.
2.
3.
4.
5.
6.

CONSULT-II.
Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
.
EC
SEF174Y
SEF058Y
WITH GST
EC-145
http://vnx.su

Wiring Diagram
EBS010MX
TBWA0597E
EC-146
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running]
PU/R
Warm-up condition
Keeping the engine speed between 3,500 and

4,000 rpm for 1 minute and at idle for 1 minute
under no load

heater
0 - 1.0V
Engine stopped
[Engine is running]
BATTERY VOLTAGE
(11 - 14V)
EBS010MY
1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-147
http://vnx.su


1.
2.

PBIB0500E
3.

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.
PBIB0541E

10A fuse
>> Repair open circuit or short to ground or short or power in harness or connectors.

1.
2.
3.


OK or NG
OK
>> GO TO 5.
NG

OK or NG
OK
>> GO TO 6.
NG
EC-148
http://vnx.su


EC
>> INSPECTION END
EBS010MZ

1.

Terminal No.
Resistance
1 and 4
5.0 - 7.0 [at 25C (77F)]
2 and 1, 3, 4
3 and 1, 2, 4

CAUTION:


I
PBIB0542E
EBS010N0

Refer to EX-2, "EXHAUST SYSTEM" .
EC-149
http://vnx.su
DTC P0102, P0103 MAF SENSOR


Component Description
PFP:22680
EBS010N1
The mass air flow sensor is placed in the stream of intake air. It measures the intake flow rate by measuring a part of the entire intake
flow. The mass air flow sensor controls the temperature of the hot
wire to a certain amount. The heat generated by the hot wire is
reduced as the intake air flows around it. The more air, the greater
the heat loss.
Therefore, the electric current supplied to hot wire is changed to
maintain the temperature of the hot wire as air flow increases. The
ECM detects the air flow by means of this current change.
PBIB1604E
EBS010N2

MONITOR ITEM
MAS A/F SE-B1
CAL/LD VALUE
MASS AIRFLOW
CONDITION
SPECIFICATION

(M/T)
No load

(M/T)
No load
Idle
10% - 35%
2,500 rpm
10% - 35%
Idle
1.0 - 4.0 gm/s
2,500 rpm
4.0 - 10.0 gm/s
EBS010N3
These self-diagnoses have the one trip detection logic.

DTC No.
P0102
0102
P0103
0103
Trouble diagnosis name

low input

high input
An excessively low voltage from the sensor

is sent to ECM when engine is running.
Possible cause
(The sensor circuit is open or shorted.)
Intake air leaks
An excessively high voltage from the sensor

is sent to ECM.
FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Detected items

EBS010N4
NOTE:
PROCEDURE FOR DTC P0102

With CONSULT-II
1.
EC-150
http://vnx.su

2.
3.
4.

Start engine and wait at least 5 seconds.
If DTC is detected, go to EC-153, "Diagnostic Procedure" .
EC
C
SEF058Y
With GST
Follow the procedure With CONSULT-II above.

With CONSULT-II
1.
2.
3.
4.
5.
6.

Wait at least 5 seconds.
If DTC is not detected, go to next step.
SEF058Y
With GST
EC-151
http://vnx.su

Wiring Diagram
EBS010N5
TBWA0598E
EC-152
http://vnx.su

CAUTION:
TERMINAL
NO.
EC
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)

Approximately 0.4V
[Engine is running]
50
OR
Warm-up condition
Idle speed

[Engine is running]
Warm-up condition
0.7 - 1.1V (QR20DE)

0.8 - 1.2V (QR25DE)

(QR20DE)
(QR25DE)
[Engine is running]
67
B/P
Sensor ground
Warm-up condition
Idle speed
Approximately 0V
G
EBS010N6
1. INSPECTION START
Which malfunction (P0102 or P0103) is duplicated?

P0102 or P0103
P0102 >> GO TO 2.
P0103 >> GO TO 3.
2. CHECK INTAKE SYSTEM
Check the following for connection.
Air duct
Vacuum hoses
Intake air passage between air duct and intake manifold

OK or NG
OK
>> GO TO 3.
NG
>> Reconnect the parts.
EC-153
http://vnx.su


1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 4.
NG
EC-154
http://vnx.su

4. CHECK MAF SENSOR POWER SUPPLY CIRCUIT

1.
2.
Disconnect MAF sensor harness connector.

EC
D
PBIB0495E
3.
Check voltage between MAF sensor terminals 2 and ground


F
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.
PBIB1168E

Harness for open or short between mass air flow sensor and ECM
Harness for open or short between mass air flow sensor and ECM relay
6. CHECK MAF SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1.
2.
3.

Check harness continuity between MAF sensor terminal 3 and ECM terminal 67.

OK or NG
OK
>> GO TO 7.
NG
EC-155
http://vnx.su

7. CHECK MAF SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

OK or NG
OK
>> GO TO 8.
NG
8. CHECK MASS AIR FLOW SENSOR

OK or NG
OK
>> GO TO 9.
NG
>> Replace mass air flow sensor.

>> INSPECTION END
EBS01FF1
MASS AIR FLOW SENSOR

With CONSULT-II
1.
2.
3.
4.
Reconnect all harness connectors disconnected.

Connect CONSULT-II and select DATA MONITOR mode.
Select MAS A/F SE-B1 and check indication under the following conditions.
Condition
Ignition switch ON (Engine stopped.)

Idle (Engine is warmed-up to normal operating
temperature.)
Idle to about 4,000 rpm
Voltage V
Approx. 0.4
0.7 - 1.1V (QR20DE)
0.8 - 1.2V (QR25DE)
0.7 - 1.1 to 2.4 (QR20DE)*
0.8 - 1.2 to 2.4 (QR25DE)*
*: Check for linear voltage rise in response to engine being increased to about
4,000 rpm.
5.
a.
b.
6.
7.
8.
9.
If the voltage is out of specification, proceed the following.

Check for the cause of uneven air flow through mass air flow sensor. Refer to following.
Crushed air ducts
Malfunctioning seal of air cleaner element
Uneven dirt of air cleaner element
Improper specification of intake air system parts
If NG, repair or replace malfunctioning part and perform step 2 to 4 again.
If OK, go to next step.
Disconnect mass air flow sensor harness connector and reconnect it again.
Perform step 2 to 4 again.
If NG, clean or replace mass air flow sensor.
EC-156
http://vnx.su
SEF178Y

Without CONSULT-II
1.
2.
3.
Condition
temperature.)
b.
5.
6.
7.
8.
EC
Voltage V
Approx. 0.4
0.7 - 1.1V (QR20DE)

0.8 - 1.2V (QR25DE)
0.7 - 1.1 to 2.4 (QR20DE)*

0.8 - 1.2 to 2.4 (QR25DE)*
4,000 rpm.
4.
a.

Check voltage between ECM terminal 50 (Mass air flow sensor
signal) and ground.
MBIB0017E

Crushed air ducts
Perform step 2 and 3 again.
I
EBS010N8

Refer to EM-16, "AIR CLEANER AND AIR DUCT" .
EC-157
http://vnx.su
DTC P0112, P0113 IAT SENSOR


PFP:22630
EBS010N9
The intake air temperature sensor is built into mass air flow sensor.
The sensor detects intake air temperature and transmits a signal to
the ECM.
The temperature sensing unit uses a thermistor which is sensitive to
the change in temperature. Electrical resistance of the thermistor
decreases in response to the temperature rise.
PBIB1604E
<Reference data>
Intake air
temperature C (F)
Voltage*
Resistance
25 (77)
3.3
1.800 - 2.200
80 (176)
1.2
0.283 - 0.359
*: These data are reference values and are measured between ECM terminal 34
(Intake air temperature sensor) and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output
voltage. Doing so may result in damage to the ECM's transistor.
Use a ground other than ECM terminals, such as the ground.
SEF012P

DTC No.
Trouble diagnosis
name
EBS010NA
P0112
0112
Intake air temperature sensor circuit

low input
An excessively low voltage from the sensor is

sent to ECM.
P0113
0113
Intake air temperature sensor circuit

high input
An excessively high voltage from the sensor is

sent to ECM.
Possible cause
EBS010NB
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

.
SEF058Y
EC-158
http://vnx.su

WITH GST
A
EC
EC-159
http://vnx.su

Wiring Diagram
EBS010NC
TBWA0599E
EC-160
http://vnx.su

EBS010ND

1.
2.

EC
J
PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-161
http://vnx.su

2. CHECK INTAKE AIR TEMPERATURE SENSOR POWER SUPPLY CIRCUIT

1.
2.
Disconnect mass air flow sensor (intake air temperature sensor

is built-into) harness connector.
PBIB0495E
3.
Check voltage between MAF sensor terminal 5 and ground with

Voltage: Approximately 5V
OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.
PBIB1169E
3. CHECK INTAKE AIR TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.


OK or NG
OK
>> GO TO 4.
NG
4. CHECK INTAKE AIR TEMPERATURE SENSOR

OK or NG
OK
>> GO TO 5.
NG
>> Replace mass air flow sensor (with intake air temperature sensor).

>> INSPECTION END
EC-162
http://vnx.su

EBS010NE
INTAKE AIR TEMPERATURE SENSOR

1.
2.
Check resistance between mass air flow sensor terminals 5 and

6 under the following conditions.
Intake air temperature C (F)
Resistance k
25 (77)
1.800 - 2.200
EC
If NG, replace mass air flow sensor (with intake air temperature
sensor).
D
PBIB1604E
SEF012P
EBS010NF

EC-163
http://vnx.su
DTC P0117, P0118 ECT SENSOR


PFP:22630
EBS010NG
The engine coolant temperature sensor is used to detect the engine

coolant temperature. The sensor modifies a voltage signal from the
ECM. The modified signal returns to the ECM as the engine coolant
temperature input. The sensor uses a thermistor which is sensitive to
the change in temperature. The electrical resistance of the thermistor decreases as temperature increases.
SEF594K
<Reference data>
Engine coolant
temperature C (F)
Voltage*
10 (14)
4.4
Resistance
7.0 - 11.4
20 (68)
3.5
2.1 - 2.9
50 (122)
2.2
0.68 - 1.00
90 (194)
0.9
0.236 - 0.260
(Engine coolant temperature sensor) and ground.
SEF012P
CAUTION:
EBS010NH

DTC No.
Trouble Diagnosis
Name
DTC Detecting Condition
P0117
0117
Engine coolant
temperature sensor circuit low input

sent to ECM.
P0118
0118
Engine coolant
temperature sensor circuit high
input

sent to ECM.
EC-164
http://vnx.su
Possible Cause

FAIL-SAFE MODE
A
When this malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Detected items

Engine coolant temperature will be determined by ECM based on the time after turning ignition switch ON
or START. CONSULT-II displays the engine coolant temperature decided by ECM.
Condition
40C (104F)
More than approx. 4 minutes after ignition ON or

START
80C (176F)
D
40 - 80C (104 - 176F)
When the fail-safe system for engine coolant temperature sensor is activated, the cooling fan operates
while engine is running.
EBS010NI
NOTE:
WITH CONSULT-II
1.
2.
3.
4.
EC

SEF058Y
WITH GST
L
EC-165
http://vnx.su

Wiring Diagram
EBS010NJ
TBWA0600E
EC-166
http://vnx.su

EBS010NK

1.
2.

EC
J
PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-167
http://vnx.su

2. CHECK ECT SENSOR POWER SUPPLY CIRCUIT

1.
2.
Disconnect engine coolant temperature (ECT) sensor harness

connector.
PBIB0496E
3.
Check voltage between ECT sensor terminal 1 and ground with

OK or NG
OK
>> GO TO 3.
NG
PBIB0080E
3. CHECK ECT SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1.
2.
3.

Check harness continuity between ECT sensor terminal 2 and ECM terminal 73.

OK or NG
OK
>> GO TO 4.
NG
4. CHECK ENGINE COOLANT TEMPERATURE SENSOR

OK or NG
OK
>> GO TO 5.
NG
>> Replace engine coolant temperature sensor.

>> INSPECTION END
EC-168
http://vnx.su

EBS010NL
ENGINE COOLANT TEMPERATURE SENSOR

1.
Check resistance between engine coolant temperature sensor

terminals 1 and 2 as shown in the figure.
EC
D
PBIB2005E
<Reference data>
2.
C (F)
Resistance
20 (68)
2.1 - 2.9
50 (122)
0.68 - 1.00
90 (194)
0.236 - 0.260
If NG, replace engine coolant temperature sensor.
SEF012P
EBS010NM
Refer to CO-23, "THERMOSTAT AND WATER CONTROL VALVE" .

J
EC-169
http://vnx.su
DTC P0122, P0123 TP SENSOR


PFP:16119
EBS010NN
Electric throttle control actuator consists of throttle control motor,

throttle position sensor, etc. The throttle position sensor responds to
the throttle valve movement.
The throttle position sensor has the two sensors. These sensors are
a kind of potentiometers which transform the throttle valve position
into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the
throttle valve and feed the voltage signals to the ECM. The ECM
judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the
throttle valve opening angle properly in response to driving condition.
PBIB0145E
EBS010NO

MONITOR ITEM
CONDITION
SPECIFICATION
Ignition switch: ON
(Engine stopped)
More than 0.36V
Less than 4.75V
THRTL SEN 1
THRTL SEN 2*
*: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal.
EBS010NP

DTC No.
Possible cause
P0122
0122

circuit low input
An excessively low voltage from the TP sensor 2

is sent to ECM.
(TP sensor 2 circuit is open or
shorted.)
(APP sensor 2 circuit is shorted.)
P0123
0123

circuit high input
An excessively high voltage from the TP sensor 2

is sent to ECM.

(TP sensor 2)

(APP sensor 2)
FAIL-SAFE MODE
Engine operation condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
EBS010NQ
NOTE:
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.
EC-170
http://vnx.su

WITH CONSULT-II
1.
2.
3.
4.

Start engine and let it idle for 1 second.
EC
D
SEF058Y
WITH GST

F
EC-171
http://vnx.su

Wiring Diagram
EBS010NR
TBWB0260E
EC-172
http://vnx.su

CAUTION:
TERMINAL NO.
47
WIRE
COLOR
R
ITEM
power supply
CONDITION
DATA (DC Voltage)

Approximately 5V
EC
49
Engine stopped
More than 0.36V
Engine stopped
E
Less than 4.75V
[Engine is running]
66
Sensor ground
Warm-up condition
Idle speed
Approximately 0V
68
Engine stopped
91
BR/Y
Sensor power supply

(Accelerator pedal position sensor 2)
Less than 4.75V
Engine stopped
I
More than 0.36V
J
Approximately 5V
EC-173
http://vnx.su

EBS010NS

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-174
http://vnx.su

2. CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT-I

1.
Disconnect electric throttle control actuator harness connector.

EC
D
PBIB1992E
PBIB1971E
2.
3.

Check voltage between electric throttle control actuator terminal
1 and ground with CONSULT-II or tester.
J
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 3.
PBIB0082E
3. CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT-II

1.
2.
3.

Check harness continuity between electric throttle control actuator terminal 1 and ECM terminal 47.
OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace open circuit.
EC-175
http://vnx.su

4. CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT-III

Check harness for short to power and short to ground, between the following terminals.
ECM terminal
Sensor terminal
Reference Wiring Diagram
47
Electric throttle control actuator terminal 1
EC-172
91
APP sensor terminal 4
EC-433
OK or NG
OK
>> GO TO 5.
NG
>> Repair short to ground or short to power in harness or connectors.
5. CHECK APP SENSOR

OK or NG
OK
>> GO TO 11
NG
>> GO TO 6.
6. REPLACE ACCELERATOR PEDAL ASSEMBLY

1.
2.
3.
4.
Replace accelerator pedal assembly.

Perform EC-46, "Idle Air Volume Learning" .
>> INSPECTION END
7. CHECK THROTTLE POSITION SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.


OK or NG
OK
>> GO TO 8.
NG
8. CHECK THROTTLE POSITION SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
Check harness continuity between electric throttle control actuator terminal 2 ECM terminal 68.

OK or NG
OK
>> GO TO 9.
NG
EC-176
http://vnx.su

9. CHECK THROTTLE POSITION SENSOR

OK or NG
OK
>> GO TO 11.
NG
>> GO TO 10.
EC
10. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR

1.
2.
3.
Replace the electric throttle control actuator.

>> INSPECTION END

F

>> INSPECTION END
EBS010NT
THROTTLE POSITION SENSOR

1.
2.
3.
4.
5.

Set selector lever to D position (A/T) or 1st position (M/T).
Check voltage between ECM terminals 49 (TP sensor 1 signal),
68 (TP sensor 2 signal) and ground under the following conditions.
Terminal
Accelerator pedal
Voltage
49
(Throttle position sensor 1)
Fully released
More than 0.36V
Fully depressed
Less than 4.75V
68
Fully released
Less than 4.75V
Fully depressed
More than 0.36V
6.
7.
8.
If NG, replace electric throttle control actuator and go to the next

step.
L
MBIB0022E
EBS010NU
ELECTRIC THROTTLE CONTROL ACTUATOR

Refer to EM-18, "INTAKE MANIFOLD" .
EC-177
http://vnx.su
DTC P0132 HO2S1

DTC P0132 HO2S1

PFP:22690
EBS010NV
The heated oxygen sensor 1 is placed into the exhaust manifold. It

detects the amount of oxygen in the exhaust gas compared to the
outside air. The heated oxygen sensor 1 has a closed-end tube
made of ceramic zirconia. The zirconia generates voltage from
approximately 1V in richer conditions to 0V in leaner conditions. The
heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts
the injection pulse duration to achieve the ideal air-fuel ratio. The
ideal air-fuel ratio occurs near the radical change from 1V to 0V.
SEF463R
SEF288D
EBS010NW

MONITOR ITEM
CONDITION
SPECIFICATION
0 - 0.3V Approx. 0.6 - 1.0V
HO2S1 (B1)
HO2S1 MNTR (B1)
Maintaining engine speed at 2,000 rpm.
LEAN RICH
Changes more than 5 times during
10 seconds.
EBS010NX
To judge the malfunction, the diagnosis checks that the heated oxygen sensor 1 output is not inordinately high.
SEF301UA
DTC No.
P0132
0132

circuit high voltage
Possible cause

is sent to ECM.
EC-178
http://vnx.su
DTC P0132 HO2S1

EBS010NY
NOTE:
EC
WITH CONSULT-II
1.
2.
3.
4.
5.
6.

Restart engine and let it idle for 2 minutes.
.
F
SEF174Y
WITH GST
EC-179
http://vnx.su
DTC P0132 HO2S1

Wiring Diagram
EBS010NZ
TBWA0602E
EC-180
http://vnx.su
DTC P0132 HO2S1

CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running]
35
74
P/L
Sensor ground
Warm-up condition
[Engine is running]
Idle speed
D
Approximately 0V
EBS010O0

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-181
http://vnx.su
DTC P0132 HO2S1

2. RETIGHTEN HEATED OXYGEN SENSOR 1

1.
Loosen and retighten heated oxygen sensor 1.

Tightening torque: 40 - 60 Nm (4.1 - 6.1 kg-m, 30 - 44 ft-lb)
>> GO TO 3.
PBIB0499E
3. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT

1.
2.
3.

Check harness continuity between HO2S1 terminal 3 and ECM
terminal 74.

OK or NG
OK
>> GO TO 4.
NG
4. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1.
Check harness continuity between HO2S1 terminal 2 and ECM terminal 35.
2.
Check harness continuity between ECM terminal 35 or HO2S1 terminal 2 and ground.
Continuity should not exist.

OK or NG
OK
>> GO TO 5.
NG
5. CHECK HO2S1 CONNECTOR FOR WATER

Check heated oxygen sensor 1 connectors for water.
Water should not exist.
OK or NG
OK
>> GO TO 6.
NG
>> Repair or replace harness or connectors.
EC-182
http://vnx.su
PBIB0500E
DTC P0132 HO2S1

6. CHECK HEATED OXYGEN SENSOR 1

OK or NG
OK
>> GO TO 7.
NG
EC

D
>> INSPECTION END
EBS010O1

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

Select MANU TRIG and adjust TRIGGER POINT to 100% in DATA MONITOR mode with CONSULTII.
Select HO2S1 (B1) and HO2S1 MNTR (B1).
Hold engine speed at 2,000 rpm under no load during the following steps.
Touch RECORD on CONSULT-II screen.
SEF646Y
6.

HO2S1 MNTR (B1) in DATA MONITOR mode changes
from RICH to LEAN to RICH more than 5 times in 10 seconds.
5 times (cycles) are counted as shown in the figure.
HO2S1 (B1) voltage goes above 0.6V at least once.
HO2S1 (B1) voltage goes below 0.3V at least once.
HO2S1 (B1) voltage never exceeds 1.0V.
M
SEF217YA
SEF648Y
CAUTION:
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
EC-183
http://vnx.su
DTC P0132 HO2S1

Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.
Without CONSULT-II
1.
2.
3.

Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground.
Check the following with engine speed held at 2,000 rpm constant under no load.
The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V
more than 5 times within 10 seconds.
The maximum voltage is over 0.6V at least 1 time.
The minimum voltage is below 0.3V at least 1 time.
The voltage never exceeds 1.0V.
1 time: 0 - 0.3V 0.6 - 1.0V 0 - 0.3V
2 times: 0 - 0.3V 0.6 - 1.0V 0 - 0.3V 0.6 - 1.0V
0 - 0.3V
MBIB0018E
CAUTION:
EBS010O2

EC-184
http://vnx.su
DTC P0133 HO2S1

DTC P0133 HO2S1

PFP:22690
A
EBS010O3

EC
D
SEF463R
H
SEF288D
EBS010O4

MONITOR ITEM
CONDITION
0 - 0.3V Approx. 0.6 - 1.0V
HO2S1 (B1)
HO2S1 MNTR (B1)
SPECIFICATION

rpm.
LEAN RICH
Changes more than 5 times during 10 seconds.
EBS010O5
To judge the malfunction of heated oxygen sensor 1, this diagnosis

measures response time of heated oxygen sensor 1 signal. The time
is compensated by engine operating (speed and load), fuel feedback
control constant, and heated oxygen sensor 1 temperature index.
Judgment is based on whether the compensated time (heated oxygen sensor 1 cycling time index) is inordinately long or not.
SEF010V
EC-185
http://vnx.su
DTC P0133 HO2S1

DTC No.
P0133
0133

circuit slow response
The response of the voltage signal from the

sensor takes more than the specified time.
Possible cause
Fuel pressure
Fuel injector
Intake air leaks
Exhaust gas leaks
PCV valve

EBS010O6
CAUTION:
Always drive vehicle at a safe speed.
NOTE:
TESTING CONDITION:
Always perform at a temperature above 10C (14F).
WITH CONSULT-II
1.
2.
3.
4.
5.

Stop engine and wait at least 10 seconds.
Turn ignition switch ON and select HO2S1 (B1) P0133 of HO2S1 in DTC WORK SUPPORT mode
with CONSULT-II.
Touch START.
Start engine and let it idle for at least 3 minutes.
NOTE:
Never raise engine speed above 3,600 rpm after this step. If
the engine speed limit is exceeded, return to step 5.
SEF338Z
6.
When the following conditions are met, TESTING will be displayed on the CONSULT-II screen. Maintain the conditions continuously until TESTING changes to COMPLETED. (It will
take approximately 40 to 50 seconds.)
ENG SPEED
QR20DE: 1,650 - 3,600 rpm

QR25DE: 1,600 - 3,300 rpm
VHCL SPEED SE
More than 80 km/h (50 MPH)
B/FUEL SCHDL
QR20DE: 4.0 - 14.5 msec

QR25DE: 4.3 - 14.5 msec
Shift lever
Suitable position
SEF339Z
If TESTING is not displayed after 5 minutes, retry from step 2.
EC-186
http://vnx.su
DTC P0133 HO2S1

7.
Make sure that OK is displayed after touching SELF-DIAG

RESULTS. If NG is displayed, refer to EC-189, "Diagnostic
Procedure" .
EC
C
SEF658Y
Overall Function Check
EBS010O7
Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st
trip DTC might not be confirmed.
WITH GST
1.
2.
3.

The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more
than 5 times within 10 seconds.
1 time:
2 times:
4.
0 - 0.3V 0.6 - 1.0V 0 - 0.3V

0 - 0.3V 0.6 - 1.0V 0 - 0.3V 0.6 - 1.0V
0 - 0.3V
If NG, go to EC-189, "Diagnostic Procedure" .

MBIB0018E
EC-187
http://vnx.su
DTC P0133 HO2S1

Wiring Diagram
EBS010O8
TBWA0602E
EC-188
http://vnx.su
DTC P0133 HO2S1

CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running]
35
P/L
Warm-up condition
[Engine is running]
74
Sensor ground
Warm-up condition
Idle speed
Approximately 0V
EBS010O9

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-189
http://vnx.su
DTC P0133 HO2S1


>> GO TO 3.
PBIB0499E
3. CHECK FOR EXHAUST GAS LEAK

1.
2.
Start engine and run it at idle.

Listen for an exhaust gas leak before three way catalyst (manifold).
SEC502D
OK or NG
OK
>> GO TO 4.
NG
4. CHECK FOR INTAKE AIR LEAK

Listen for an intake air leak after the mass air flow sensor.
OK or NG
OK
>> GO TO 5.
NG
EC-190
http://vnx.su
DTC P0133 HO2S1

5. CLEAR THE SELF-LEARNING DATA

1.
2.
3.
4.
With CONSULT-II
Select SELF-LEARNING CONT in WORK SUPPORT mode with CONSULT-II.
Clear the self-learning control coefficient by touching CLEAR.
Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171 or P0172 detected?
Is it difficult to start engine?
EC
E
SEF215Z
Without CONSULT-II
2. Turn ignition switch OFF.
3. Disconnect mass air flow sensor harness connector, and restart
and run engine for at least 5 seconds at idle speed.
4. Stop engine and reconnect mass air flow sensor harness connector.
5. Make sure that DTC P0102 is displayed.
6. Erase the DTC memory. Refer to EC-62, "HOW TO ERASE
EMISSION-RELATED DIAGNOSTIC INFORMATION" .
8. Run engine for at least 10 minutes at idle speed.
PBIB0495E
Yes or No
Yes
>> Perform trouble diagnosis for DTC P0171 or DTC P0172 (Refer to EC-218, "DTC P0171 FUEL
INJECTION SYSTEM FUNCTION" or EC-224, "DTC P0172 FUEL INJECTION SYSTEM FUNCTION" ).
No
>> GO TO 6.

1.
2.
3.
4.

terminal 74. Refer to Wiring Diagram.

OK or NG
OK
>> GO TO 7.
NG
EC-191
http://vnx.su
PBIB0500E
DTC P0133 HO2S1


1.
2.

OK or NG
OK
>> GO TO 8.
NG

OK or NG
OK
>> GO TO 9.
NG
9. CHECK PCV VALVE

OK or NG
OK
>> GO TO 10.
NG
>> Replace PCV valve.

OK or NG
OK
>> GO TO 11.
NG

>> INSPECTION END
EBS010OA

With CONSULT-II
1.
2.

EC-192
http://vnx.su
DTC P0133 HO2S1

3.
4.
5.

EC
C
SEF646Y
6.

G
SEF217YA
SEF648Y
CAUTION:
EC-193
http://vnx.su
DTC P0133 HO2S1

Without CONSULT-II
1.
2.
3.

1 time: 0 - 0.3V 0.6 - 1.0V 0 - 0.3V
2 times: 0 - 0.3V 0.6 - 1.0V 0 - 0.3V 0.6 - 1.0V
0 - 0.3V
MBIB0018E
CAUTION:
EBS010OB

EC-194
http://vnx.su
DTC P0134 HO2S1

DTC P0134 HO2S1

PFP:22690
A
EBS010OC

EC
D
SEF463R
H
SEF288D
EBS010OD

MONITOR ITEM
CONDITION
SPECIFICATION
0 - 0.3V Approx. 0.6 - 1.0V
HO2S1 (B1)
HO2S1 MNTR (B1)

rpm.
LEAN RICH
EBS010OE
Under the condition in which the heated oxygen sensor 1 signal is

not input, the ECM circuits will read a continuous approximately
0.3V. Therefore, for this diagnosis, the time that output voltage is
within 200 to 400 mV range is monitored, and the diagnosis checks
that this time is not inordinately long.
SEF237U
DTC No.
P0134
0134

circuit no activity detected
Possible cause
The voltage from the sensor is constantly

approx. 0.3V.
EC-195
http://vnx.su
DTC P0134 HO2S1

EBS010OF
CAUTION:
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.

Select HO2S1 (B1) P0134 of HO2S1 in DTC WORK SUPPORT mode with CONSULT-II.
Touch START.
Let it idle for at least 3 minutes.
NOTE:
PBIB0544E
5.
take approximately 10 to 60 seconds.)
ENG SPEED
QR20DE: 1,550 - 4,100 rpm

QR25DE: 1,500 - 3,300 rpm
VHCL SPEED SE
B/FUEL SCHDL
QR20DE: 2.9 - 14.5 msec

QR25DE: 1.9 - 14.5 msec
Shift lever
Suitable position
6.
PBIB0545E

Procedure" .
SEC750C
EBS010OG
EC-196
http://vnx.su
DTC P0134 HO2S1

WITH GST
1.
2.
3.
4.

The voltage does not remain in the range of 0.2 to 0.4V.
EC
MBIB0018E
EC-197
http://vnx.su
DTC P0134 HO2S1

Wiring Diagram
EBS010OH
TBWA0602E
EC-198
http://vnx.su
DTC P0134 HO2S1

CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running]
35
P/L
Warm-up condition
[Engine is running]
74
Sensor ground
Warm-up condition
Idle speed
Approximately 0V
EBS010OI

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-199
http://vnx.su
DTC P0134 HO2S1


1.
2.
3.


OK or NG
OK
>> GO TO 3.
NG
PBIB0500E

1.
2.

OK or NG
OK
>> GO TO 4.
NG

OK or NG
OK
>> GO TO 5.
NG

>> INSPECTION END
EBS010OJ

With CONSULT-II
1.
2.

EC-200
http://vnx.su
DTC P0134 HO2S1

3.
4.
5.

EC
C
SEF646Y
6.

G
SEF217YA
SEF648Y
CAUTION:
Without CONSULT-II
1.
2.
3.

1 time: 0 - 0.3V 0.6 - 1.0V 0 - 0.3V
2 times: 0 - 0.3V 0.6 - 1.0V 0 - 0.3V 0.6 - 1.0V
0 - 0.3V
MBIB0018E
CAUTION:
EC-201
http://vnx.su
DTC P0134 HO2S1

EBS010OK

EC-202
http://vnx.su
DTC P0138 HO2S2

DTC P0138 HO2S2

PFP:226A0
A
EBS010OL
The heated oxygen sensor 2, after three way catalyst (manifold),

monitors the oxygen level in the exhaust gas.
Even if switching characteristics of the heated oxygen sensor 1 are
shifted, the air-fuel ratio is controlled to stoichiometric, by the signal
from the heated oxygen sensor 2.
This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions.
Under normal conditions the heated oxygen sensor 2 is not used for
engine control operation.
EC
D
SEF327R
EBS010OM

MONITOR ITEM
HO2S2 (B1)
HO2S2 MNTR (B1)
CONDITION
SPECIFICATION
0 - 0.3V Approx. 0.6 - 1.0V

Revving engine from idle to 3,000

rpm quickly.
LEAN RICH
EBS010ON
The heated oxygen sensor 2 has a much longer switching time

between rich and lean than the heated oxygen sensor 1. The oxygen
storage capacity before the three way catalyst (manifold) causes the
longer switching time. To judge the malfunctions of heated oxygen
sensor 2, ECM monitors whether the voltage is unusually high during
the various driving condition such as fuel-cut.
K
SEF305UA
L
DTC No.
P0138
0138

Possible cause

is sent to ECM.
EBS010OO
CAUTION:
NOTE:
EC-203
http://vnx.su
DTC P0138 HO2S2

WITH CONSULT-II
1.
2.
3.
4.
5.
6.
Turn ignition switch ON and select DATA MONITOR mode with CONSULT-II.
Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least 1 minute under no load.
Let engine idle for 2 minutes.
.
SEF174Y
WITH GST
EC-204
http://vnx.su
DTC P0138 HO2S2

Wiring Diagram
EBS010OQ
EC
TBWA0603E
EC-205
http://vnx.su
DTC P0138 HO2S2

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running]
16
OR/B
Warm-up condition


under no load
[Engine is running]
74
Sensor ground
Warm-up condition
Idle speed
Approximately 0V
EBS010OR

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-206
http://vnx.su
DTC P0138 HO2S2


1.
2.
3.

terminal 74.
EC

OK or NG
OK
>> GO TO 3.
NG
D
PBIB0500E

1.
Check harness continuity between HO2S2 terminal 2 ECM terminal 16.

2.

OK or NG
OK
>> GO TO 4.
NG

OK or NG
OK
>> GO TO 5.
NG

>> INSPECTION END
EBS010OS

With CONSULT-II
1.
2.
3.
4.

Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
EC-207
http://vnx.su
DTC P0138 HO2S2

5.
Select FUEL INJECTION in ACTIVE TEST mode, and select

HO2S2(B1) as the monitor item with CONSULT-II.
SEF662Y
6.
Check HO2S2 (B1) at idle speed when adjusting FUEL INJECTION to 25%.
PBIB0551E
HO2S2 (B1) should be above 0.68V at least once when the FUEL INJECTION is +25%.
HO2S2 (B1) should be below 0.50V at least once when the FUEL INJECTION is 25%.
CAUTION:
Without CONSULT-II
1.
2.
3.
4.
5.
6.

Check the voltage when revving up to 4,000 rpm under no load
at least 10 times.
(Depress and release accelerator pedal as soon as possible.)
The voltage should be above 0.68V at least once during this
procedure.
If the voltage is above 0.68V at step 6, step 7 is not necessary.
7. Keep vehicle idling for 10 minutes, then check voltage. Or check
the voltage when coasting from 80 km/h (50 MPH) in D position
with OD OFF (A/T), 3rd gear position (M/T).
The voltage should be below 0.50V at least once during this
MBIB0020E
procedure.
CAUTION:
EC-208
http://vnx.su
DTC P0138 HO2S2

EBS010OT

EC
EC-209
http://vnx.su
DTC P0139 HO2S2

DTC P0139 HO2S2

PFP:226A0
EBS010OU

SEF327R
EBS010OV

MONITOR ITEM
HO2S2 (B1)
HO2S2 MNTR (B1)
CONDITION
SPECIFICATION
0 - 0.3V Approx. 0.6 - 1.0V


rpm quickly.
LEAN RICH
EBS010OW

sensor 2, ECM monitors whether the switching response of the sensor's voltage is faster than specified during the various driving condition such as fuel-cut.
SEF302U
DTC No.
P0139
0139

circuit slow response
It takes more time for the sensor to respond

between rich and lean than the specified time.
EC-210
http://vnx.su
Possible cause
Fuel pressure
Fuel injector
Intake air leaks
DTC P0139 HO2S2

EBS010OX
A
CAUTION:
NOTE:
COMPLETED will appear on CONSULT-II screen when all tests COND1, COND2 and EC
COND3 are completed.
C
TESTING CONDITION:
Never stop engine during this procedure. If the engine is stopped, retry this procedure from step 2 in
D
Procedure for COND1.
WITH CONSULT-II
Procedure for COND1
For the best results, perform DTC WORK SUPPORT at a temperature of 0 to 30(32 to 86F).
3. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
4. Let engine idle 1 minute.
5. Select HO2S2 (B1) P0139 of HO2S2 in DTC WORK SUPPORT mode with CONSULT-II.
6. Touch START.
7. Start engine and let it idle for at least 30 seconds.
8. Rev engine up to 2,000 rpm two or three times quickly under no load.
If COMPLETED appears on CONSULT-II screen, go to step 2 in Procedure for COND3.
If COMPLETED does not appear on CONSULT-II screen, go to the following step.
9. When the following conditions are met, TESTING will be displayed at COND1 on the CONSULT-II
screen. Maintain the conditions continuously until TESTING changes to COMPLETED. (It will take
approximately 60 seconds.)
ENG SPEED
More than 1.0 msec
COOLAN TEMP/S
70 - 105 C
Shift level
Suitable position
More than 1,000 rpm
B/FUEL SCHDL
PBIB0552E
NOTE:
If TESTING is not displayed after 5 minutes, retry from step 2 in Procedure for COND1.
If COMPLETED already appears at COND2 on CONSULT-II screen before Procedure for
COND2 is conducted, it is unnecessary to conduct step 1 in Procedure for COND2.
EC-211
http://vnx.su
DTC P0139 HO2S2

Procedure for COND2
1.
While driving, release accelerator pedal completely with OD

OFF (A/T) from the above condition [step 9] until INCOMPLETE at COND2 on CONSULT-II screen has turned to
COMPLETED. (It will take approximately 4 seconds.)
NOTE:
If COMPLETED already appears at COND3 on CONSULT-II
screen before Procedure for COND3 is conducted, it is unnecessary to conduct step 1 in Procedure for COND3.
PBIB0553E
Procedure for COND3

1.
2.
a.
b.
c.
d.
Stop vehicle and let it idle until INCOMPLETE of COND3 on

CONSULT-II screen has turned to COMPLETED. (It will take a
maximum of approximately 6 minutes.)
RESULTS.
If NG is displayed, refer to EC-214, "Diagnostic Procedure" .
If CAN NOT BE DIAGNOSED is displayed, perform the following.
Turn ignition switch OFF and leave the vehicle in a cool place
(soak the vehicle).
Turn ignition switch ON and select COOLAN TEMP/S in DATA
MONITOR mode with CONSULT-II.
Start engine and warm it up while monitoring COOLAN TEMP/S indication on CONSULT-II.
When COOLAN TEMP/S indication reaches to 70(158F), go to Procedure for COND1 step 3.
SEF668Y
EBS010OY
WITH GST
1.
2.
3.
4.
5.
6.
7.
8.

Start engine and keep the engine between 3,500 and 4,000 rpm for at least 1 minute under no load.
at least 10 times.
A change of voltage should be more than 0.06V for 1 second during this procedure.
If the voltage can be confirmed in step 6, step 7 is not necessary.
Keep vehicle at idling for 10 minutes, then check the voltage. Or
check the voltage when coasting from 80 km/h (50 MPH) in D
position with OD OFF (A/T), 3rd gear position (M/T).
A change of voltage should be more than 0.06V for 1 secMBIB0020E
ond during this procedure.
EC-212
http://vnx.su
DTC P0139 HO2S2

Wiring Diagram
EBS010OZ
EC
TBWA0603E
EC-213
http://vnx.su
DTC P0139 HO2S2

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running]
16
OR/B
Warm-up condition
Revving engine form idle to 3,000 rpm quickly


under no load
[Engine is running]
74
Sensor ground
Warm-up condition
Idle speed
Approximately 0V
EBS010P0

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-214
http://vnx.su
DTC P0139 HO2S2

With CONSULT-II
Select SELF-LEARNING CONT in WORK SUPPORT mode
with CONSULT-II.
3. Clear the self-learning control coefficient by touching CLEAR.
1.
2.
EC
E
SEF215Z
Without CONSULT-II
PBIB0495E
Yes or No
Yes
>> Perform trouble diagnosis for DTC P0171 or P0172. Refer to EC-218, "DTC P0171 FUEL INJECTION SYSTEM FUNCTION" or EC-224, "DTC P0172 FUEL INJECTION SYSTEM FUNCTION" .
No
>> GO TO 3.
1.
2.
3.
4.

Check harness continuity between and HO2S2 terminal 3 and
ECM terminal 74.

OK or NG
OK
>> GO TO 4.
NG
EC-215
http://vnx.su
PBIB0500E
DTC P0139 HO2S2


1.
2.

OK or NG
OK
>> GO TO 5.
NG

OK or NG
OK
>> GO TO 6.
NG

>> INSPECTION END
EBS010P1

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

HO2S2 (B1) as the monitor item with CONSULT-II.
SEF662Y
EC-216
http://vnx.su
DTC P0139 HO2S2

6.
A
EC
PBIB0551E
CAUTION:
Without CONSULT-II
1.
2.
3.
4.
5.
6.

at least 10 times.
procedure.
MBIB0020E
procedure.
CAUTION:
EBS010P2

EC-217
http://vnx.su
DTC P0171 FUEL INJECTION SYSTEM FUNCTION


PFP:16600
EBS010P3
With the Air-Fuel Mixture Ratio Self-Learning Control, the actual mixture ratio can be brought closely to the
theoretical mixture ratio based on the mixture ratio feedback signal from the heated oxygen sensor 1. The
ECM calculates the necessary compensation to correct the offset between the actual and the theoretical
ratios.
In case the amount of the compensation value is extremely large (The actual mixture ratio is too lean.), the
ECM judges the condition as the fuel injection system malfunction and lights up the MI (2 trip detection logic).
Sensor
Input Signal to ECM

(Mixture ratio feedback signal)
Trouble diagnosis
name
DTC No.
Fuel injection system

too lean
Fuel injection control
Actuator
Fuel injector
P0171
0171
ECM function
Possible cause
Intake air leaks
Fuel injection system does not operate properly.
Fuel injector
The amount of mixture ratio compensation is too

large.
(The mixture ratio is too lean.)
Exhaust gas leaks
Incorrect fuel pressure
Lack of fuel
Incorrect PCV hose connection
EBS010P4
NOTE:
WITH CONSULT-II
1.
2.
3.
4.
5.
6.
a.
b.

Turn ignition switch ON and select SELF-LEARNING CONT in WORK SUPPORT mode with CONSULT-II.
Start engine again and let it idle for at least 10 minutes.
The 1st trip DTC P0171 should be detected at this stage, if a
malfunction exists. If so, go to EC-221, "Diagnostic Procedure" .
NOTE:
If 1st trip DTC is not detected during above procedure, performing the following procedure is advised.
Start engine and drive the vehicle under the similar conditions to
SEF215Z
(1st trip) Freeze Frame Data for 10 minutes. Refer to the table
below.
The similar conditions to (1st trip) Freeze Frame Data means the vehicle operation that the following conditions should be satisfied at the same time.
Engine speed
Engine speed in the freeze frame data 400 rpm
Vehicle speed
Vehicle speed in the freeze frame data 10 km/h (6 MPH)
EC-218
http://vnx.su

(T) condition
7.
8.
When the freeze frame data shows lower than 70 C (158 F),
T should be lower than 70 C (158 F).
When the freeze frame data shows higher than or equal to 70 C (158 F),
T should be higher than or equal to 70 C (158 F).
EC
If it is difficult to start engine at step 6, the fuel injection system has a malfunction, too.
Crank engine while depressing accelerator pedal. If engine starts, go to EC-221, "Diagnostic Procedure" .
If engine does not start, check exhaust and intake air leak visually.
C
WITH GST
1.
2.
3.
4.
5.
6.
7.
8.
9.
a.
b.

Disconnect mass air flow sensor harness connector.
Restart engine and let idle for at least 5 seconds.
Stop engine and reconnect mass air flow sensor harness connector.
Select Service $03 with GST. Make sure DTC P0102 is
detected.
Select Service $04 with GST and erase the DTC P0102.
Select Service $07 with GST. The 1st trip DTC P0171 should be
PBIB0495E
detected at this stage, if a malfunction exists. If so, go to EC221, "Diagnostic Procedure" .
NOTE:
Start engine and drive the vehicle under the similar conditions to (1st trip) Freeze Frame Data for 10 minutes. Refer to the table below.
Engine speed
Vehicle speed

(T) condition
10. If it is difficult to start engine at step 8, the fuel injection system has a malfunction.
11. Crank engine while depressing accelerator pedal. If engine starts, go to EC-221, "Diagnostic Procedure" .
If engine does not start, check exhaust and intake air leak visually.
EC-219
http://vnx.su

Wiring Diagram
EBS010P5
TBWA0604E
EC-220
http://vnx.su

EBS010P6
1. CHECK EXHAUST GAS LEAK

1.
2.

EC
E
SEC502D
OK or NG
OK
>> GO TO 2.
NG
2. CHECK FOR INTAKE AIR LEAK AND PCV HOSE
1. Listen for an intake air leak after the mass air flow sensor.
2. Check PCV hose connection.
OK or NG
OK
>> GO TO 3.
NG
3. CHECK HEATED OXYGEN SENSOR 1 CIRCUIT FOR OPEN AND SHORT

1.
2.
3.
4.

Disconnect heated oxygen sensor 1 (HO2S1) harness connector.
terminal 35.

5.
Check harness continuity between ECM terminal 35 or HO2S1

terminal 2 and ground.

OK or NG
OK
>> GO TO 4.
NG
EC-221
http://vnx.su
M
PBIB0500E

4. CHECK FUEL PRESSURE

1.
2.
Release fuel pressure to zero. Refer to EC-48, "FUEL PRESSURE RELEASE" .

Install fuel pressure gauge and check fuel pressure. Refer to EC-48, "FUEL PRESSURE CHECK" .
At idling: Approximately 350 kPa (3.5 bar, 3.57 kg/cm2 , 51 psi)
OK or NG
OK
>> GO TO 5.
NG
>> Follow the construction of EC-48, "FUEL PRESSURE CHECK" .

With CONSULT-II
1. Install all removed parts.
2. Check MASS AIR FLOW in DATA MONITOR mode with CONSULT-II.
1.0 - 4.0 gm/sec:
4.0 - 10 gm/sec:
1.
2.
at idling
at 2,500 rpm
With GST
Install all removed parts.
Check mass air flow sensor signal in Service $01 with GST.
1.0 - 4.0 gm/sec:
4.0 - 10 gm/sec:
at idling
at 2,500 rpm
OK or NG
OK
>> GO TO 6.
NG
>> Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or
grounds. Refer to EC-150, "DTC P0102, P0103 MAF SENSOR" .
EC-222
http://vnx.su

6. CHECK FUNCTION OF INJECTORS
With CONSULT-II
Start engine.
Perform POWER BALANCE in ACTIVE TEST mode with
CONSULT-II.
3. Make sure that each circuit produces a momentary engine
speed drop.
1.
2.
EC
E
PBIB0133E
Without CONSULT-II
1. Start engine.
2. Listen to each injector operating sound.
Clicking noise should be heard.

OK or NG
OK
>> GO TO 7.
NG
>> Perform trouble diagnosis for EC-450, "INJECTOR CIRCUIT" .
I
PBIB1986E
7. CHECK INJECTOR
1.
2.
3.
4.
5.
6.
Confirm that the engine is cooled down and there are no fire hazards near the vehicle.
Remove injector gallery assembly. Refer to EM-34, "FUEL INJECTOR AND FUEL TUBE" .
Keep fuel hose and all injectors connected to injector gallery.
The injector harness connectors should remain connected.
Disconnect all ignition coil harness connectors.
Prepare pans or saucers under each injector.
Crank engine for about 3 seconds. Make sure that fuel sprays
out from injectors.
Fuel should be sprayed evenly for each injector.

OK or NG
OK
>> GO TO 8.
NG
>> Replace injectors from which fuel does not spray out.
Always replace O-ring with new ones.
PBIB1726E

>> INSPECTION END
EC-223
http://vnx.su


PFP:16600
EBS010P7
With the Air-Fuel Mixture Ratio Self-Learning Control, the actual mixture ratio can be brought closely to the
theoretical mixture ratio based on the mixture ratio feedback signal from the heated oxygen sensors 1. The
ECM calculates the necessary compensation to correct the offset between the actual and the theoretical
ratios.
In case the amount of the compensation value is extremely large (The actual mixture ratio is too rich.), the
ECM judges the condition as the fuel injection system malfunction and lights up the MI (2 trip detection logic).
Sensor

Trouble diagnosis
name
DTC No.
P0172
0172
Input Signal to ECM
Fuel injection system

too rich
ECM function
Fuel injection system does not operate properly.
The amount of mixture ratio compensation is too

large.
(The mixture ratio is too rich.)
Actuator
Fuel injector
Possible cause
Fuel injector
Exhaust gas leaks
EBS010P8
NOTE:
WITH CONSULT-II
1.
2.
3.
4.
5.
6.
a.
b.

Turn ignition switch ON and select SELF-LEARNING CONT in WORK SUPPORT mode with CONSULT-II.
The 1st trip DTC P0172 should be detected at this stage, if a
malfunction exists. If so, go to EC-227, "Diagnostic Procedure" .
NOTE:
Start engine and drive the vehicle under the similar conditions to
SEF215Z
(1st trip) Freeze Frame Data for 10 minutes. Refer to the table
below.
Engine speed
Vehicle speed

(T) condition
7.
If it is difficult to start engine at step 6, the fuel injection system has a malfunction, too.
EC-224
http://vnx.su

8.
Crank engine while depressing accelerator pedal.

If engine starts, go to EC-227, "Diagnostic Procedure" . If engine does not start, remove ignition plugs and
check for fouling, etc.
WITH GST
1.
2.
3.
4.
5.
6.
7.
8.
9.
a.
b.
EC

Restart engine and let idle for at least 5 seconds.
Stop engine and reconnect mass air flow sensor harness connector.
Select Service $03 with GST. Make sure DTC P0102 is
detected.
Select Service $04 with GST and erase the DTC P0102.
Select Service $07 with GST. The 1st trip DTC P0172 should be
PBIB0495E
detected at this stage, if a malfunction exists. If so, go to EC227, "Diagnostic Procedure" .
NOTE:
Start engine and drive the vehicle under the similar conditions to (1st trip) Freeze Frame Data for 10 minutes. Refer to the table below.
Engine speed
Vehicle speed

(T) condition
10. If it is difficult to start engine at step 8, the fuel injection system has a malfunction.
11. Crank engine while depressing accelerator pedal.
If engine starts, go to EC-227, "Diagnostic Procedure" . If engine does not start, remove ignition plugs and
check for fouling, etc.
EC-225
http://vnx.su

Wiring Diagram
EBS010P9
TBWA0604E
EC-226
http://vnx.su

EBS010PA

1.
2.

EC
E
SEC502D
OK or NG
OK
>> GO TO 2.
NG
OK or NG
OK
>> GO TO 3.
NG
3. CHECK HEATED OXYGEN SENSOR 1 CIRCUIT FOR OPEN AND SHORT
1.
2.
3.
4.

Disconnect heated oxygen sensor 1 (HO2S1) harness connector.
terminal 35.

5.
Check harness continuity between ECM terminal 35 or HO2S1

terminal 2 and ground.
PBIB0500E

OK or NG
OK
>> GO TO 4.
NG

1.
2.

At idling: 350 kPa (3.5 bar, 3.57 kg/cm2, 51 psi)
OK or NG
OK
>> GO TO 5.
NG
>> Follow the construction of EC-48, "FUEL PRESSURE CHECK" .
EC-227
http://vnx.su


1.
2.
With CONSULT-II
Check MASS AIR FLOW in DATA MONITOR mode with CONSULT-II.
1.0 - 4.0 gm/sec:
4.0 - 10 gm/sec:
1.
2.
at idling
at 2,500 rpm
With GST
1.0 - 4.0 gm/sec:
4.0 - 10 gm/sec:
at idling
at 2,500 rpm
OK or NG
OK
>> GO TO 6.
NG
grounds. Refer to EC-150, "DTC P0102, P0103 MAF SENSOR" .
6. CHECK FUNCTION OF INJECTORS

With CONSULT-II
Start engine.
CONSULT-II.
speed drop.
1.
2.
PBIB0133E
Without CONSULT-II
1. Start engine.
OK or NG
OK
>> GO TO 7.
NG
>> Perform trouble diagnosis for EC-450, "INJECTOR CIRCUIT" .
PBIB1986E
EC-228
http://vnx.su

7. CHECK INJECTOR
Remove injector assembly. Refer to EM-34, "FUEL INJECTOR AND FUEL TUBE" .
2. Confirm that the engine is cooled down and there are no fire hazards near the vehicle.
3. Disconnect injector harness connectors.
4. Disconnect all ignition coil harness connectors.
5. Prepare pans or saucers under each injectors.
6. Crank engine for about 3 seconds.
Make sure fuel does not drip from injector.
OK or NG
OK (Does not drip.)>>GO TO 8.
NG (Drips.)>>Replace the injectors from which fuel is dripping. Always replace O-ring with new one.
1.

EC
>> INSPECTION END

G
EC-229
http://vnx.su


PFP:16119
EBS010PB

PBIB0145E
EBS010PC

MONITOR ITEM
CONDITION
SPECIFICATION
Ignition switch: ON
(Engine stopped)
More than 0.36V
Less than 4.75V
THRTL SEN 1
THRTL SEN 2*
EBS010PD

DTC No.
P0222
0222

circuit low input

is sent to ECM.
P0223
0223

circuit high input
An excessively high voltage from the TP sensor

1 is sent to ECM.
Possible cause
(TP sensor 1 circuit is open or shorted.)

(TP sensor 1)

(APP sensor 2)
FAIL-SAFE MODE
degrees.
EBS010PE
NOTE:
TESTING CONDITION:
EC-230
http://vnx.su

WITH CONSULT-II
1.
2.
3.
4.

EC
D
SEF058Y
WITH GST

F
EC-231
http://vnx.su

Wiring Diagram
EBS010PF
TBWB0261E
EC-232
http://vnx.su

CAUTION:
TERMINAL
NO.
47
WIRE
COLOR
R
EC
ITEM
power supply
CONDITION
DATA (DC Voltage)
Approximately 5V
49
Engine stopped
More than 0.36V
Engine stopped
Less than 4.75V
[Engine is running]
66
Sensor ground
Warm-up condition
Idle speed
Approximately 0V
68
91
BR/Y
Sensor power supply

Engine stopped
Less than 4.75V
Engine stopped
More than 0.36V
J
Approximately 5V
EC-233
http://vnx.su

EBS010PG

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-234
http://vnx.su


1.

EC
D
PBIB1992E
PBIB1971E
2.
3.

J
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 3.
PBIB0082E

1.
2.
3.

OK or NG
OK
>> GO TO 4.
NG
EC-235
http://vnx.su


ECM terminal
Sensor terminal
47
EC-232
91
EC-433
OK or NG
OK
>> GO TO 5.
NG
5. CHECK APP SENSOR

OK or NG
OK
>> GO TO 11
NG
>> GO TO 6.

1.
2.
3.
4.

>> INSPECTION END
1.
2.
3.


OK or NG
OK
>> GO TO 8.
NG
1.

OK or NG
OK
>> GO TO 9.
NG
EC-236
http://vnx.su


OK or NG
OK
>> GO TO 11.
NG
>> GO TO10.
EC

1.
2.
3.

>> INSPECTION END

F

>> INSPECTION END
EBS010PH

1.
2.
3.
4.
5.

Terminal
Accelerator pedal
Voltage
49
Fully released
More than 0.36V
Fully depressed
Less than 4.75V
68
Fully released
Less than 4.75V
Fully depressed
More than 0.36V
6.
7.
8.

step.
L
MBIB0022E
EBS010PI

EC-237
http://vnx.su
DTC P0300 - P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 - 4 CYLINDER MISFIRE

DTC P0300 - P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 - 4 CYLINDER MISPFP:00000

FIRE
EBS010PJ
When a misfire occurs, engine speed will fluctuate. If the engine speed fluctuates enough to cause the crankshaft position (CKP) sensor (POS) signal to vary, ECM can determine that a misfire is occurring.
Sensor
Input Signal to ECM

Engine speed
ECM function
On board diagnosis of misfire
The misfire detection logic consists of the following two conditions.

1. One Trip Detection Logic (Three Way Catalyst Damage)
On the first trip that a misfire condition occurs that can damage the three way catalyst (TWC) due to overheating, the MI will blink.
When a misfire condition occurs, the ECM monitors the CKP sensor (POS) signal every 200 engine revolutions for a change.
When the misfire condition decreases to a level that will not damage the TWC, the MI will turn off.
If another misfire condition occurs that can damage the TWC on a second trip, the MI will blink.
When the misfire condition decreases to a level that will not damage the TWC, the MI will remain on.
If another misfire condition occurs that can damage the TWC, the MI will begin to blink again.
2. Two Trip Detection Logic (Exhaust quality deterioration)
For misfire conditions that will not damage the TWC (but will affect vehicle emissions), the MI will only light
when the misfire is detected on a second trip. During this condition, the ECM monitors the CKP sensor
signal every 1,000 engine revolutions.
A misfire malfunction can be detected on any one cylinder or on multiple cylinders.
DTC No.
P0300
0300
Multiple cylinder misfire

detected
Multiple cylinder misfire.
P0301
0301
No.1 cylinder misfire

detected
No. 1 cylinder misfires.
P0302
0302
No. 2 cylinder misfire

detected
P0303
0303

detected
P0304
0304

detected
Possible cause
Improper spark plug
Insufficient compression
The injector circuit is open or shorted
Fuel injector
Intake air leak
The ignition signal circuit is open or

shorted
Lack of fuel
Drive plate or flywheel
Incorrect PCV hose connection

EBS010PK
CAUTION:
Always drive vehicle in safe manner according to traffic conditions and obey all traffic laws when driving.
NOTE:
EC-238
http://vnx.su

WITH CONSULT-II
A
Turn ignition switch ON, and select DATA MONITOR mode
with CONSULT-II.
EC
4. Restart engine and let it idle for about 15 minutes.
5. If 1st trip DTC is detected, go to EC-239, "Diagnostic Procedure"
C
.
NOTE:
If 1st trip DTC is not detected during above procedure, performing
D
the following procedure is advised.
PBIB0164E
2. Start engine and drive the vehicle under the similar conditions to (1st trip) Freeze Frame Data for a certain
E
time. Refer to table below.
1.
The similar conditions to (1st trip) Freeze Frame Data means the vehicle operation that the following condition should be satisfied at the same time:
Engine speed
Vehicle speed
When the freeze frame data shows lower than 70C (158F), T should be lower than 70C (158F)
(T) condition
When the freeze frame data shows higher than or equal to 70C (158F), T should be higher than or
equal to 70C (158F)
The time to driving varies according to the engine speed in the freeze frame data.
Refer to the following table.
Engine speed
Time
Around 1,000 rpm
Approximately 10 minutes
Around 2,000 rpm
Approximately 5 minutes
More than 3,000 rpm
Approximately 3.5 minutes
WITH GST
EBS010PL
1. CHECK FOR INTAKE AIR LEAK AND PCV HOSE

1. Start engine and run it at idle speed.
2. Listen for the sound of the intake air leak.
3. Check PCV hose connection.
OK or NG
OK
>> GO TO 2.
NG
2. CHECK FOR EXHAUST SYSTEM CLOGGING

Stop engine and visually check exhaust tube, three way catalyst and muffler for dents.
OK or NG
OK
>> GO TO 3.
NG
EC-239
http://vnx.su

3. PERFORM POWER BALANCE TEST

1.
2.
With CONSULT-II
Perform POWER BALANCE in ACTIVE TEST mode.
Is there any cylinder which does not produce a momentary
engine speed drop?
PBIB0133E
Without CONSULT-II
When disconnecting each injector harness connector one at a time,
is there any cylinder which does not produce a momentary engine
speed drop?
PBIB1970E
Yes or No
Yes
>> GO TO 4.
No
>> GO TO 7.
4. CHECK INJECTOR
Does each injector make an operating sound at idle?
Yes or No
Yes
>> GO TO 5.
No
>> Check injector(s) and circuit(s). Refer to EC-450,
"INJECTOR CIRCUIT" .
PBIB1986E
EC-240
http://vnx.su

5. CHECK IGNITION SPARK
1. Stop engine.
2. Disconnect ignition coil assembly from rocker cover.
3. Disconnect spark plug from ignition coil assembly.
4. Connect a known-good spark plug to the ignition coil assembly.
5. Disconnect all injector harness connectors.
6. Place end of spark plug against a suitable ground and crank engine.
7. Check for spark.
OK or NG
OK
>> GO TO 6.
NG
>> Check ignition coil, power transistor and their circuits.
Refer to EC-439, "IGNITION SIGNAL" .
EC
F
SEF575Q
6. CHECK SPARK PLUGS
Remove the spark plugs and check for fouling, etc.

OK or NG
OK
>> GO TO 7.
NG
>> Repair or replace spark plug(s) with standard type
one(s). For spark plug type, refer to MA-26, "Checking
and Changing Spark Plugs" .
J
SEF156I
7. CHECK COMPRESSION PRESSURE

Check compression pressure. Refer to EM-70, "CHECKING COMPRESSION PRESSURE" .
Standard:
1,190 kPa (11.9 bar, 12.1 kg/cm2 , 172 psi)/250 rpm
Minimum:
990 kPa (9.9 bar, 10.1 kg/cm2 , 144 psi)/250 rpm
Difference between each

cylinder:
98 kPa (0.98 bar, 1.0 kg/cm2 , 14 psi)/250 rpm
OK or NG
OK
>> GO TO 8.
NG
>> Check pistons, piston rings, valves, valve seats and cylinder head gaskets.

1.
2.
3.

At idle: Approx. 350 kPa (3.5 bar, 3.57 kg/cm2 , 51 psi)
OK or NG
OK
>> GO TO 10.
NG
>> GO TO 9.
EC-241
http://vnx.su


Fuel pump and circuit (Refer to EC-465, "FUEL PUMP CIRCUIT" .)
Fuel pressure regulator (Refer to EC-48, "FUEL PRESSURE CHECK" .)
Fuel lines


Check the following items. Refer to EC-78, "Basic Inspection" .
Items
Target idle speed
Specifications
650 50 rpm (in Neutral position)
Except above
700 50 rpm [in P or N (A/T), Neutral (M/T) position]

15 5 BTDC [in P or N (A/T), Neutral (M/T) position]
Ignition timing
OK or NG
OK
>> GO TO 11.
NG
>> Follow the EC-78, "Basic Inspection" .

OK or NG
OK
>> GO TO 12.
NG

With CONSULT-II
Check mass air flow sensor signal in DATA MONITOR mode with CONSULT-II.
1.0 - 4.0 gm/sec:
4.0 - 10.0 gm/sec:
at idling
at 2,500 rpm
With GST
1.0 - 4.0 gm/sec:
4.0 - 10.0 gm/sec:
at idling
at 2,500 rpm
OK or NG
OK
>> GO TO 13.
NG
engine grounds. Refer to EC-150, "DTC P0102, P0103 MAF SENSOR" .
13. CHECK SYMPTOM MATRIX CHART

Check items on the rough idle symptom in EC-83, "Symptom Matrix Chart" .
OK or NG
OK
>> GO TO 14.
NG
EC-242
http://vnx.su

14. ERASE THE 1ST TRIP DTC
A
Some tests may cause a 1st trip DTC to be set.
Erase the 1st trip DTC from the ECM memory after performing the tests. Refer to EC-62, "HOW TO ERASE
EC
>> GO TO 15.
C

>> INSPECTION END

E
EC-243
http://vnx.su
DTC P0327, P0328 KS

DTC P0327, P0328 KS

PFP:22060
EBS010PM
The knock sensor is attached to the cylinder block. It senses engine knocking using a piezoelectric element. A
knocking vibration from the cylinder block is sensed as vibrational pressure. This pressure is converted into a
voltage signal and sent to the ECM.
PBIB0512E
EBS010PN
The MI will not light up for these self-diagnoses.

DTC No.
Trouble Diagnosis Name
DTC Detected Condition
P0327
0327
Knock sensor circuit low

input

sent to ECM.
P0328
0328
Knock sensor circuit high

input

sent to ECM.
Knock sensor
Possible Cause
EBS010PO
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.

CONSULT-II.
.
SEF058Y
WITH GST
EC-244
http://vnx.su
DTC P0327, P0328 KS

Wiring Diagram
EBS010PP
EC
TBWA0606E
EC-245
http://vnx.su
DTC P0327, P0328 KS

CAUTION:
TERMINAL
NO.
15
WIRE
COLOR
W
ITEM
Knock sensor
CONDITION
[Engine is running]
Idle speed
DATA (DC Voltage)
Approximately 2.5V
[Engine is running]
54
Sensor ground
(Knock sensor)
Warm-up condition
Idle speed
Approximately 0V
EBS010PQ
1. CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT-I

1.
2.
3.

Check resistance between ECM terminal 15 and ground. Refer to Wiring Diagram.
NOTE:
It is necessary to use an ohmmeter which can measure more than 10 M.
Resistance: Approximately 530 - 590k [at 20C (68F)]

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 2.
2. CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT-II

1.
Disconnect knock sensor harness connector.
2.
Check harness continuity between ECM terminal 15 and knock sensor terminal 1.
PBIB0512E

OK or NG
OK
>> GO TO 3.
NG
EC-246
http://vnx.su
DTC P0327, P0328 KS

3. CHECK KNOCK SENSOR

OK or NG
OK
>> GO TO 6.
NG
>> Replace knock sensor.
EC

L
PBIB2021E
OK or NG
OK
>> GO TO 5.
NG
5. CHECK KNOCK SENSOR SHIELD CIRCUIT FOR OPEN AND SHORT

1.
2.
Reconnect knock sensor harness connector.

Check harness continuity between ECM terminal 54 and ground.
Continuity should exist

OK or NG
OK
>> GO TO 6.
NG
EC-247
http://vnx.su
DTC P0327, P0328 KS


>> INSPECTION END
EBS010PR
KNOCK SENSOR
Check resistance between knock sensor terminal 1 and ground.
NOTE:
It is necessary to use an ohmmeter which can measure more
than 10 M.
CAUTION:
Do not use any knock sensors that have been dropped or physically damaged. Use only new ones.
SEF227W
EBS010PS
KNOCK SENSOR
Refer to EM-86, "CYLINDER BLOCK" .
EC-248
http://vnx.su
DTC P0335 CKP SENSOR (POS)


PFP:23731
A
EBS010PT
The crankshaft position sensor (POS) is located on the cylinder

block rear housing facing the gear teeth (cogs) of the signal plate at
the end of the crankshaft. It detects the fluctuation of the engine revolution.
The sensor consists of a permanent magnet and Hall IC.
When the engine is running, the high and low parts of the teeth
cause the gap with the sensor to change.
The changing gap causes the magnetic field near the sensor to
change.
Due to the changing magnetic field, the voltage from the sensor
changes.
The ECM receives the voltage signal and detects the fluctuation of
the engine revolution.
EC
D
PBIB0562E
EBS010PU

MONITOR ITEM
ENG SPEED
CONDITION
SPECIFICATION

EBS010PV
H
DTC No.
P0335
0335
Crankshaft position
sensor (POS) circuit
The crankshaft position sensor (POS) signal is not

detected by the ECM during the first few seconds of
engine cranking.
The proper pulse signal from the crankshaft position
sensor (POS) is not sent to ECM while the engine is
running.
The crankshaft position sensor (POS) signal is not in
the normal pattern during engine running.
Possible cause
(The sensor circuit is open or
shorted.)
Signal plate
EBS010PW
NOTE:
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10.5V with ignition switch ON.
WITH CONSULT-II
1.
2.
3.
4.
5.

CONSULT-II.
Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed.
.
If 1st trip DTC is not detected, go to next step.
Maintain engine speed at more than 800 rpm for at least 5 seconds.
.
WITH GST
EC-249
http://vnx.su
SEF058Y

Wiring Diagram
EBS010PX
TBWA0607E
EC-250
http://vnx.su

A
CAUTION:
EC
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
C
[Engine is running]
Warm-up condition
Idle speed
Approximately 3.0V
NOTE:
at idle
14
PU/R
E
PBIB0527E
Crankshaft position
sensor (POS)
Approximately 3.0V
F
[Engine is running]
G
PBIB0528E
30
Sensor ground
[Engine is running]
Warm-up condition
Idle speed
Approximately 0V
EC-251
http://vnx.su

EBS010PY

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-252
http://vnx.su

2. CHECK CRANKSHAFT POSITION (CKP) SENSOR (POS) POWER SUPPLY CIRCUIT

1.
Disconnect crankshaft position (CKP) sensor (POS) harness connector.

EC
D
PBIB0512E
2.
3.

Check voltage between CKP sensor (POS) terminal 1 and
ground with CONSULT-II or tester.

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.
H
PBIB0664E
Harness for open or short between crankshaft position sensor (POS) and ECM
Harness for open or short between crankshaft position sensor (POS) and ECM relay
4. CHECK CKP SENSOR (POS) GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Check harness continuity between CKP sensor (POS) terminal 3 and ECM terminal 30.

OK or NG
OK
>> GO TO 5.
NG
EC-253
http://vnx.su

5. CHECK CKP SENSOR (POS) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

OK or NG
OK
>> GO TO 6.
NG

OK or NG
OK
>> GO TO 7.
NG
7. CHECK GEAR TOOTH

Visually check for chipping signal plate gear tooth.
OK or NG
OK
>> GO TO 8.
NG
>> Replace the signal plate.

>> INSPECTION END
EBS010PZ
CRANKSHAFT POSITION SENSOR (POS)

1.
2.
3.
4.
Loosen the fixing bolt of the sensor.

Disconnect crankshaft position sensor (POS) harness connector.
Remove the sensor.
Visually check the sensor for chipping.
PBIB0563E
EC-254
http://vnx.su

5.
Check resistance as shown in the figure.

Terminal No. (Polarity)
Resistance [at 25C (77F)]
3 (+) - 1 (-)
3 (+) - 2 (-)
Except 0 or
EC
2 (+) - 1 (-)
6.
If NG, replace crankshaft position sensor (POS).
C
MBIB0024E
EBS010Q0

EC-255
http://vnx.su
DTC P0340 CMP SENSOR (PHASE)


PFP:23731
EBS010Q1
The camshaft position sensor (PHASE) senses the retraction of

intake valve camshaft to identify a particular cylinder. The camshaft
position sensor (PHASE) senses the piston position.
When the crankshaft position sensor (POS) system becomes inoperative, the camshaft position sensor (PHASE) provides various controls of engine parts instead, utilizing timing of cylinder identification
signals.
When engine is running, the high and low parts of the teeth cause
the gap with the sensor to change.
change.
Due to the changing magnetic field, the voltage from the sensor changes.
PBIB0562E

DTC No.
P0340
0340

(PHASE) circuit
EBS010Q2
The cylinder No. signal is not sent to ECM

for the first few seconds during engine
cranking.
Possible cause
Camshaft (Intake)
The cylinder No. signal is not set to ECM

during engine running.
Starter motor (Refer to SC-22, "STARTING SYSTEM" .)
The cylinder No. signal is not in the normal

pattern during engine running.
Starting system circuit (Refer to SC-22,

"STARTING SYSTEM" .)
Dead (Weak) battery
EBS010Q3
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.
5.
6.

.
.
WITH GST
EC-256
http://vnx.su
SEF058Y

Wiring Diagram
EBS010Q4
EC
TBWA0608E
EC-257
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
[Engine is running]
Warm-up condition
Idle speed
DATA (DC Voltage)
1.0 - 4.0V
NOTE:
at idle
13
L/W
PBIB0525E

(PHASE)
1.0 - 4.0V
[Engine is running]
PBIB0526E
29
Sensor ground
[Engine is running]
Warm-up condition
Idle speed
Approximately 0V
EBS010Q5
1. CHECK STARTING SYSTEM

Turn ignition switch to START position.
Does the engine turn over?
Does the starter motor operate?
Yes or No
Yes
>> GO TO 2.
No
>> Check starting system. (Refer to SC-22, "STARTING SYSTEM" .)
EC-258
http://vnx.su


1.
2.

EC
J
PBIB2021E
OK or NG
OK
>> GO TO 3.
NG
EC-259
http://vnx.su

3. CHECK CAMSHAFT POSITION (CMP) SENSOR (PHASE) POWER SUPPLY CIRCUIT

1.
2.
Disconnect camshaft position (CMP) sensor (PHASE) harness

connector.
PBIB0496E
3.
Check voltage between CMP sensor (PHASE) terminal 1 and


OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
PBIB0664E

Harness for open or short between camshaft position sensor (PHASE) and ECM
Harness for open or short between camshaft position sensor (PHASE) and ECM relay
5. CHECK CMP SENSOR (PHASE) GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Check harness continuity between CMP sensor (PHASE) terminal 3 and ECM terminal 29.

OK or NG
OK
>> GO TO 6.
NG
EC-260
http://vnx.su

6. CHECK CMP SENSOR (PHASE) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
EC

OK or NG
OK
>> GO TO 7.
NG

OK or NG
OK
>> GO TO 8.
NG


OK or NG
OK
>> GO TO 9.
NG
PBIB0565E

>> INSPECTION END

L
EBS010Q6
CAMSHAFT POSITION SENSOR (PHASE)

1.
2.
3.
4.

Disconnect camshaft position sensor (PHASE) harness connector.
Remove the sensor.
PBIB0563E
EC-261
http://vnx.su

5.

3 (+) - 1 (-)
3 (+) - 2 (-)
Except 0 or
2 (+) - 1 (-)
MBIB0024E
EBS010Q7

Refer to EM-56, "CAMSHAFT" .
EC-262
http://vnx.su
DTC P0420 THREE WAY CATALYST FUNCTION


PFP:20905
A
EBS010Q8
The ECM monitors the switching frequency ratio of heated oxygen

sensors 1 and 2.
A three way catalyst (manifold) with high oxygen storage capacity
will indicate a low switching frequency of heated oxygen sensor 2.
As oxygen storage capacity decreases, the heated oxygen sensor 2
switching frequency will increase.
When the frequency ratio of heated oxygen sensors 1 and 2
approaches a specified limit value, the three way catalyst (manifold)
malfunction is diagnosed.
EC
D
SEF484YF
E
DTC No.
P0420
0420
Catalyst system efficiency

below threshold
Three way catalyst (manifold) does not operate

properly.
Three way catalyst (manifold) does not have

enough oxygen storage capacity.
Possible cause
Three way catalyst (manifold)
Exhaust tube
Intake air leaks
Fuel injector
Fuel injector leaks
Spark plug
H
EBS010Q9
NOTE:
WITH CONSULT-II
TESTING CONDITION:
Open engine hood before conducting the following procedure.
Do not hold engine speed for more than the specified minutes below.
1. Start Engine and warm it up to the normal operating temperature.
4. Let engine idle for 1 minute.
5. Select DTC & SRT CONFIRMATION then SRT WORK SUPPORT mode with CONSULT-II.
6. Start engine.
7. Rev engine up to 2,000 to 3,000 rpm and hold it for 3 consecutive minutes then release the accelerator pedal completely.
If INCMP of CATALYST changed to COMPLT, go to step 10
8. Wait 5 seconds at idle.
PBIB0566E
EC-263
http://vnx.su

9.
Rev engine up to 2,000 to 3,000 rpm and maintain it until

INCMP of CATALYST changes to CMPLT (It will take
approximately 5 minutes).
If not CMPLT, stop engine and cool it down to less than 70C
(158F) and then retest from step 1.
PBIB0567E
a.
b.
c.
d.
(soak the vehicle)
Turn ignition switch ON and select COOLANT TEMP/S in
DATA MONITOR mode with CONSULT-II.
Start engine and warm it up while monitoring COOLANT TEMP/
S indication on CONSULT-II.
When COOLANT TEMP/S indication reaches to 70(158F),
go to step 3.
SEF013Y
10. Select SELF-DIAG RESULTS mode with CONSULT-II.

11. Confirm that the 1st trip DTC is not detected.
SEF535Z
EBS010QA
Use this procedure to check the overall function of the three way catalyst (manifold). During this check, a 1st
WITH GST
1.
2.
3.
4.
5.
6.

Set voltmeters probes between ECM terminal 35 (HO2S1 signal) and ground, and ECM terminal 16 (HO2S2 signal) and
ground.
Keep engine speed at 2,000 rpm constant under no load.
MBIB0018E
EC-264
http://vnx.su

7.
Make sure that the voltage switching frequency (high & low)
between ECM terminal 16 and ground is very less than that of
A
ECM terminal 35 and ground.
Switching frequency ratio = A/B
A: Heated oxygen sensor 2 voltage switching frequency
EC
B: Heated oxygen sensor 1 voltage switching frequency
This ratio should be less than 0.75.
If the ratio is greater than above, it means three way catalyst
does not operate properly. Go to EC-265, "Diagnostic ProceC
dure" .
NOTE:
MBIB0124E
If the voltage at terminal 35 does not switch periodically more than 5
D
times within 10 seconds at step 7, perform trouble diagnosis for DTC P0133 first. (See EC-185, "DTC P0133
HO2S1" .)
EBS010QB
1. CHECK EXHAUST SYSTEM

Visually check exhaust tubes and muffler for dent.
OK or NG
OK
>> GO TO 2.
NG

1.
2.

Listen for an exhaust gas leak before the three way catalyst (manifold).
SEC502D
OK or NG
OK
>> GO TO 3.
NG
3. CHECK INTAKE AIR LEAK

OK or NG
OK
>> GO TO 4.
NG

Check the following items. Refer to EC-78, "Basic Inspection" .
Items
Target idle speed
Ignition timing
Specifications
650 50 rpm (in Neutral position)
Except above
700 50 rpm [in P or N (A/T), Neutral (M/T) position]

15 5 BTDC [in P or N (A/T), Neutral (M/T) position]
EC-265
http://vnx.su

OK or NG
OK
>> GO TO 5.
NG
>> Follow the EC-78, "Basic Inspection" .
5. CHECK INJECTORS
1.
2.
3.
Refer to Wiring Diagram for Injectors, EC-451 .

Stop engine and then turn ignition switch ON.
Check voltage between ECM terminals 22, 23, 41, 42 and
OK or NG
OK
>> GO TO 6.
NG
>> Perform EC-452, "Diagnostic Procedure" .
MBIB0030E
6. CHECK IGNITION SPARK

2. Disconnect all injector harness connectors.
3. Disconnect ignition coil assembly from rocker cover.
4. Disconnect spark plug from ignition coil assembly.
5. Connect a known-good spark plug to the ignition coil assembly.
6. Place end of spark plug against a suitable ground and crank engine.
7. Check for spark.
OK or NG
OK
>> GO TO 7.
NG
>> Check ignition coil with power transistor and their circuit.
Refer to EC-439, "IGNITION SIGNAL" .
SEF575Q
7. CHECK INJECTOR
1.
2.

Remove injector assembly.
Refer to EM-34, "FUEL INJECTOR AND FUEL TUBE" .
3. Disconnect all ignition coil harness connectors.
4. Reconnect all injector harness connectors disconnected.
5. Turn ignition switch ON.
Make sure fuel does not drip from injector.
OK or NG
OK (Does not drip.)>>GO TO 8.
NG (Drips.)>>Replace the injector(s) from which fuel is dripping.
EC-266
http://vnx.su


Trouble is fixed.>>INSPECTION END
Trouble is not fixed.>>Replace three way catalyst (manifold).
EC
EC-267
http://vnx.su
DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE


PFP:14920
Description
EBS010QC
SYSTEM DESCRIPTION
Sensor
Input Signal to ECM

ECM function
Actuator
Engine speed*1
Battery
Battery voltage*1
Throttle position
Closed throttle position

Wheel sensor*2
Vehicle speed
EVAP canister
purge flow control
EVAP canister purge volume

This system controls flow rate of fuel vapor from the EVAP canister. The opening of the vapor by-pass passage in the EVAP canister purge volume control solenoid valve changes to control the flow rate. The EVAP
canister purge volume control solenoid valve repeats ON/OFF operation according to the signal sent from the
ECM. The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is
determined by considering various engine conditions. When the engine is operating, the flow rate of fuel vapor
from the EVAP canister is regulated as the air flow changes.
COMPONENT DESCRIPTION
The EVAP canister purge volume control solenoid valve uses a ON/
OFF duty to control the flow rate of fuel vapor from the EVAP canister. The EVAP canister purge volume control solenoid valve is
moved by ON/OFF pulses from the ECM. The longer the ON pulse,
the greater the amount of fuel vapor that will flow through the valve.
SEF337U
EBS010QD

MONITOR ITEM
CONDITION

(M/T)
No load
PURG VOL C/V
SPECIFICATION
Idle
0%
2,000 rpm
20 - 30%

DTC No.
P0444
0444

control solenoid valve circuit
open
EBS010QE
Possible cause
(The solenoid valve circuit is open or
shorted.)

solenoid valve
An excessively low voltage signal is sent

to ECM through the valve
EC-268
http://vnx.su

EBS010QF
A
NOTE:
EC
TESTING CONDITION:
Before performing the following procedure, confirm battery voltage is more than 11V at idle.
WITH CONSULT-II
1.
2.
3.
4.

Start engine and let it idle for at least 13 seconds.
.
F
SEF058Y
WITH GST

H
EC-269
http://vnx.su

Wiring Diagram
EBS010QG
TBWA0609E
EC-270
http://vnx.su

A
CAUTION:
EC
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
C
BATTERY VOLTAGE
(11 - 14V)
D
[Engine is running]
Idle speed
E
19
PBIB0050E
Approximately 10V
[Engine is running]
Engine speed is about 2,000 rpm (More than

100 seconds after starting engine)
PBIB0520E
EC-271
http://vnx.su

EBS010QH
1. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT
1.
2.
3.

Disconnect EVAP canister purge volume control solenoid valve
harness connector.
PBIB1993E
PBIB1968E
4.
Check voltage between EVAP canister purge volume control

solenoid valve terminal 1 and ground with CONSULT-II or tester.
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
PBIB0148E

Harness connectors M61, F41
Harness for open or short between EVAP canister purge volume control solenoid valve and ECM relay.
Harness for open or short between EVAP canister purge volume control solenoid valve and ECM
>> Repair harness or connectors.
EC-272
http://vnx.su

3. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

EC
Check harness continuity between EVAP canister purge volume control solenoid valve terminal 2 and
ECM terminal 19. Refer to Wiring Diagram.
C

OK or NG
OK (With CONSULT-II)>>GO TO 4.
OK (Without CONSULT-II)>>GO TO 5.
NG
>> Repair open circuit or short to ground and short to power in harness or connectors.
4. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION

F
With CONSULT-II
1. Reconnect all harness connectors disconnected.
2. Start engine.
3. Perform PURG VOL CONT/V in ACTIVE TEST mode with
CONSULT-II. Check that engine speed varies according to the
valve opening.
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.
J
PBIB0569E
5. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

OK or NG
OK
>> GO TO 6.
NG
>> Replace EVAP canister purge volume control solenoid valve.

>> INSPECTION END
EC-273
http://vnx.su

EBS010QI
EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

With CONSULT-II
Check air passage continuity of EVAP canister purge volume control
solenoid valve under the following conditions.
Condition
(PURG VOL CONT/V value)
Air passage continuity

between A and B
100%
Yes
0%
No
PBIB0149E
Without CONSULT-II
Condition

between A and B
12V direct current supply between terminals 1 and 2
Yes
No supply
No
PBIB0150E
EBS010QJ

EC-274
http://vnx.su
DTC P0500 VSS

DTC P0500 VSS

Description
PFP:32702
A
EBS010QK
NOTE:
If DTC P0500 is displayed with DTC U1000 or U1001, first perform the trouble diagnosis for DTC U1000, EC
The vehicle speed signal is sent to the combination meter from the ESP/TCS/ABS control unit (with ESP
models) or ABS actuator and electric unit (control unit) (without ESP models) through CAN communication
C
line. The combination meter then sends a signal to the ECM through CAN communication line.

DTC No.
EBS010QL
P0500
0500
Vehicle speed sensor
The almost 0 km/h (0 MPH) signal from

vehicle speed sensor is sent to ECM
even when vehicle is being driven.
Possible cause
(The CAN communication line is open or
shorted.)
ESP/TCS/ABS control unit (with ESP models)

(without ESP models)
Wheel sensor
Combination meter
G
EBS010QM
CAUTION:
NOTE:
TESTING CONDITION:
Steps 1 and 2 may be conducted with the drive wheels lifted in the shop or by driving the vehicle. If a
road test is expected to be easier, it is unnecessary to lift the vehicle.
WITH CONSULT-II
1.
2.
3.
4.
5.
Start engine.
Read VHCL SPEED SE in DATA MONITOR mode with CONSULT-II. The vehicle speed on CONSULTII should exceed 10 km/h (6 MPH) when rotating wheels with suitable gear position.
If OK, go to following step.
Warm engine up to normal operating temperature.
ENG SPEED
M/T: 2,000 - 6,000 rpm

A/T: 1,750 - 6,000 rpm
COOLAN TEMP/S
B/FUEL SCHDL
QR20DE
4.9 - 31.8 msec
QR25DE
M/T: 5.0 - 31.8 msec

A/T: 6.0 - 31.8 msec
Shift lever
Suitable position
PW/ST SIGNAL
OFF
SEF196Y
6.
EBS010QN
Use this procedure to check the overall function of the vehicle speed signal circuit. During this check, a 1st trip
DTC might not be confirmed.
EC-275
http://vnx.su
DTC P0500 VSS

WITH GST
1.
2.
3.
4.
Lift up drive wheels.

Start engine.
Read vehicle speed signal in Service $01 with GST.
The vehicle speed signal on GST should be able to exceed 10 km/h (6 MPH) when rotating wheels with
suitable gear position.
EBS010QO
1. CHECK DTC WITH ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) (WITHOUT ESP
MODELS) OR ESP/TCS/ABS CONTROL UNIT (WITH ESP MODELS)
Refer to BRC-11, "TROUBLE DIAGNOSIS" (Without ESP models) or BRC-58, "TROUBLE DIAGNOSIS"
(With ESP models).
OK or NG
OK
>> GO TO 2.
NG
2. CHECK COMBINATION METER

Check combination meter function.
Refer to DI-4, "COMBINATION METERS" .
>> INSPECTION END
EC-276
http://vnx.su
DTC P0550 PSP SENSOR


PFP:49763
A
EBS010QP
Power steering pressure (PSP) sensor is installed to the power

steering high-pressure tube and detects a power steering load. This
sensor is a potentiometer which transforms the power steering load
into output voltage, and emits the voltage signal to the ECM. The
ECM controls the electric throttle control actuator and adjusts the
throttle valve opening angle to increase the engine speed and
adjusts the idle speed for the increased load.
EC
D
PBIB0502E
EBS010QQ

MONITOR ITEM
PW/ST SIGNAL
CONDITION

the engine
SPECIFICATION
Steering wheel is not being turned.
OFF
Steering wheel is being turned.
ON
G
EBS010QR
The MI will not light up for this self-diagnosis.

NOTE:
If DTC P0550 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to
EC-371, "DTC P1229 SENSOR POWER SUPPLY" .
I
DTC No.
P0550
0550

sensor circuit
Possible cause
An excessively low or high voltage from the

sensor is sent to ECM.
EBS010QS
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

.
WITH GST
EC-277
http://vnx.su
SEF058Y

Wiring Diagram
EBS010QT
TBWA0610E
EC-278
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
[Engine is running]
12

sensor
[Engine is running]
DATA (DC Voltage)
0.5 - 4.0V
0.4 - 0.8V
[Engine is running]
57
65
Sensor ground
Sensor power supply

sensor)
Warm-up condition
Idle speed
Approximately 0V
E
Approximately 5V
EBS010QU
1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-279
http://vnx.su

2. CHECK PSP SENSOR POWER SUPPLY CIRCUIT

1.
2.
Disconnect PSP sensor harness connector.

PBIB0502E
3.
Check voltage between PSP sensor terminal 3 and ground with

OK or NG
OK
>> GO TO 3.
NG
SEF509Y
3. CHECK PSP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1.
2.
3.

Check harness continuity between PSP sensor terminal 1 and ECM terminal 57.

OK or NG
OK
>> GO TO 4.
NG
4. CHECK PSP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

OK or NG
OK
>> GO TO 5.
NG
5. CHECK PSP SENSOR

OK or NG
OK
>> GO TO 6.
NG
>> Replace PSP sensor.
EC-280
http://vnx.su


EC
>> INSPECTION END
EBS010QV
POWER STEERING PRESSURE SENSOR

1.
2.
3.

Start engine and let it idle.
Check voltage between ECM terminal 12 and ground under the
following conditions.
Condition
Voltage
0.5 - 4.0V
0.4 - 0.8V
MBIB0025E
EBS0128D

H
Refer to PS-37, "HYDRAULIC LINE" .
EC-281
http://vnx.su
DTC P0605 ECM

DTC P0605 ECM

PFP:23710
EBS010QW
The ECM consists of a microcomputer and connectors for signal

input and output and for power supply. The ECM controls the engine.
PBIB1164E
EBS010QX
This self-diagnosis has one or two trip detection logic.

DTC No.
P0605
0605
Engine control module

A)
ECM calculation function is malfunctioning.
B)
ECM EEP-ROM system is malfunctioning.
C)
ECM self shut-off function is malfunctioning.
Possible cause
ECM
FAIL-SAFE MODE
ECM enters fail-safe mode when malfunction A is detected.
Detected items
ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5
degrees) by the return spring.
ECM deactivates ASCD operation.
Malfunction A
EBS010QY
Perform PROCEDURE FOR MALFUNCTION A first. If the 1st trip DTC cannot be confirmed, perform
PROCEDURE FOR MALFUNCTION B. If there is no problem on PROCEDURE FOR MALFUNCTION B,
perform PROCEDURE FOR MALFUNCTION C.
NOTE:
PROCEDURE FOR MALFUNCTION A

With CONSULT-II
1.
2.
3.

.
SEF058Y
With GST
EC-282
http://vnx.su
DTC P0605 ECM

PROCEDURE FOR MALFUNCTION B
With CONSULT-II
1.
2.
3.
4.
Turn ignition switch ON and wait at least 1 second.

Turn ignition switch OFF, wait at least 10 seconds and then turn
ON.
.
EC
SEF058Y
With GST
F
PROCEDURE FOR MALFUNCTION C

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

ON.
Repeat step 3 for 32 times.
.
J
SEF058Y
With GST
EBS010QZ
1. INSPECTION START
With CONSULT-II
Select SELF DIAG RESULTS mode with CONSULT-II.
Touch ERASE.
Perform DTC Confirmation Procedure.
See EC-282, "DTC Confirmation Procedure" .
5. Is the 1st trip DTC P0605 displayed again?
1.
2.
3.
4.
With GST
2. Select Service $04 with GST.
3. Touch ERASE.
4. Perform DTC Confirmation Procedure.
Yes or No
Yes
>> GO TO 2.
No
>> INSPECTION END
EC-283
http://vnx.su
DTC P0605 ECM

2. REPLACE ECM
1.
2.
3.
4.
5.
Replace ECM.
>> INSPECTION END
EC-284
http://vnx.su
DTC P1065 ECM POWER SUPPLY


PFP:23710
A
EBS010R0
Battery voltage is supplied to the ECM even when the ignition switch
is turned OFF for the ECM memory function of the DTC memory, the
air-fuel ratio feedback compensation value memory, the Idle Air Volume Learning value memory, etc.
EC
D
PBIB1164E

DTC No.
P1065
1065
ECM power supply circuit
EBS010R1
Possible cause
[ECM power supply (back-up) circuit is
open or shorted.]
ECM
ECM back-up RAM system does not function

properly.
G
EBS010R2
NOTE:
5.
6.
WITH CONSULT-II
1.
2.
3.
4.

ON.
Repeat steps 3 and 4 for 4 times.
.
SEF058Y
WITH GST
EC-285
http://vnx.su

Wiring Diagram
EBS010R3
TBWA0611E
EC-286
http://vnx.su

CAUTION:
TERMINAL
NO.
121
EC
WIRE
COLOR
W/L
ITEM
(Back-up)
CONDITION
DATA (DC Voltage)

BATTERY VOLTAGE
(11 - 14V)
C
EBS010R4
1. CHECK ECM POWER SUPPLY
1.
2.
3.


OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
H
MBIB0026E
Harness connectors E60, M36
10A fuse
Harness for open or short between ECM and battery


OK or NG
OK
>> GO TO 4.
NG
EC-287
http://vnx.su

4. PERFORM DTC CONFIRMATION PROCEDURE

With CONSULT-II
Touch ERASE.
1.
2.
3.
4.
With GST
Select Service $04 with GST.
Touch ERASE.
Yes or No
Yes
>> GO TO 5.
No
>> INSPECTION END
1.
2.
3.
4.
5. REPLACE ECM
1.
2.
3.
4.
5.
Replace ECM.
>> INSPECTION END
EC-288
http://vnx.su
DTC P1111 IVT CONTROL SOLENOID VALVE


PFP:23796
A
EBS010R5
Intake valve timing control solenoid valve is activated by ON/OFF

pulse duty (ratio) signals from the ECM.
The intake valve timing control solenoid valve changes the oil
amount and direction of flow through intake valve timing control unit
or stops oil flow.
The longer pulse width advances valve angle.
The shorter pulse width retards valve angle.
When ON and OFF pulse widths become equal, the solenoid valve
stops oil pressure flow to fix the intake valve angle at the control
position.
EC
D
PBIB1842E
EBS010R6

MONITOR ITEM
INT/V SOL (B1)
CONDITION

(M/T)
No load
Idle
0% - 2%
2,000 rpm
Approx. 0% - 50%

DTC No.
P1111
1111

solenoid valve circuit
SPECIFICATION
EBS010R7

An improper voltage is sent to the ECM
through intake valve timing control solenoid
valve.
Possible cause
(Solenoid valve circuit is open or shorted.)

EBS010R8
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and
wait at least 10 seconds before conducting the next test.
WITH CONSULT-II
1.
2.
3.
4.

Start engine and let it idle for 5 seconds.
.
SEF058Y
WITH GST
Following the procedure WITH CONSULT-II above.
EC-289
http://vnx.su

Wiring Diagram
EBS010R9
TBWA0612E
EC-290
http://vnx.su

A
CAUTION:
EC
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
C
[Engine is running]
Warm-up condition
Idle speed
BATTERY VOLTAGE
(11 - 14V)
D
62
Intake valve timing

VOLTAGE (11 - 14V)
[Engine is running]
Warm-up condition
F
PBIB1790E
EBS010RA
1. CHECK POWER SUPPLY CIRCUIT
1.
2.

L
PBIB0511E
3.

M
4.
Check voltage between intake valve timing control solenoid

valve terminal 1 and ground with CONSULT-II or tester.
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
PBIB0285E
2. DETECT MALFUNCTION PART

Check harness for open or short between intake valve timing control solenoid valve and ECM relay.
EC-291
http://vnx.su

3. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR
OPEN AND SHORT
1.
2.
3.

Check harness continuity between intake valve timing control solenoid valve terminal 2 and ECM terminal
62. Refer to Wiring Diagram.

OK or NG
OK
>> GO TO 4.
NG
4. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE

OK or NG
OK
>> GO TO 5.
NG
>> Replace intake valve timing control solenoid valve.

>> INSPECTION END
EBS010RB
INTAKE VALVE TIMING CONTROL SOLENOID VALVE

1.
2.

Check resistance between intake valve timing control solenoid
valve terminals 1 and 2 under the following conditions.
Terminals
Resistance
1 and 2
Approximately 8 [at 20C (68F)]
1 or 2 and ground
MBIB0027E
EBS010RC

Refer to EM-46, "TIMING CHAIN" .
EC-292
http://vnx.su
DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR


PFP:16119
A
EBS010RD
Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc.
The throttle control motor is operated by the ECM and it opens and closes the throttle valve.
EC
The throttle position sensor detects the throttle valve position, and the opening and closing speed of the throttle valve and feeds the voltage signals to the ECM. The ECM judges the current opening angle of the throttle
valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening
C
angle properly in response to driving condition.
EBS010RE
This self-diagnosis has the one trip detection logic.

DTC No.
P1121
1121

actuator

A)
Electric throttle control actuator does not function

properly due to the return spring malfunction.
B)
Throttle valve opening angle in fail-safe mode is

not in specified range.
C)
ECM detect the throttle valve is stuck open.
Possible cause
FAIL-SAFE MODE
Detected items
Malfunction A
The ECM controls the electric throttle actuator by regulating the throttle opening around the idle position.
The engine speed will not rise more than 2,000 rpm.
Malfunction B
ECM controls the electric throttle control actuator by regulating the throttle opening to 20 degrees or less.
Malfunction C
While the vehicle is driving, it slows down gradually by fuel cut. After the vehicle stops, the engine stalls.
The engine can restart in N or P position, and engine speed will not exceed 1,000 rpm or more.
EBS010RF
NOTE:
Perform PROCEDURE FOR MALFUNCTION A AND B first. If the DTC cannot be confirmed, perform
PROCEDURE FOR MALFUNCTION C.
PROCEDURE FOR MALFUNCTION A AND B

With CONSULT-II
1.
2.
3.
Turn ignition witch ON and wait at least 1 second.

Shift selector lever to D position (A/T), 1st position (M/T) and
wait at least 3 seconds.
4. Shift selector lever to P position (A/T), Neutral position (M/T).
6. Turn ignition switch ON and wait at least 1 second.
7. Shift selector lever to D position (A/T), 1st position (M/T) and
9. Turn ignition switch OFF, wait at least 10 seconds and then turn
ON.
10. If DTC is detected, go to EC-294, "Diagnostic Procedure" .
EC-293
http://vnx.su
SEF058Y

With GST

With CONSULT-II
1.
2.
3.
4.
5.
6.

Shift selector lever to P position (A/T), Neutral position (M/T).
SEF058Y
With GST
EBS010RG
1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY

1.
2.
Remove the intake air duct.

Check if a foreign matter is caught between the throttle valve
and the housing.
OK or NG
OK
>> GO TO 2.
NG
>> Remove the foreign matter and clean the electric throttle
control actuator inside.
PBIB0518E

1.
2.
3.

>> INSPECTION END
EBS010RH
EC-294
http://vnx.su
DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION


Description
PFP:16119
A
EBS010RI
NOTE:
If DTC P1122 is displayed with DTC P1121 or 1126, first perform the trouble diagnosis for DTC P1121 or EC
P1126. Refer to EC-293, "DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR" or EC-305, "DTC
P1124, P1126 THROTTLE CONTROL MOTOR RELAY" .
C
The current opening angle of the throttle valve is detected by the throttle position sensor and it provides feedback to the ECM to control the throttle control motor to make the throttle valve opening angle properly in
response to driving condition.
D
EBS010RJ

DTC No.
Possible cause
P1122
1122

performance problem
Electric throttle control function does not

operate properly.
(Throttle control motor circuit is open or
shorted.)
(Throttle control motor relay circuit is open or
shorted.)
FAIL-SAFE MODE

ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return
spring.
EBS010RK
NOTE:
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 11V when engine
is running.
WITH CONSULT-II
1.
2.
3.
4.
SEF058Y
EC-295
http://vnx.su

WITH GST

Wiring Diagram
EBS010RL
LHD MODELS
TBWA0613E
EC-296
http://vnx.su

A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damEC
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
3
WIRE
COLOR
W/B
ITEM
relay power supply
CONDITION
DATA (DC Voltage)
BATTERY VOLTAGE
(11 - 14V)
0 - 14V
4

(Close)
Engine stopped
F
PBIB1104E
0 - 14V

5

(Open)
Engine stopped
H
PBIB1105E
104
W/B

relay
BATTERY VOLTAGE
(11 - 14V)
0 - 1.0V
EC-297
http://vnx.su

RHD MODELS
TBWA0614E
EC-298
http://vnx.su

A
CAUTION:
EC
TERMINAL
NO.
3
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
C
W/B

relay power supply
BATTERY VOLTAGE
(11 - 14V)
0 - 14V

4

(Close)
Engine stopped
PBIB1104E
0 - 14V
5

(Open)
Engine stopped
H
PBIB1105E
104
W/B

relay
BATTERY VOLTAGE
(11 - 14V)
0 - 1.0V
EC-299
http://vnx.su

EBS010RM

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
2. CHECK THROTTLE CONTROL MOTOR RELAY SIGNAL CIRCUIT

Check voltage between ECM terminal 3 and ground under the following conditions with CONSULT-II or tester.
Ignition switch
Voltage
OFF
Approximately 0V
ON
Battery voltage
(11 - 14V)
OK or NG
OK
>> GO TO 10.
NG
>> GO TO 3.
MBIB0028E
EC-300
http://vnx.su

3. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT

1.
2.

Disconnect throttle control motor relay.
EC
D
PBIB1972E
3.
Check voltage between throttle control motor relay terminals 2, 5

and ground with CONSULT-II or tester.
F

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
H
PBIB0575E
15A fuse
Harness for open or short between throttle control motor relay and battery
5. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT

1.
2.

Check harness continuity between throttle control motor relay terminal 3 and ECM terminal 3.

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

Harness for open or short between throttle control motor relay and ECM
EC-301
http://vnx.su

7. CHECK THROTTLE CONTROL MOTOR RELAY OUTPUT SIGNAL CIRCUIT

1.
Check continuity between throttle control motor relay terminal 1 and ECM terminal 104.

OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.

Harness connectors E116, M75 (LHD models)
Harness connectors E106, M14 (RHD models)
9. CHECK THROTTLE CONTROL MOTOR RELAY

OK or NG
OK
>> GO TO 13.
NG
>> Replace throttle control motor relay.
10. CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT
1.
2.
3.
4.

Check harness continuity between the following terminals.
actuator terminal
3
ECM terminal
Continuity
Should exist
Should not exist
Should not exist
Should exist
PBIB1992E

OK or NG
OK
>> GO TO 11.
NG
PBIB1971E
EC-302
http://vnx.su

1.
2.

Check if foreign matter is caught between the throttle valve and
the housing.
OK or NG
OK
>> GO TO 12.
NG
EC
D
PBIB0518E
12. CHECK THROTTLE CONTROL MOTOR

OK or NG
OK
>> GO TO 13.
NG
>> GO TO 14.

H

OK or NG
OK
>> GO TO 14.
NG

1.
2.
3.

>> INSPECTION END
EBS010RN
THROTTLE CONTROL MOTOR RELAY

1.
2.
Apply 12V direct current between relay terminals 1 and 2.

Check continuity between relay terminals 3 and 5.
Conditions
Continuity
12V direct current supply between terminals

1 and 2
Yes
No current supply
No
3.
If NG, replace throttle control motor relay.
PBIB0098E
THROTTLE CONTROL MOTOR

1.
EC-303
http://vnx.su

2.
Check resistance between terminals 3 and 6.

Resistance: Approximately 1 - 15 [at 25 C (77F)]
3.
4.
5.
If NG, replace electric throttle control actuator and go to next

step.
PBIB0095E
EBS010RO

EC-304
http://vnx.su
DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY


PFP:16119
A
EBS010RP
Power supply for the throttle control motor is provided to the ECM via throttle control motor relay. The throttle
control motor relay is ON/OFF controlled by the ECM. When the ignition switch is turned ON, the ECM sends EC
an ON signal to throttle control motor relay and battery voltage is provided to the ECM. When the ignition
switch is turned OFF, the ECM sends an OFF signal to throttle control motor relay and battery voltage is not
provided to the ECM.
C
EBS010RQ

MONITOR ITEM
THRTL RELAY
CONDITION
SPECIFICATION
Ignition switch: ON
ON
EBS010RR

DTC No.
P1124
1124
P1126
1126

relay circuit short

relay circuit open
Possible cause
(Throttle control motor relay circuit is shorted.)
(Throttle control motor relay circuit is open.)
ECM detect the throttle control motor relay

is stuck ON.
ECM detects a voltage of power source for

throttle control motor is excessively low.
FAIL-SAFE MODE
I
spring.
EBS010RS
NOTE:

TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 8V.
SEF058Y
With GST
EC-305
http://vnx.su
With CONSULT-II
1.
2.
3.

With CONSULT-II
1.
2.
3.
4.

SEF058Y
With GST
EC-306
http://vnx.su

Wiring Diagram
EBS010RT
LHD MODELS
EC
TBWA0615E
EC-307
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
W/B

relay power supply
104
W/B

relay
CONDITION
DATA (DC Voltage)
BATTERY VOLTAGE
(11 - 14V)
BATTERY VOLTAGE
(11 - 14V)
0 - 1.0V
EC-308
http://vnx.su

RHD MODELS
A
EC
TBWA0616E
EC-309
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
W/B

relay power supply
104
W/B

relay
CONDITION
DATA (DC Voltage)
BATTERY VOLTAGE
(11 - 14V)
BATTERY VOLTAGE
(11 - 14V)
0 - 1.0V
EBS010RU

1.
2.

PBIB1972E
3.

and ground.
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
PBIB0575E

15A fuse
EC-310
http://vnx.su


1.
2.

EC

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.


1.

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.


OK or NG
OK
>> GO TO 8.
NG

>> INSPECTION END
EC-311
http://vnx.su

EBS010RV

1.
2.

Conditions
Continuity

1 and 2
Yes
No current supply
No
3.
PBIB0098E
EC-312
http://vnx.su
DTC P1128 THROTTLE CONTROL MOTOR


PFP:16119
A
EBS010RW
The current opening angle of the throttle valve is detected by the throttle position sensor and it provides feed- EC
back to the ECM to control the throttle control motor to make the throttle valve opening angle properly in
EBS010RX

DTC No.
P1128
1128

circuit short

ECM detects short in both circuits between
ECM and throttle control motor.
Possible cause
(Throttle control motor circuit is shorted.)

(Throttle control motor)
FAIL-SAFE MODE
spring.
EBS010RY
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF058Y
WITH GST
EC-313
http://vnx.su

Wiring Diagram
EBS010RZ
LHD MODELS
TBWA0617E
EC-314
http://vnx.su

A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damEC
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
0 - 14V
4

(Close)
Engine stopped
E
PBIB1104E
0 - 14V

5

(Open)
Engine stopped
PBIB1105E
EC-315
http://vnx.su

RHD MODELS
TBWA0618E
EC-316
http://vnx.su

A
CAUTION:
EC
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
C
0 - 14V

(Close)
Engine stopped
E
PBIB1104E
0 - 14V

5

(Open)
Engine stopped
G
PBIB1105E
H
EC-317
http://vnx.su

EBS010S0

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-318
http://vnx.su

1.
2.
3.

actuator terminal
ECM terminal
EC
Continuity
Should exist
Should not exist
Should not exist
Should exist
D
PBIB1992E

OK or NG
OK
>> GO TO 3.
NG
H
PBIB1971E

I

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 5.

OK or NG
OK
>> GO TO 5.
NG
1.
2.
3.

>> INSPECTION END
EBS010S1

1.
EC-319
http://vnx.su

2.

3.
4.
5.

step.
PBIB0095E
EBS010S2

EC-320
http://vnx.su
DTC P1143 HO2S1

DTC P1143 HO2S1

PFP:22690
A
EBS010S3

EC
D
SEF463R
H
SEF288D
EBS010S4

MONITOR ITEM
CONDITION
SPECIFICATION
0 - 0.3V Approx. 0.6 - 1.0V
HO2S1 (B1)
HO2S1 MNTR (B1)

rpm
LEAN RICH
EBS010S5
To judge the malfunction, the output from the heated oxygen sensor
1 is monitored to determine whether the rich output is sufficiently
high and whether the lean output is sufficiently low. When both the
outputs are shifting to the lean side, the malfunction will be detected.
SEF300U
DTC No.
P1143
1143

lean shift monitoring
The maximum and minimum voltage from the

sensor are not reached to the specified voltages.
EC-321
http://vnx.su
Possible cause
Fuel pressure
Fuel injector
Intake air leaks
DTC P1143 HO2S1

EBS010S6
CAUTION:
NOTE:
TESTING CONDITION:
Before performing following procedure, confirm that battery voltage is more than 11V at idle.
WITH CONSULT-II
1.
2.
3.
4.
5.

with CONSULT-II.
Touch START.
NOTE:
PBIB0546E
6.
take approximately 50 seconds or more.)
ENG SPEED
QR20DE: 1,400 - 3,200 rpm

QR25DE: 1,200 - 2,800 rpm
VHCL SPEED SE
Less than 100 km/h (62 MPH)
B/FUEL SCHDL
QR20DE: 2.9 - 14.5 msec

QR25DE: 1.9 - 14.5 msec
Shift lever
Suitable position
7.
PBIB0547E

Procedure" .
SEC769C
EBS010S7
EC-322
http://vnx.su
DTC P1143 HO2S1

WITH GST
1.
2.
3.
4.

Check one of the following with engine speed held at 2,000 rpm
constant under no load.
The minimum voltage is over 0.1V at least 1 time.
EC
MBIB0018E
EBS010S8

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-323
http://vnx.su
DTC P1143 HO2S1


>> GO TO 3.
PBIB0499E

1.
2.
3.
4.
With CONSULT-II
Is the 1st trip DTC P0171 detected?
SEF215Z
Without CONSULT-II
Disconnect mass air flow sensor harness connector, and restart
PBIB0495E
Yes or No
Yes
>> Perform trouble diagnosis for DTC P0171. Refer to EC-218, "DTC P0171 FUEL INJECTION SYSTEM FUNCTION" .
No
>> GO TO 4.
1.
2.
3.

OK or NG
OK
>> GO TO 5.
NG
EC-324
http://vnx.su
DTC P1143 HO2S1


OK or NG
OK
>> GO TO 6.
NG
EC

For circuit, refer to EC-180, "Wiring Diagram" .
>> INSPECTION END
EBS010S9

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

SEF646Y
6.

M
SEF217YA
SEF648Y
CAUTION:
EC-325
http://vnx.su
DTC P1143 HO2S1

Without CONSULT-II
1.
2.
3.

1 time: 0 - 0.3V 0.6 - 1.0V 0 - 0.3V
2 times: 0 - 0.3V 0.6 - 1.0V 0 - 0.3V 0.6 - 1.0V
0 - 0.3V
MBIB0018E
CAUTION:
EBS010SA

EC-326
http://vnx.su
DTC P1144 HO2S1

DTC P1144 HO2S1

PFP:22690
A
EBS010SB

EC
D
SEF463R
H
SEF288D
EBS010SC

MONITOR ITEM
CONDITION
SPECIFICATION
0 - 0.3V Approx. 0.6 - 1.0V
HO2S1 (B1)
HO2S1 MNTR (B1)

rpm
LEAN RICH
EBS010SD
To judge the malfunction, the output from the heated oxygen sensor
1 is monitored to determine whether the rich output is sufficiently
high and lean output is sufficiently low. When both the outputs are
shifting to the rich side, the malfunction will be detected.
SEF299U
DTC No.
P1144
1144

rich shift monitoring
The maximum and minimum voltages from the

sensor are beyond the specified voltages.
EC-327
http://vnx.su
Possible cause
Fuel pressure
Fuel injector
DTC P1144 HO2S1

EBS010SE
CAUTION:
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.
5.

with CONSULT-II.
Touch START.
NOTE:
PBIB0548E
6.
take approximately 50 seconds or more.)
ENG SPEED
QR20DE: 1,400 - 3,200 rpm

QR25DE: 1,200 - 2,800 rpm
VHCL SPEED SE
Less than 100 km/h (62 MPH)
B/FUEL SCHDL
QR20DE: 2.9 - 14.5 msec

QR25DE: 1.9 - 14.5 msec
Shift lever
Suitable position
7.
PBIB0549E

Procedure" .
SEC772C
EBS010SF
EC-328
http://vnx.su
DTC P1144 HO2S1

WITH GST
1.
2.
3.
4.

Check one of the following with engine speed held at 2,000 rpm
constant under no load.
The maximum voltage is below 0.8V at least 1 time.
EC
MBIB0018E
EBS010SG

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-329
http://vnx.su
DTC P1144 HO2S1


>> GO TO 3.
PBIB0499E

1.
2.
3.
4.
With CONSULT-II
SEF215Z
Without CONSULT-II
Disconnect mass air flow sensor harness connector, and restart
PBIB0495E
Yes or No
Yes
No
>> GO TO 4.
1.
2.
3.
EC-330
http://vnx.su
DTC P1144 HO2S1


1.
2.
3.

Check connectors for water.
EC

C
OK or NG
OK
>> GO TO 5.
NG
D
PBIB0500E

OK or NG
OK
>> GO TO 6.
NG

H

OK or NG
OK
>> GO TO 7.
NG

J

For circuit, refer to EC-180, "Wiring Diagram" .
>> INSPECTION END
EBS010SH

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

SEF646Y
EC-331
http://vnx.su
DTC P1144 HO2S1

6.

SEF217YA
SEF648Y
CAUTION:
Without CONSULT-II
1.
2.
3.

1 time: 0 - 0.3V 0.6 - 1.0V 0 - 0.3V
2 times: 0 - 0.3V 0.6 - 1.0V 0 - 0.3V 0.6 - 1.0V
0 - 0.3V
MBIB0018E
CAUTION:
EBS010SI

EC-332
http://vnx.su
DTC P1146 HO2S2

DTC P1146 HO2S2

PFP:226A0
A
EBS010SJ

EC
D
SEF327R
EBS010SK

MONITOR ITEM
HO2S2 (B1)
HO2S2 MNTR (B1)
CONDITION
SPECIFICATION
0 - 0.3V Approx. 0.6 - 1.0V


rpm quickly.
LEAN RICH
EBS010SL

storage capacity of the three way catalyst (manifold) causes the
sensor 2, ECM monitors whether the minimum voltage of sensor is
sufficiently low during the various driving condition such as fuel-cut.
K
PBIB0554E
L
DTC No.
P1146
1146

minimum voltage monitoring
The minimum voltage from the sensor is not

reached to the specified voltage.
EC-333
http://vnx.su
Possible cause
Fuel pressure
Fuel injector
DTC P1146 HO2S2

EBS010SM
CAUTION:
NOTE:
COMPLETED will appear on CONSULT-II screen when all tests COND1, COND2 and
If DTC confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait
TESTING CONDITION:
Never stop engine during this procedure. If the engine is stopped, retry procedure from step 2 in Procedure for COND1
WITH CONSULT-II
Procedure for COND1
For the best results, perform DTC WORK SUPPORT at a temperature of 0 to 30C(32 to 86F).
6. Touch START.
ENG SPEED
More than 1,000 rpm
B/FUEL SCHDL
More than 1.0 msec
COOLAN TEMP/S
70 - 105C
Shift lever
Suitable position
PBIB0555E
NOTE:
EC-334
http://vnx.su
DTC P1146 HO2S2

Procedure for COND2
1.
While driving, release accelerator pedal completed with OD

COMPLETED (It will take approximately 4 seconds.)
NOTE:
If COMPLETE already appears at COND3 on CONSULTII screen before Procedure for COND3 is conducted, it is
unnecessary to conduct step 1 in Procedure for COND3.
EC
PBIB0556E
Procedure for COND3

1.
2.
a.
b.
c.
d.

RESULTS.
If CAN NOT BE DIAGNOSED is displayed, performed the following.
(soak the vehicle).
SEC775C
When COOLAN TEMP/S indication reaches to 70C(158F), go to Procedure for COND1 step 3.
EBS010SN
WITH GST
1.
2.
3.
4.
5.
6.
7.
8.
Start engine and warm it up to the operating temperature.

at least 10 times.
procedure.
Keep vehicle at idling for 10 minutes, then check the voltage. Or
MBIB0020E
procedure.
EC-335
http://vnx.su
DTC P1146 HO2S2

Wiring Diagram
EBS010SO
TBWA0603E
EC-336
http://vnx.su
DTC P1146 HO2S2

CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running]
16
OR/B
Warm-up condition


under no load
[Engine is running]
74
Sensor ground
Warm-up condition
Idle speed
Approximately 0V
F
EBS010SP

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-337
http://vnx.su
DTC P1146 HO2S2


With CONSULT-II
with CONSULT-II.
1.
2.
SEF215Z
Without CONSULT-II
PBIB0495E
Yes or No
Yes
No
>> GO TO 3.

1.
2.
3.
4.

terminal 74.

OK or NG
OK
>> GO TO 4.
NG
EC-338
http://vnx.su
PBIB0500E
DTC P1146 HO2S2


1.
EC

2.

OK or NG
OK
>> GO TO 5.
NG

OK or NG
OK
>> GO TO 6.
NG

H

>> INSPECTION END
EBS010SQ

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

SEF662Y
EC-339
http://vnx.su
DTC P1146 HO2S2

6.
PBIB0551E
CAUTION:
Without CONSULT-II
1.
2.
3.
4.
5.
6.

at least 10 times.
procedure.
7. Keep vehicle at idling for 10 minutes, then check voltage. Or
MBIB0020E
procedure.
CAUTION:
EBS010SR

EC-340
http://vnx.su
DTC P1147 HO2S2

DTC P1147 HO2S2

PFP:226A0
A
EBS010SS

EC
D
SEF327R
EBS010ST

MONITOR ITEM
HO2S2 (B1)
HO2S2 MNTR (B1)
CONDITION
SPECIFICATION
0 - 0.3V Approx. 0.6 - 1.0V


rpm quickly.
LEAN RICH
EBS010SU

sensor 2, ECM monitors whether the maximum voltage of the sensor
is sufficiently high during the various driving condition such as fuelcut.
K
SEF259VA
L
DTC No.
P1147
1147

maximum voltage monitoring
The maximum voltage from the sensor is

not reached to the specified voltage.
EC-341
http://vnx.su
Possible cause
(The sensor circuit open or shorted.)
Fuel pressure
Fuel injector
Intake air leaks
DTC P1147 HO2S2

EBS010SV
CAUTION:
NOTE:
COMPLETED will appear on CONSULT-II screen when all tests COND1, COND2 and
If DTC confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait
TESTING CONDITION:
Never stop engine during this procedure. If the engine is stopped, retry procedure from step 2 in Procedure for COND1
WITH CONSULT-II
Procedure for COND1
For the best results, perform DTC WORK SUPPORT at a temperature of 0 to 30C(32 to 86F).
6. Touch START.
ENG SPEED
More than 1,000 rpm
B/FUEL SCHDL
More than 1.0 msec
COOLAN TEMP/S
70 - 105C
Shift lever
Suitable position
PBIB0557E
NOTE:
EC-342
http://vnx.su
DTC P1147 HO2S2

Procedure for COND2
1.
While driving, release accelerator pedal completed with OD

COMPLETED (It will take approximately 4 seconds.)
NOTE:
If COMPLETE already appears at COND3 on CONSULTII screen before Procedure for COND3 is conducted, it is
unnecessary to conduct step 1 in Procedure for COND3.
EC
PBIB0558E
Procedure for COND3

1.
2.
a.
b.
c.
d.

RESULTS.
If CAN NOT BE DIAGNOSED is displayed, perform the following.
(soak the vehicle).
SEC778C
When COOLAN TEMP/S indication reaches to 70C(158F), go to Procedure for COND1 step 3.
EBS010SW
WITH GST
1.
2.
3.
4.
5.
6.
7.
8.

at least 10 times.
procedure.
Keep vehicle idling for 10 minutes, then check the voltage. Or
MBIB0020E
procedure.
EC-343
http://vnx.su
DTC P1147 HO2S2

Wiring Diagram
EBS010SX
TBWA0603E
EC-344
http://vnx.su
DTC P1147 HO2S2

CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running]
16
OR/B
Warm-up condition


under no load
[Engine is running]
74
Sensor ground
Warm-up condition
Idle speed
Approximately 0V
F
EBS010SY

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-345
http://vnx.su
DTC P1147 HO2S2


With CONSULT-II
with CONSULT-II.
1.
2.
SEF215Z
Without CONSULT-II
PBIB0495E
Yes or No
Yes
No
>> GO TO 3.

1.
2.
3.
4.

terminal 74.

OK or NG
OK
>> GO TO 4.
NG
EC-346
http://vnx.su
PBIB0500E
DTC P1147 HO2S2


1.
EC

2.

OK or NG
OK
>> GO TO 5.
NG

OK or NG
OK
>> GO TO 6.
NG

H

>> INSPECTION END
EBS010SZ

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

SEF662Y
EC-347
http://vnx.su
DTC P1147 HO2S2

6.
PBIB0551E
CAUTION:
Without CONSULT-II
1.
2.
3.
4.
5.
6.

at least 10 times.
procedure.
MBIB0020E
procedure.
CAUTION:
EBS010T0

EC-348
http://vnx.su
DTC P1211 TCS CONTROL UNIT


Description
PFP:47850
A
EBS010T1
The malfunction information related to TCS is transferred through the CAN communication line from ESP/
TCS/ABS control unit to ECM.
EC
Be sure to erase the malfunction information such as DTC not only for ESP/TCS/ABS control unit but
also for ECM after TCS related repair.
EBS010T2
Freeze frame data is not stored in the ECM for this self-diagnosis.
D
DTC No.
P1211
1211

TCS control unit

ECM receives a malfunction information from
ESP/TCS/ABS control unit.
Possible cause
ESP/TCS/ABS control unit
TCS related parts
EBS010T3
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.

.
SEF058Y
WITH GST
EBS010T4
Go to BRC-58, "TROUBLE DIAGNOSIS" .

M
EC-349
http://vnx.su
DTC P1212 TCS COMMUNICATION LINE


Description
PFP:47850
EBS010T5
NOTE:
If DTC P1212 is displayed with DTC U1000 or U1001, first perform the trouble diagnosis for DTC U1000,
This CAN communication line is used to control the smooth engine operation during the TCS operation. Pulse
signals are exchanged between ECM and ESP/TCS/ABS control unit.
EBS010T6
DTC No.
P1212
1212
TCS communication
line
ECM can not receive the information

from ESP/TCS/ABS control unit continuously.
Possible cause
shorted.)
Dead (Weak) battery

EBS010T7
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10.5V at idle.
WITH CONSULT-II
1.
2.
3.
4.

If a 1st trip DTC is detected, go to EC-350, "Diagnostic Procedure" .
SEF058Y
WITH GST
EBS01FF5
EC-350
http://vnx.su
DTC P1217 ENGINE OVER TEMPERATURE


System Description
PFP:00000
A
EBS010T9
COOLING FAN CONTROL

Sensor
Input Signal to ECM

Engine speed*2

2
Battery
Battery voltage*
Wheel sensor*1
Vehicle speed
ECM function
Actuator
EC
C
Cooling fan
control
Cooling fan relay
*1: This signal is sent to ECM through CAN communication line.

The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, refrigerant
pressure, and air conditioner ON signal. The control system has 3-step control [HIGH/LOW/OFF].
OPERATION
G
PBIB1987E
EC-351
http://vnx.su

EBS010TA

MONITOR ITEM
AIR COND SIG
CONDITION

the engine

the engine
COOLING FAN
SPECIFICATION
OFF

ON

(201F) or less
OFF

(210F) or more
LOW

(212F) or more
HIGH
EBS010TB
If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will
rise. When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction
is indicated.
DTC No.
P1217
1217
Engine over temperature (Overheat)
Possible cause
(The cooling fan circuit is open or
shorted.)
Cooling fan
Cooling fan relays
Radiator hose
Engine coolant was not added to the system

using the proper filling method.
Radiator
Radiator cap
Engine coolant is not within the specified

range.
Water pump
Thermostat
Cooling fan does not operate properly (Overheat).

Cooling fan system does not operate properly (Overheat).
For more information, refer to EC-365,

"Main 12 Causes of Overheating" .
CAUTION:
When a malfunction is indicated, be sure to replace the coolant. Refer to CO-9, "Changing Engine
Coolant" . Also, replace the engine oil. Refer to LU-8, "Changing Engine Oil" .
1. Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure to
use coolant with the proper mixture ratio. Refer to MA-19, "Engine Coolant Mixture Ratio" .
2. After refilling coolant, run engine to ensure that no water-flow noise is emitted.
EBS010TC
Use this procedure to check the overall function of the cooling fan. During this check, a DTC might not be confirmed.
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could be caused by high pressure fluid escaping from the radiator.
Wrap a thick cloth around cap. Carefully remove the cap by turning it a quarter turn to allow built-up
pressure to escape. Then turn the cap all the way off.
EC-352
http://vnx.su

WITH CONSULT-II
1.
2.
3.
Check the coolant level in the reservoir tank and radiator.

Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to EC-358,
"Diagnostic Procedure" .
Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to EC-358,
EC
SEF621W
4.
5.
Perform COOLING FAN in ACTIVE TEST mode with CONSULT-II.

If the results are NG, go to EC-358, "Diagnostic Procedure" .
SEF646X
WITH GST
2. Confirm whether customer filled the coolant or not. If customer
3. Start engine.
CAUTION:
Be careful not to overheat engine.
4. Set temperature control dial to full cold position.
5. Turn air conditioner switch ON.
6. Turn blower fan switch ON.
7. Run engine at idle for a few minutes with air conditioner operating.
CAUTION:
8. Make sure that cooling fans operates at low speed.
If OK, go to the following step.
10. Turn air conditioner switch and blower fan switch OFF.
11. Disconnect engine coolant temperature sensor harness connector.
12. Connect 150 resistor to engine coolant temperature sensor
harness connector.
1.
K
SEF621W
SEC163BA
EC-353
http://vnx.su

13. Restart engine and make sure that cooling fan operates at
higher speed than low speed.
CAUTION:
MEC475B
EC-354
http://vnx.su

Wiring Diagram
EBS010TD
LHD MODELS
EC
TBWA0619E
EC-355
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
[Engine is running]
89
[Engine is running]
97
PU
EC-356
http://vnx.su
DATA (DC Voltage)

BATTERY VOLTAGE
(11 - 14V)
0 - 1.0V
BATTERY VOLTAGE
(11 - 14V)
0 - 1.0V

RHD MODELS
A
EC
TBWA0620E
EC-357
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
[Engine is running]
89
[Engine is running]
97
PU
DATA (DC Voltage)

BATTERY VOLTAGE
(11 - 14V)
0 - 1.0V
BATTERY VOLTAGE
(11 - 14V)
0 - 1.0V
EBS010TE
1. INSPECTION START
Do you have CONSULT-II?
Yes or No
Yes
>> GO TO 2.
No
>> GO TO 4.
2. CHECK COOLING FAN LOW SPEED OPERATION

With CONSULT-II
2. Perform COOLING FAN in ACTIVE TEST mode with CONSULT-II and touch LOW on the CONSULT-II screen.
3. Make sure that cooling fans-1 and -2 operates at low speed.
OK or NG
OK
>> GO TO 3.
NG
>> Check cooling fan low speed control circuit. (Go to EC362, "PROCEDURE A" .)
SEF784Z
3. CHECK COOLING FAN HIGH SPEED OPERATION

With CONSULT-II
Touch HIGHon the CONSULT-II screen.
Make sure that cooling fan-2 operate at higher speed than low
speed.
OK or NG
OK
>> GO TO 6.
NG
>> Check cooling fan high speed control circuit. (Go to EC364, "PROCEDURE B" .)
1.
2.
SEF785Z
EC-358
http://vnx.su


1.
2.
3.
4.
5.
Without CONSULT-II
Disconnect cooling fan relay-3.
Turn air conditioner switch ON.
Turn blower fan switch ON.
EC
E
PBIB1972E

OK or NG
OK
>> GO TO 5.
NG
SEC163BA

J
Without CONSULT-II
2. Reconnect cooling fan relay-3.
5. Connect 150 resistor to engine coolant temperature sensor harness connector.
6. Restart engine and make sure that cooling fan-2 operates at
OK or NG
OK
>> GO TO 6.
NG
MEC475B
EC-359
http://vnx.su

6. CHECK COOLING SYSTEM FOR LEAK

Apply pressure to the cooling system with a tester, and check if the pressure drops.
Testing pressure: 157 kPa (1.57 bar, 1.6 kg/cm2 , 23psi)
CAUTION:
Higher than the specified pressure may cause radiator damage.
Pressure should not drop.
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.
SLC756AA

Check the following for leak.
Hose
Radiator
8. CHECK RADIATOR CAP

Apply pressure to cap with a tester and check radiator cap relief
pressure.
Radiator cap
relief pressure:
59 - 98 kPa (0.59 - 0.98 bar, 0.6 - 1.0

kg/cm2 , 9 - 14 psi)
OK or NG
OK
>> GO TO 9.
NG
>> Replace radiator cap.
SLC755AC
EC-360
http://vnx.su

9. CHECK THERMOSTAT
1.
2.
3.
Remove thermostat.
Check valve seating condition at normal room temperatures.
It should seat tightly.
Check valve opening temperature and valve lift.
Valve opening
temperature:
Valve lift:
EC
82 C (180 F) [standard]
More than 8 mm/95 C (0.31 in/203 F)
Check if valve is closed at 5C (9F) below valve opening temperature.

For details, refer to CO-23, "THERMOSTAT AND WATER CONTROL VALVE" .
OK or NG
OK
>> GO TO 10.
NG
>> Replace thermostat.
4.
E
SLC343

OK or NG
OK
>> GO TO 11.
NG
11. CHECK MAIN 12 CAUSES

If the cause cannot be isolated, go to EC-365, "Main 12 Causes of Overheating" .
>> INSPECTION END
EC-361
http://vnx.su

PROCEDURE A
1. CHECK COOLING FAN POWER SUPPLY CIRCUIT

1.
2.
3.

PBIB1972E
4.
Check voltage between cooling fan relay-1 terminals 1, 5, 7 and

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
PBIB0577E

10A fuse
40A fusible links
Harness for open or short between cooling fan relay-1 and fuse
Harness for open or short between cooling fan relay-1 and battery
EC-362
http://vnx.su

3. CHECK COOLING FAN MOTORS CONTROL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Disconnect cooling fan motor-1 harness connector and cooling
fan motor-2 harness connector.
Check harness continuity between cooling fan relay-1 terminal 3
and cooling fan motor-1 terminal 1, cooling fan motor-1 terminal
2 and ground.
EC

4.
5.
Also check harness for short to ground and short to power.

4 and ground.
D
PBIB0504E

OK or NG
OK
>> GO TO 4.
NG
4. CHECK COOLING FAN MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.

Check harness continuity between cooling fan relay-1 terminal 2 and ECM terminal 97. Refer to Wiring
Diagram.

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.
Harness for open or short between cooling fan relay-1 and ECM
6. CHECK COOLING FAN RELAY-1

OK or NG
OK
>> GO TO 7.
NG
>> Replace cooling fan relay.
7. CHECK COOLING FAN MOTORS-1 AND -2

OK or NG
OK
>> GO TO 8.
NG
>> Replace cooling fan motors.
EC-363
http://vnx.su


Perform EC-123, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
>> INSPECTION END
PROCEDURE B

1.
2.
3.

PBIB1972E
4.
Check voltage between cooling fan relay-3 terminals 1, 3 and

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
PBIB0251E

1.
2.
3.

Disconnect cooling fan motor-2 harness connector.
3 and cooling fan relay-3 terminal 6, cooling fan relay-3 terminal
7 and ground.

OK or NG
OK
>> GO TO 4.
NG
EC-364
http://vnx.su
PBIB0504E

1.
2.

Check harness continuity between cooling fan relay-3 terminal 2 and ECM terminal 89.
EC

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

E

OK or NG
OK
>> GO TO 7.
NG

>> INSPECTION END
Main 12 Causes of Overheating

Engine
Step
OFF
Inspection item
Blocked radiator
Blocked condenser
Blocked bumper
EBS010TF
Equipment
Standard
Reference page
Visual
No blocking
Coolant mixture
Coolant tester
50 - 50% coolant mixture
See MA-19 .
Coolant level
Visual
Coolant up to MAX level

in reservoir tank and radiator filler neck
See CO-9 .
Radiator cap
Pressure tester
59 - 98 kPa
(0.59 - 0.98 bar, 0.6 - 1.0
See CO-13 .
kg/cm2 , 9 - 14 psi) (Limit)

ON*2
Coolant leaks
Visual
No leaks
See CO-9 .
ON*2
Thermostat
Touch the upper and

lower radiator hoses
Both hoses should be hot
See CO-23 , and CO-12 .
ON*1
Cooling fan
CONSULT-II
Operating
See trouble diagnosis for

DTC P1217 (EC-351 ).
OFF
Combustion gas leak
Color checker chemical

tester 4 Gas analyzer
Negative
EC-365
http://vnx.su

Engine
Step
ON*3
Inspection item
Equipment
Standard
Reference page
Coolant temperature
gauge
Visual
Gauge less than 3/4

when driving
Coolant overflow to
reservoir tank
Visual
No overflow during driving

and idling
See CO-9 .
OFF*4
10
Coolant return from

reservoir tank to radiator
Visual
Should be initial level in

reservoir tank
See CO-9 .
OFF
11
Cylinder head
Straight gauge feeler

gauge
0.1 mm (0.004 in) Maximum distortion (warping)
See EM-70 .
12
Cylinder block and pistons
Visual
No scuffing on cylinder
walls or piston
See EM-86 .
*1: Turn the ignition switch ON.

*2: Engine running at 3,000 rpm for 10 minutes.
*3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes.
*4: After 60 minutes of cool down time.
For more information, refer to CO-5, "OVERHEATING CAUSE ANALYSIS" .
EBS010TG
COOLING FAN RELAYS-1 AND -3

Check continuity between terminals 3 and 5, 6 and 7.
Conditions
Continuity
Yes
No current supply
No
SEF745U
COOLING FAN MOTOR-1

1.
2.
Disconnect cooling fan motor harness connector.

Supply cooling fan motor terminals with battery voltage and
check operation.
Terminals
Cooling fan motor
(+)
(-)
PBIB1999E
COOLING FAN MOTOR-2

1.
2.

check operation.
Terminals
Speed
Cooling fan motor
(+)
(-)
Low
High
1, 2
3, 4
SEF734W
EC-366
http://vnx.su
DTC P1225 TP SENSOR

DTC P1225 TP SENSOR

PFP:16119
A
EBS010TH

EC
D
PBIB0145E
EBS010TI

F
DTC No.
P1225
1225

learning performance
problem
Closed throttle position learning value is excessively

low.
Possible cause

(TP sensor 1 and 2)
G
EBS010TJ
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.
5.

.
SEF058Y
WITH GST
EC-367
http://vnx.su
DTC P1225 TP SENSOR

EBS010TK

1.
2.
3.

the housing.
OK or NG
OK
>> GO TO 2.
NG
PBIB0518E

1.
2.
3.

>> INSPECTION END
EBS010TL

EC-368
http://vnx.su
DTC P1226 TP SENSOR

DTC P1226 TP SENSOR

PFP:16119
A
EBS010TM

EC
D
PBIB0145E
EBS010TN

F
DTC No.
P1226
1226

problem
Closed throttle position learning is not performed

successfully, repeatedly.
Possible cause

(TP sensor 1 and 2)
G
EBS010TO
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.
5.
6.

.
M
SEF058Y
WITH GST
EC-369
http://vnx.su
DTC P1226 TP SENSOR

EBS010TP

1.
2.
3.

the housing.
OK or NG
OK
>> GO TO 2.
NG
PBIB0518E

1.
2.
3.

>> INSPECTION END
EBS010TQ

EC-370
http://vnx.su
DTC P1229 SENSOR POWER SUPPLY


PFP:16119
A
EBS010TR

DTC No.
P1229
1229
Sensor power supply circuit

short
ECM detects a voltage of power source

for sensor is excessively low or high.
EC
Possible cause
(PSP sensor circuit is shorted.)
(Refrigerant pressure sensor circuit is
shorted.)

(APP sensor 1)
FAIL-SAFE MODE

spring.
EBS010TS
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.

M
SEF058Y
WITH GST
EC-371
http://vnx.su

Wiring Diagram
EBS010TT
TBWB0262E
EC-372
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
DATA (DC Voltage)
46
Sensor power supply

Approximately 5V
65
Sensor power supply

sensor)
Approximately 5V
90
Sensor power supply

sensor 1)
Approximately 5V
EBS010TU

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-373
http://vnx.su

2. CHECK ACCELERATOR PEDAL POSITION SENSOR 1 POWER SUPPLY CIRCUIT

1.
2.
Disconnect accelerator pedal position sensor (APP) sensor harness connector.

PBIB0498E
3.
Check voltage between APP sensor terminal 6 and ground with

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.
PBIB0914E
3. CHECK SENSOR POWER SUPPLY CIRCUIT

Check harness for short to power and short to ground, between the following terminals
ECM terminal
Sensor terminal
90
EC-372
46
Refrigerant pressure sensor terminal 3
EC-474
65
PSP sensor terminal 3
EC-277
OK or NG
OK
>> GO TO 4.
NG
4. CHECK COMPONENTS
Refrigerant pressure sensor (Refer to ATC-94, "COMPONENT INSPECTION" .)
Power steering pressure sensor (Refer to EC-281, "Component Inspection" .)

OK or NG
OK
>> GO TO 7.
NG
>> Replace malfunctioning component.
5. CHECK APP SENSOR

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.
EC-374
http://vnx.su


1.
2.
3.
4.

EC
>> INSPECTION END

E
>> INSPECTION END
EC-375
http://vnx.su
DTC P1564 ASCD STEERING SWITCH


PFP:25551
EBS01FA4
ASCD steering switch has variant values of electrical resistance for each button. ECM reads voltage variation
of switch, and determines which button is operated.
PBIB2877E
1.
2.
RESUME/ACCELERATE switch
4.
SET/COAST switch
5.
MAIN switch
3.
CANCEL switch
Refer to EC-527, "AUTOMATIC SPEED CONTROL DEVICE (ASCD)" for the ASCD function.
EBS01FA5

MONITOR ITEM
MAIN SW
CANCEL SW
RESUME/ACC SW
SET SW
CONDITION
Ignition switch: ON
Ignition switch: ON
Ignition switch: ON
Ignition switch: ON
SPECIFICATION
ON
OFF
ON
OFF
Pressed
ON
Released
OFF
ON
OFF
EBS01FA6

NOTE:
If DTC P1564 is displayed with DTC P0605, first perform the trouble diagnosis for DTC P0605.
Refer to EC-282, "DTC P0605 ECM".
DTC No.
P1564
1564
Trouble Diagnosis
Name
ASCD steering
switch
Possible Cause
An excessively high voltage signal from the ASCD

steering switch is sent to ECM.
ECM detects that input signal from the ASCD

steering switch is out of the specified range.
(The switch circuit is open or shorted.)
ECM detects that the ASCD steering switch is

stuck ON.
ECM
EC-376
http://vnx.su

EBS01FA7
NOTE:
EC
WITH CONSULT-II
1.
2.
3.
4.
5.
6.
7.
8.

Press MAIN switch for at least 10 seconds, then release it and wait at least 10 seconds.
Press CANCEL switch for at least 10 seconds, then release it and wait at least 10 seconds.
Press RESUME/ACCELERATE switch for at least 10 seconds, then release it and wait at least 10 seconds.
Press SET/COAST switch for at least 10 seconds, then release it and wait at least 10 seconds.
WITH GST
EC-377
http://vnx.su

Wiring Diagram
EBS01FF6
LHD MODELS
TBWB0463E
EC-378
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running]
57
Sensor ground
Warm-up condition
Idle speed
99
W/R
C
Approximately 0V
D
Approximately 4V
Approximately 0V
Approximately 1V
F
Approximately 3V
Approximately 2V
EC-379
http://vnx.su

RHD MODELS
TBWB0464E
EC-380
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running]
57
Sensor ground
Warm-up condition
Idle speed
99
W/R
C
Approximately 0V
D
Approximately 4V
Approximately 0V
Approximately 1V
F
Approximately 3V
Approximately 2V
EC-381
http://vnx.su

EBS01FA9

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-382
http://vnx.su

2. CHECK ASCD STEERING SWITCH CIRCUIT
With CONSULT-II
EC
Select MAIN SW, RESUME/ACC SW, SET SW and CANCEL SW in DATA MONITOR mode with
CONSULT-II.
3. Check each item indication under the following conditions.
C
1.
2.
Switch
Monitor item
MAIN switch
MAIN SW
CANCEL switch
CANCEL SW
RESUME/ACCELERARE switch
RESUME/ACC SW
Condition
Indication
Pressed
ON
Released
OFF
Pressed
ON
Released
OFF
Pressed
ON
Released
OFF
Pressed
ON
Released
OFF
SEC006D
SET/COAST switch
SET SW
Without CONSULT-II
2. Check voltage between ECM terminal 99 and ground with pressing each button.
Switch
MAIN switch
CANCEL switch
RESUME/ACCELERATE
switch
SET/COAST switch
Condition
Voltage [V]
Pressed
Approx. 0
Released
Approx. 4
Pressed
Approx. 1
Released
Approx. 4
Pressed
Approx. 3
Released
Approx. 4
Pressed
Approx. 2
Released
Approx. 4
PBIB0311E
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 3.
3. CHECK ASCD STEERING SWITCH GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.
4.

Disconnect ASCD steering switch (1) harness connector M205.
Check harness continuity between ASCD steering switch terminal 2 and ECM terminal 57. Refer to Wiring Diagram.

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
PBIB2879E
EC-383
http://vnx.su


Harness connectors M202, M206
Combination switch (spiral cable)
Harness for open and short between ECM and ASCD steering switch
5. CHECK ASCD STEERING SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
Check harness continuity between ECM terminal 99 and ASCD steering switch terminal 1.

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

7. CHECK ASCD STEERING SWITCH

Refer to EC-382, "Diagnostic Procedure" .
OK or NG
OK
>> GO TO 8.
NG
>> Replace ASCD steering switch.

>> INSPECTION END
EC-384
http://vnx.su

EBS01FAA
ASCD STEERING SWITCH

1.
2.
Disconnect ASCD steering switch harness connector M205.

Check continuity between ASCD steering switch terminals 1 and
2 with pushing each switch.
Switch
MAIN switch
CANCEL switch
RESUME/ACCELERATE
switch
SET/COAST switch
Condition
Resistance []
Pressed
Approx. 0
Released
Approx. 4,000
Pressed
Approx. 250
Released
Approx. 4,000
Pressed
Approx. 1,480
Released
Approx. 4,000
Pressed
Approx. 660
Released
Approx. 4,000
EC
PBIB2202E
EC-385
http://vnx.su
DTC P1572 ASCD BRAKE SWITCH


PFP:25320
EBS01FAB
When the brake pedal is depressed, ASCD brake switch is turned

OFF and stop lamp switch is turned ON. ECM detects the state of
the brake pedal by this input of two kinds (ON/OFF signal).
Refer to EC-527, "AUTOMATIC SPEED CONTROL DEVICE
(ASCD)" for the ASCD function.
SEC009D
EBS01FAC

MONITOR ITEM
CONDITION
BRAKE SW1
(ASCD brake switch)
BRAKE SW2
(Stop lamp switch)
Ignition switch: ON
Ignition switch: ON
SPECIFICATION
Clutch pedal (M/T) and brake pedal:

Fully released
ON
Clutch pedal (M/T) and/or brake pedal:

Slightly depressed
OFF
OFF
ON
EBS01FAD

NOTE:
This self-diagnosis has the one trip detection logic. When malfunction A is detected, DTC is not
stored in ECM memory. And in that case, 1st trip DTC and 1st trip freeze frame data are displayed.
1st trip DTC is erased when ignition switch OFF. And even when malfunction A is detected in two
consecutive trips, DTC is not stored in ECM memory.
DTC No.
Trouble Diagnosis
Name
A)
P1572
1572
When the vehicle speed is above 30km/h

(19 MPH), ON signals from the stop lamp
switch and the ASCD brake switch are sent
to ECM at the same time.
ASCD brake switch

B)
ASCD brake switch signal is not sent to

ECM for extremely long time while the vehicle is driving
EC-386
http://vnx.su
Possible Cause
(The stop lamp switch circuit is shorted.)
(The ASCD brake switch circuit is shorted.)
(The ASCD clutch switch circuit is shorted.)
(M/T models)
Stop lamp switch
ASCD brake switch
ASCD clutch switch

(M/T models)
Incorrect stop lamp switch installation
Incorrect ASCD brake switch installation
Incorrect ASCD clutch switch installation

(M/T models)
ECM

EBS01FAE
A
CAUTION:
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait EC
Procedure for malfunction B is not described here. It takes extremely long time to complete procedure for
malfunction B. By performing procedure for malfunction A, the incident that causes malfunction B can be C
detected.
TESTING CONDITION:
Steps 4 and 5 may be conducted with the drive wheels lifted in the shop or by driving the vehicle. If a D
WITH CONSULT-II
1.
2.
3.
4.
Start engine (EPS switch OFF).

Press MAIN switch and make sure that CRUISE indicator lights
up.
Drive the vehicle for at least 5 consecutive seconds under the
following condition.
G
VHCL SPEED SE
Shift lever
Suitable position
5.

.
If 1st trip DTC is not detected, go to the following step.
Drive the vehicle for at least 5 consecutive seconds under the following condition.
H
PBIB2386E
VHCL SPEED SE
Shift lever
Suitable position
Driving location
Depress the brake pedal for more than

five seconds so as not to come off from
the above-mentioned vehicle speed.
6.
WITH GST
EC-387
http://vnx.su

Wiring Diagram
EBS01FAF
TBWA0756E
EC-388
http://vnx.su

CAUTION:
TERMINAL
NO.
EC
WIRE
COLOR
ITEM
CONDITION
101
Stop lamp switch
DATA (DC Voltage)
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
108
GY/L
ASCD brake switch
Brake pedal and/or clutch pedal (M/T):

Slightly depressed
Brake pedal and clutch pedal (M/T):

Fully released
Approximately 0V
E
BATTERY VOLTAGE
(11 - 14V)
F
EBS01FAH
1. CHECK OVERALL FUNCTION-I
With CONSULT-II
2. Select BRAKE SW1 in DATA MONITOR mode with CONSULT-II.
3. Check BRAKE SW1 indication under the following conditions.
A/T models
I
CONDITION
INDICATION
OFF
ON
M/T models
CONDITION
INDICATION
Clutch pedal and/or brake pedal: Slightly depressed
OFF
Clutch pedal and brake pedal: Fully released
ON
SEC011D
1.
2.
Without CONSULT-II
A/T models
CONDITION
VOLTAGE
Approximately 0V
Battery voltage
M/T models
CONDITION
VOLTAGE
Approximately 0V
Battery voltage
OK or NG
OK
>> GO TO 2.
NG
>> GO TO 3.
EC-389
http://vnx.su
MBIB0061E

2. CHECK OVERALL FUNCTION-II

1.
2.
With CONSULT-II
Select BRAKE SW2 in DATA MONITOR mode with CONSULT-II.
Check BRAKE SW2 indication under the following conditions.
CONDITION
INDICATION
OFF
ON
SEC013D
Without CONSULT-II
Check voltage between ECM terminal 101 and ground under the following conditions.
CONDITION
VOLTAGE
Approximately 0V
Battery voltage
OK or NG
OK
>> GO TO 15.
NG
>> GO TO 11.
MBIB0060E
3. CHECK ASCD BRAKE SWITCH POWER SUPPLY CIRCUIT

1.
2.
3.

Disconnect ASCD brake switch harness connector.
SEC009D
4.
Check voltage between ASCD brake switch terminal 1 and

OK or NG
OK
>> GO TO 9.
NG (A/T models)>>GO TO 4.
NG (M/T models)>>GO TO 5.
PBIB0857E
EC-390
http://vnx.su

10A fuse
Harness for open or short between ASCD brake switch and fuse
EC
5. CHECK ASCD CLUTCH SWITCH POWER SUPPLY CIRCUIT

1.
2.
3.
4.

Disconnect ASCD clutch switch harness connector.
Check voltage between ASCD clutch switch terminal 1 and

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.
H
PBIB0799E
10A fuse
Harness for open or short between ASCD clutch switch and fuse
7. CHECK ASCD BRAKE SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.

Check harness continuity between ASCD clutch switch terminal 2 and ASCD brake switch terminal 1.

OK or NG
OK
>> GO TO 8.
NG
8. CHECK ASCD CLUTCH SWITCH

Refer to EC-394, "Component Inspection"
OK or NG
OK
>> GO TO 15.
NG
>> Replace ASCD clutch switch.
EC-391
http://vnx.su

1.
2.
3.

Check harness continuity between ASCD brake switch terminal 2 and ECM terminal 108.

OK or NG
OK
>> GO TO 10.
NG
10. CHECK ASCD BRAKE SWITCH

OK or NG
OK
>> GO TO 15.
NG
>> Replace ASCD brake switch.
11. CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT

1.
2.

Disconnect stop lamp switch harness connector.
PBIB0498E
3.
Check voltage between stop lamp switch terminal 1 and ground with CONSULT -II or tester.
PBIB2284E

OK or NG
OK
>> GO TO 13.
NG
>> GO TO 12.
EC-392
http://vnx.su

15A fuse
Harness for open or short between stop lamp switch and battery
13. CHECK STOP LAMP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.

Check harness continuity between ECM terminal 101 and stop lamp switch terminal 2.
EC

OK or NG
OK
>> GO TO 14.
NG
14. CHECK STOP LAMP SWITCH

H

OK or NG
OK
>> GO TO 15.
NG
>> Replace stop lamp switch.

>> INSPECTION END
EC-393
http://vnx.su

EBS01FAI
ASCD BRAKE SWITCH

1.
2.
3.

Check continuity between ASCD brake switch terminals 1 and 2
under the following conditions.
Condition

Continuity
Should exist
Should not exist
If NG, adjust ASCD brake switch installation, refer to BR-6,

"BRAKE PEDAL" , and perform step 3 again.
SEC023D
ASCD CLUTCH SWITCH

1.
2.
3.

Check continuity between ASCD clutch switch terminals 1 and 2
Condition
Clutch pedal: Fully released

Clutch pedal: Slightly depressed
Continuity
Should exist
Should not exist
If NG, adjust ASCD clutch switch installation, refer to CL-5,

"CLUTCH PEDAL" , and perform step 3 again.
SEC024D
STOP LAMP SWITCH

1.
2.
3.

Check continuity between stop lamp switch terminals 1 and 2 under the following conditions.
PBIB2285E
Condition
Continuity
Should not exist
Should exist
If NG, adjust stop lamp switch installation, refer to BR-6, "BRAKE PEDAL" , and perform step 3 again.
EC-394
http://vnx.su
DTC P1574 ASCD VEHICLE SPEED SENSOR


System Description
PFP:31036
A
EBS01FF7
ECM receives two vehicle speed sensor signals via CAN communication line. One is sent from ESP/TCS/ABS
control unit (models with ESP) or ABS actuator and electric unit (control unit)(models without ESP), and the EC
other is from TCM (Transmission control module).
The ECM uses these signals for ASCD control. Refer to EC-527, "AUTOMATIC SPEED CONTROL DEVICE
(ASCD)" for ASCD functions.
C
EBS01FAK

NOTE:
If DTC P1574 is displayed with DTC U1000 or U1001, first perform the trouble diagnosis for DTC
U1000, U1001. Refer to EC-132, "DTC U1000, U1001 CAN COMMUNICATION LINE" .
Refer to EC-275, "DTC P0500 VSS" .
Refer to EC-282, "DTC P0605 ECM" .
DTC No.
Trouble Diagnosis
Name
Possible Cause
P1574
1574
ASCD vehicle speed

sensor
ECM detects a difference between two vehicle

speed signals is out of the specified range.
shorted)
(Revolution sensor circuit is open or shorted)
(Wheel sensor circuit is open or shorted.)
TCM
ESP/TCS/ABS control unit (models with ESP)

Combination meter
Wheel sensor
Revolution sensor
ECM
L
EBS01FAL
CAUTION:
NOTE:
TESTING CONDITION:
Step 3 may be conducted with the drive wheels lifted in the shop or by driving the vehicle. If a road test
is expected to be easier, it is unnecessary to lift the vehicle.
EC-395
http://vnx.su

WITH CONSULT-II
1.
2.
3.
4.
Start engine (ESP switch OFF).

Drive the vehicle at more than 40 km/h (25 MPH).
PBIB2673E
WITH GST
EBS01FAM
1. CHECK DTC WITH TCM

Check DTC with TCM.
Refer to AT-40, "HOW TO READ DTC AND 1ST TRIP DTC" .
OK or NG
OK
>> GO TO 2.
NG
>> Perform trouble shooting relevant to DTC indicated.
2. CHECK DTC WITH ESP/TCS/ABS CONTROL UNIT (MODELS WITH ESP), ABS ACTUATOR AND
ELECTRIC UNIT (CONTROL UNIT) (MODELS WITHOUT ESP)
Check DTC with ESP/TCS/ABS control unit (models with ESP), ABS actuator and electric unit (control unit)
(models without ESP). Refer to BRC-58, "TROUBLE DIAGNOSIS" (models with ESP), BRC-11, "TROUBLE
DIAGNOSIS" (models without ESP).
OK or NG
OK
>> GO TO 3.
NG

>> INSPECTION END
EC-396
http://vnx.su
DTC P1706 PNP SWITCH


PFP:32006
A
EBS010TV
When the shift lever position is P or N (A/T), Neutral (M/T), park/neutral position (PNP) switch is ON.
ECM detects the position because the continuity of the line (the ON signal) exists.
EC
EBS010TW

MONITOR ITEM
P/N POSI SW
C
CONDITION
Ignition switch: ON
SPECIFICATION
ON
OFF

DTC No.
P1706
1706
EBS010TX
Park/neutral position switch
The signal of the park/neutral position (PNP)

switch is not changed in the process of
engine starting and driving.
Possible cause
(PNP switch circuit is open or shorted.)

EBS010TY
CAUTION:
NOTE:
WITH CONSULT-II
1.
2.
ON
OFF

ENG SPEED
1,500 - 6,375 rpm
COOLAN TEMP/S
B/FUEL SCHDL
3.0 - 31.8 msec
VHCL SPEED SE
Shift lever
Suitable position
6.
Known-good signal
N or P position (A/T)
Neutral position (M/T)
3.
4.
5.

Select P/N POSI SW in DATA MONITOR mode with CONSULT-II. Then check the P/N POSI SW signal under the following conditions.
Position (Selector lever)

.
EC-397
http://vnx.su
L
SEF212Y
SEF213Y

EBS010TZ
Use this procedure to check the overall function of the park/neutral position (PNP) switch circuit. During this
check, a 1st trip DTC might not be confirmed.
WITH GST
1.
2.

Check voltage between ECM terminal 102 (PNP switch signal)
and body ground under the following conditions.
Condition (Gear position)
Voltage V (Known-good data)
P or N position (A/T)
Approx. 0
A/T: Battery voltage

M/T: Approximately 5V
3.

MBIB0029E
EC-398
http://vnx.su

Wiring Diagram
EBS010U0
EC
TBWA0622E
EC-399
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
102
G/OR
PNP switch
DATA (DC Voltage)
Approximately 0V
A/T models
BATTERY VOLTAGE
(11 - 14V)
M/T models
Approximately 5V
EBS010U1
1. CHECK PNP SWITCH GROUND CIRCUIT FOR OPEN AND SHORT

1.
2.
3.

Disconnect PNP switch harness connector.
Check harness continuity between PNP switch terminal 2 and ground.

OK or NG
OK
>> GO TO 2.
NG
2. CHECK PNP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Disconnect combination meter harness connector.
Check harness continuity between PNP switch terminal 1 and ECM terminal 102, combination meter terminal 55. Refer to Wiring Diagram.

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

Harness for open or short between PNP switch and ECM
Harness for open or short between PNP switch and combination meter
EC-400
http://vnx.su

4. CHECK PNP SWITCH
Refer to AT-408, "Park/Neutral Position (PNP) Switch"

SWITCH" (M/T).
OK or NG
OK
>> GO TO 5.
NG
>> Replace PNP switch.
(A/T) or MT-13, "PARK/NEUTRAL POSITION

EC

>> INSPECTION END

E
EC-401
http://vnx.su
DTC P1720 VSS

DTC P1720 VSS

Description
PFP:31036
EBS018LQ
NOTE:
If DTC P1720 is displayed with DTC U1000, first perform the trouble diagnosis for DTC U1000. Refer to
EC-132, "DTC U1000, U1001 CAN COMMUNICATION LINE" .
control unit (models with ESP) or ABS actuator and electric unit (control unit)(models without ESP), and the
other is from TCM (Transmission control module). ECM uses these two signals for engine control.
EBS018LR

MONITOR ITEM
VEH SPEED SE
CONDITION
SPECIFICATION
Turn drive wheels and compare the CONSULT-II value with speedometer
indication

EBS018LS

DTC No.
P1720
1720

(A/T output)
ECM detects a difference between two

vehicle speed sensor signals is out of the
specified range.
Possible cause
shorted)
TCM

Combination meter
Wheel sensor
Revolution sensor
EBS018LT
CAUTION:
NOTE:
WITH CONSULT-II
1.
2.
3.
4.
5.

Start engine.
Drive vehicle at a speed of 20 km/h (12 MPH) or more for at least 5 seconds without brake pedal depressing.
WITH GST
EC-402
http://vnx.su
DTC P1720 VSS

EBS018LU
Check DTC with TCM. Refer to AT-6, "TROUBLE DIAGNOSIS INDEX" .

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

OK or NG
OK
>> GO TO 3.
NG

Check combination meter function. Refer to DI-4, "COMBINATION METERS" .
>> INSPECTION END

H
EC-403
http://vnx.su
DTC P1805 BRAKE SWITCH


Description
PFP:25320
EBS010U2
Brake switch signal is applied to the ECM through the stop lamp switch when the brake pedal is depressed.
This signal is used mainly to decrease the engine speed when the vehicle is driving.
EBS010U3

MONITOR ITEM
BRAKE SW
CONDITION
Ignition switch: ON
SPECIFICATION
OFF
ON
EBS010U4

DTC No.
P1805
1805
Brake switch

A brake switch signal is not sent to ECM for
extremely long time while the vehicle is driving.
Possible cause
(Stop lamp switch circuit is open or shorted.)
Stop lamp switch
FAIL-SAFE MODE
EBS010U5
When the malfunction is detected, the ECM enters in fail-safe mode.

Engine operation condition in fail-fail safe mode
ECM controls the electric throttle control actuator by regulating the throttle opening to a small range.Therefore,acceleration will be
poor.
Vehicle condition
Driving condition
When engine is idling
Normal
When accelerating
Poor acceleration
EBS010U6
WITH CONSULT-II
1.
2.
3.
4.
5.

Fully depress the brake pedal for at least 5 seconds.
Erase the DTC with CONSULT-II.
.
PBIB1952E
WITH GST
EC-404
http://vnx.su

Wiring Diagram
EBS010U7
EC
TBWA0623E
EC-405
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
101
Stop lamp switch
DATA (DC Voltage)
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
EBS010U8
1. CHECK STOP LAMP SWITCH CIRCUIT

1.
2.

Check the stop lamp when depressing and releasing the brake pedal.
Brake pedal
Stop lamp
Fully released
Not illuminated
Slightly depressed
Illuminated
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 2.

1.
PBIB0498E
2.
Check voltage between stop lamp switch terminal 1 and ground with CONSULT-II or tester.
PBIB2284E

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.
EC-406
http://vnx.su

15A fuse
Harness for open and short between stop lamp switch and battery
EC
1.
2.

Check harness continuity between stop lamp switch terminal 2 and ECM terminal 101.

OK or NG
OK
>> GO TO 5.
NG

H

OK or NG
OK
>> GO TO 6.
NG

J

>> INSPECTION END
EBS01FF8
STOP LAMP SWITCH

1.
2.
3.

PBIB2285E
Condition
Brake pedal: Fully released.
Brake pedal: Slightly depressed.
Continuity
Should not exist.
Should exist.
EC-407
http://vnx.su
DTC P2122, P2123 APP SENSOR


PFP:18002
EBS010UA
The accelerator pedal position sensor is installed on the upper end

of the accelerator pedal assembly. The sensor detects the accelerator position and sends a signal to the ECM.
Accelerator pedal position sensor has two sensors. These sensors
are a kind of potentiometers which transform the accelerator pedal
position into output voltage, and emit the voltage signal to the ECM.
In addition, these sensors detect the opening and closing speed of
the accelerator pedal and feed the voltage signals to the ECM. The
ECM judges the current opening angle of the accelerator pedal from
these signals and controls the throttle control motor based on these
signals.
PBIB1741E
Idle position of the accelerator pedal is determined by the ECM
receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut.
EBS010UB

MONITOR ITEM
ACCEL SEN 1
ACCEL SEN 2*
CLSD THL POS
CONDITION
SPECIFICATION
Ignition switch: ON
(engine stopped)
0.5 - 1.0V
4.0 - 4.7V
Ignition switch: ON
(engine stopped)
0.3 - 1.2V
3.9 - 4.8V
ON
OFF
Ignition switch: ON
*: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage.
EBS010UC

NOTE:
If DTC P2122 or P2123 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229.
Refer to EC-371, "DTC P1229 SENSOR POWER SUPPLY" .
DTC No.
P2122
2122

sensor 1 circuit low input
An excessively low voltage from the APP sensor 1

is sent to ECM.
P2123
2123

sensor 1 circuit high input
An excessively high voltage from the APP sensor 1

is sent to ECM.
Possible cause
(The APP sensor 1 circuit is open or
shorted.)

(APPsensor 1)
FAIL-SAFE MODE
degrees.
EC-408
http://vnx.su

EBS010UD
A
NOTE:
EC
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.

F
SEF058Y
WITH GST

H
EC-409
http://vnx.su

Wiring Diagram
EBS010UE
TBWA0624E
EC-410
http://vnx.su

CAUTION:
TERMINAL
NO.
82
83
WIRE
COLOR
R/Y
EC
ITEM
CONDITION
Sensor ground
sensor 1)
[Engine is running]
Sensor ground
sensor 2)
[Engine is running]
90
Sensor power supply

sensor 1)
91
BR/Y
Sensor power supply

sensor 2)
Warm-up condition
Idle speed
Warm-up condition
Idle speed
DATA (DC Voltage)
C
Approximately 0V
D
Approximately 0V
E
Approximately 5V
Approximately 5V
98
B/W

sensor 2
Engine stopped
G
0.15 - 0.6V
Engine stopped
1.95 - 2.4V
106

sensor 1
Engine stopped
0.5 - 1.0V
Engine stopped
3.9 - 4.7V
EC-411
http://vnx.su

EBS010UF

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-412
http://vnx.su

2. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT

1.
2.
Disconnect accelerator pedal position (APP) sensor harness

connector.
EC
D
PBIB0498E
3.

F
OK or NG
OK
>> GO TO 3.
NG
PBIB0914E
3. CHECK APP SENSOR 1 GROUND CIRCUIT FOR OPEN AND SHORT

1.
2.
3.

Check harness continuity between APP sensor terminal 3 and ECM terminal 82.

OK or NG
OK
>> GO TO 4.
NG
4. CHECK APP SENSOR 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

OK or NG
OK
>> GO TO 5.
NG
5. CHECK APP SENSOR

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.
EC-413
http://vnx.su


1.
2.
3.
4.
Replace the accelerator pedal assembly.

>> INSPECTION END

>> INSPECTION END
EBS010UG
ACCELERATOR PEDAL POSITION SENSOR

1.
2.
3.

Check voltage between ECM terminals 106 (APP sensor 1 signal), 98 (APP sensor 2 signal) and ground under the following
conditions.
Terminal
Accelerator pedal
Voltage
106
sensor 1)
Fully released
0.5 - 1.0V
Fully depressed
3.9 - 4.7V
Fully released
0.15 - 0.6V
Fully depressed
1.95 - 2.4V
98
sensor 2)
4.
5.
6.
7.
MBIB0023E
If NG, replace accelerator pedal assembly and go to the next

step.
EBS010UH
ACCELERATOR PEDAL
Refer to ACC-2, "ACCELERATOR CONTROL SYSTEM" .
EC-414
http://vnx.su


PFP:18002
A
EBS010UI

of the accelerator pedal assembly. The sensor detects the acceleraEC
tor position and sends a signal to the ECM.
C
D
signals.
PBIB1741E
E
EBS010UJ

MONITOR ITEM
ACCEL SEN 1
ACCEL SEN 2*
CLSD THL POS
CONDITION
SPECIFICATION
Ignition switch: ON
(engine stopped)
0.5 - 1.0V
4.0 - 4.7V
Ignition switch: ON
(engine stopped)
0.3 - 1.2V
3.9 - 4.8V
ON
OFF
Ignition switch: ON
EBS010UK

DTC No.
P2127
2127
P2128
2128


is sent to ECM.


is sent to ECM.
Possible cause
(APP sensor 2 circuit is open or
shorted.)
(TP sensor circuit is shorted.)

(APP sensor 2)

(TP sensor 1 and 2)
FAIL-SAFE MODE
degrees.
The ECM regulates the opening speed of throttle valve to be shower than the normal condition.
EC-415
http://vnx.su

EBS010UL
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.

SEF058Y
WITH GST
EC-416
http://vnx.su

Wiring Diagram
EBS010UM
EC
TBWB0263E
EC-417
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
47
Sensor power supply

82
R/Y
Sensor ground
sensor 1)
Warm-up condition
Idle speed
83
DATA (DC Voltage)
Approximately 5V
[Engine is running]
Approximately 0V
[Engine is running]
Sensor ground
sensor 2)
Warm-up condition
Idle speed
Approximately 0V
90
Sensor power supply

sensor 1)
Approximately 5V
91
BR/Y
Sensor power supply

sensor 2)
Approximately 5V
98
B/W

sensor 2
Engine stopped
0.15 - 0.6V
Engine stopped
1.95 - 2.4V
106

sensor 1
Engine stopped
0.5 - 1.0V
Engine stopped
EC-418
http://vnx.su
3.9 - 4.7V

EBS010UN

1.
2.

EC
J
PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-419
http://vnx.su

2. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-I

1.
2.

connector.
PBIB0498E
3.

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 3.
PBIB0915E
3. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-II

1.
2.
3.

OK or NG
OK
>> GO TO 4.
NG
4. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-III

ECM terminal
Sensor terminal
91
EC-417
47
EC-425
OK or NG
OK
>> GO TO 5.
NG

OK or NG
OK
>> GO TO 11.
NG
>> GO TO 6.
EC-420
http://vnx.su


1.
2.
3.

>> INSPECTION END
EC

1.
2.
3.


OK or NG
OK
>> GO TO 8.
NG
1.

OK or NG
OK
>> GO TO 9.
NG
9. CHECK APP SENSOR

OK or NG
OK
>> GO TO 11.
NG
>> GO TO 10.
1.
2.
3.
4.

>> INSPECTION END

>> INSPECTION END
EC-421
http://vnx.su

EBS010UO

1.
2.
3.

conditions.
Terminal
Accelerator pedal
Voltage
106
sensor 1)
Fully released
0.5 - 1.0V
Fully depressed
3.9 - 4.7V
Fully released
0.15 - 0.6V
Fully depressed
1.95 - 2.4V
98
sensor 2)
4.
5.
6.
7.
MBIB0023E

step.
EBS010UP
ACCELERATOR PEDAL
EC-422
http://vnx.su
DTC P2135 TP SENSOR

DTC P2135 TP SENSOR

PFP:16119
A
EBS010UQ

EC
D
PBIB0145E
EBS010UR

MONITOR ITEM
CONDITION
Ignition switch: ON
(Engine stopped)
More than 0.36V
Less than 4.75V
THRTL SEN 1
THRTL SEN 2*
SPECIFICATION
EBS010US

DTC No.
P2135
2135

circuit range/performance
problem
Rationally incorrect voltage is sent to ECM

compared with the signals from TP sensor 1
and TP sensor 2.
Possible cause
Harness or connector
(TP sensor 1 and 2 circuit is open or
shorted.)

(TP sensor 1 and 2)

(APP sensor 2)
FAIL-SAFE MODE

degrees.
EBS010UT
NOTE:
TESTING CONDITION:
EC-423
http://vnx.su
DTC P2135 TP SENSOR

WITH CONSULT-II
1.
2.
3.
4.

SEF058Y
WITH GST
EC-424
http://vnx.su
DTC P2135 TP SENSOR

Wiring Diagram
EBS010UU
EC
TBWB0264E
EC-425
http://vnx.su
DTC P2135 TP SENSOR

CAUTION:
TERMINAL NO.
47
WIRE
COLOR
R
ITEM
power supply
CONDITION
DATA (DC Voltage)

Approximately 5V
49
Engine stopped
More than 0.36V
Engine stopped
Less than 4.75V
[Engine is running]
66
Sensor ground
Warm-up condition
Idle speed
Approximately 0V
68
91
BR/Y
Sensor power supply

Engine stopped
Less than 4.75V
Engine stopped
EC-426
http://vnx.su
More than 0.36V
Approximately 5V
DTC P2135 TP SENSOR

EBS010UV

1.
2.

EC
J
PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-427
http://vnx.su
DTC P2135 TP SENSOR

2. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT-I

1.
2.

PBIB1992E
PBIB1971E
3.

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 3.
PBIB0082E
3. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT-II

1.
2.
3.

OK or NG
OK
>> GO TO 4.
NG
EC-428
http://vnx.su
DTC P2135 TP SENSOR

4. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT-III
ECM terminal
Sensor terminal
47
EC-425
91
EC-417
OK or NG
OK
>> GO TO 5.
NG
EC
5. CHECK APP SENSOR

OK or NG
OK
>> GO TO 11
NG
>> GO TO 6.

1.
2.
3.
4.

>> INSPECTION END
7. CHECK THROTTLE POSITION SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.


OK or NG
OK
>> GO TO 8.
NG
8. CHECK THROTTLE POSITION SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
Check harness continuity between electric throttle control actuator terminal 4 and ECM terminal 49, electric throttle control actuator terminal 2 and ECM terminal 68.

OK or NG
OK
>> GO TO 9.
NG
EC-429
http://vnx.su
DTC P2135 TP SENSOR


OK or NG
OK
>> GO TO 11.
NG
>> GO TO 10.

1.
2.
3.

>> INSPECTION END

>> INSPECTION END
EBS010UW

1.
2.
3.
4.
5.

Terminal
Accelerator pedal
Voltage
49
Fully released
More than 0.36V
Fully depressed
Less than 4.75V
68
Fully released
Less than 4.75V
Fully depressed
More than 0.36V
6.
7.
8.

step.
MBIB0022E
EBS010UX

EC-430
http://vnx.su
DTC P2138 APP SENSOR


PFP:18002
A
EBS010UY

C
D
signals.
PBIB1741E
E
EBS010UZ

MONITOR ITEM
ACCEL SEN 1
ACCEL SEN 2*
CLSD THL POS
CONDITION
SPECIFICATION
Ignition switch: ON
(engine stopped)
0.5 - 1.0V
4.0 - 4.7V
Ignition switch: ON
(engine stopped)
0.3 - 1.2V
3.9 - 4.8V
ON
OFF
Ignition switch: ON
EBS010V0

NOTE:
DTC No.
Possible cause
P2138
2138

circuit range/performance problem

compared with the signals from APP sensor
1 and APP sensor 2.
(APP sensor 1 and 2 circuit is open
or shorted.)

(APP sensor 1 and 2)

(TP sensor 1 and 2)
FAIL-SAFE MODE
degrees.
EC-431
http://vnx.su

EBS010V1
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.

SEF058Y
WITH GST
EC-432
http://vnx.su

Wiring Diagram
EBS010V2
EC
TBWB0265E
EC-433
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
47
Sensor power supply

82
R/Y
Sensor ground
sensor 1)
Warm-up condition
Idle speed
83
DATA (DC Voltage)
Approximately 5V
[Engine is running]
Approximately 0V
[Engine is running]
Sensor ground
sensor 2)
Warm-up condition
Idle speed
Approximately 0V
90
Sensor power supply

sensor 1)
Approximately 5V
91
BR/Y
Sensor power supply

sensor 2)
Approximately 5V
98
B/W

sensor 2
Engine stopped
0.15 - 0.6V
Engine stopped
1.95 - 2.4V
106

sensor 1
Engine stopped
0.5 - 1.0V
Engine stopped
EC-434
http://vnx.su
3.9 - 4.7V

EBS010V3

1.
2.

EC
J
PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-435
http://vnx.su


1.
2.

connector.
PBIB0498E
3.

OK or NG
OK
>> GO TO 3.
NG
PBIB0914E

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 4.
PBIB0915E

1.
2.
3.

OK or NG
OK
>> GO TO 5.
NG
EC-436
http://vnx.su

ECM terminal
Sensor terminal
91
EC-433
47
EC-425
OK or NG
OK
>> GO TO 6.
NG
EC

OK or NG
OK
>> GO TO 12.
NG
>> GO TO 7.

1.
2.
3.

>> INSPECTION END
8. CHECK APP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Check harness continuity between APP sensor terminal 3 and ECM terminal 82, APP sensor terminal 1
and ECM terminal 83.

OK or NG
OK
>> GO TO 9.
NG
9. CHECK APP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

OK or NG
OK
>> GO TO 10.
NG
EC-437
http://vnx.su

10. CHECK APP SENSOR

OK or NG
OK
>> GO TO 12.
NG
>> GO TO 11.

1.
2.
3.
4.

>> INSPECTION END

>> INSPECTION END
EBS010V4

1.
2.
3.

conditions.
Terminal
Accelerator pedal
Voltage
106
sensor 1)
Fully released
0.5 - 1.0V
Fully depressed
3.9 - 4.7V
Fully released
0.15 - 0.6V
Fully depressed
1.95 - 2.4V
98
sensor 2)
4.
5.
6.
7.
MBIB0023E

step.
EBS010V5
ACCELERATOR PEDAL
EC-438
http://vnx.su
IGNITION SIGNAL
IGNITION SIGNAL
PFP:22448
A
EBS010V6
IGNITION COIL & POWER TRANSISTOR

The ignition signal from the ECM is sent to and amplified by the
power transistor. The power transistor turns ON and OFF the ignition
coil primary circuit. This ON/OFF operation induces the proper high
voltage in the coil secondary circuit.
EC
PBIB1969E
EC-439
http://vnx.su
IGNITION SIGNAL
Wiring Diagram
EBS010V7
TBWA0628E
EC-440
http://vnx.su
IGNITION SIGNAL
CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
[Engine is running]
111
G/W
ECM relay
(Self shut-off)

OFF
More than a few seconds after turning ignition

switch OFF
DATA (DC Voltage)
C
0 - 1.0V
D
BATTERY VOLTAGE
(11 - 14V)
119
120
SB
GY
BATTERY VOLTAGE
(11 - 14V)
121
W/L

(Back-up)
BATTERY VOLTAGE
(11 - 14V)
EC-441
http://vnx.su
IGNITION SIGNAL
TBWA0629E
EC-442
http://vnx.su
IGNITION SIGNAL
A
CAUTION:
EC
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
C
[Engine is running]
60
61
79
80
DATA (DC Voltage)
L/R
BR
GY/R
PU
Warm-up condition
Idle speed
0 - 0.1V
NOTE:
at idle

E
PBIB0521E
0 - 0.2V
F
[Engine is running]
Warm-up condition
G
PBIB0522E
H
EBS010V8
1. CHECK ENGINE START

Turn ignition switch OFF, and restart engine.
Is engine running?
Yes or No
Yes (With CONSULT-II)>>GO TO 2.
Yes (Without CONSULT-II)>>GO TO 3.
No
>> GO TO 4.
2. CHECK OVERALL FUNCTION
With CONSULT-II
Perform POWER BALANCE in ACTIVE TEST mode with CONSULT-II.
Make sure that each circuit produces a momentary engine
speed drop.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 12.
1.
2.
PBIB0133E
EC-443
http://vnx.su
IGNITION SIGNAL

Without CONSULT-II
Let engine idle.
Read the voltage signal between ECM terminals 60, 61, 79, 80
and ground with an oscilloscope.
3. Verify that the oscilloscope screen shows the signal wave as
shown below.
NOTE:
The pulse cycle changes depending on rpm at idle.
1.
2.
MBIB0033E
PBIB0521E
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 12.
4. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-I

1.
2.

OK or NG
OK
>> GO TO 5.
NG
>> Go to EC-124, "POWER SUPPLY AND GROUND CIRCUIT" .
MBIB0034E
EC-444
http://vnx.su
IGNITION SIGNAL
5. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-II

1.
2.
3.

Disconnect condenser harness connector.
EC
D
PBIB1969E
4.
Check voltage between condenser terminal 1 and ground with

F

OK or NG
OK
>> GO TO 10.
NG
>> GO TO 6.
H
PBIB0624E
6. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-III
1.
2.
3.

Check harness continuity between ECM relay terminal 7 and
condenser terminal 1.

OK or NG
OK
>> GO TO 7.
NG
PBIB1973E
7. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-IV

Check voltage between ECM relay terminal 6 and ground with CONSULT-II or tester.
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.
PBIB0625E
EC-445
http://vnx.su
IGNITION SIGNAL

20A fuse

9. CHECK ECM RELAY

OK or NG
OK
>> GO TO 17.
NG
10. CHECK CONDENSER GROUND CIRCUIT FOR OPEN AND SHORT

1.
2.

Check harness continuity between condenser terminal 2 and ground.
Refer to Wiring diagram.

OK or NG
OK
>> GO TO 11.
NG
>> Repair open circuit or short to power in harness or connector.
11. CHECK CONDENSER

OK or NG
OK
>> GO TO 12.
NG
>> Replace condenser.
EC-446
http://vnx.su
IGNITION SIGNAL
12. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-V

1.
2.
3.
4.

Disconnect ignition coil harness connector.
EC
PBIB1969E
5.
Check voltage between ignition coil terminal 1 and ground with


OK or NG
OK
>> GO TO 14.
NG
>> GO TO 13.
H
SEF107S

Check harness for open or short between ignition coil and ECM relay.
14. CHECK IGNITION COIL GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.

Check harness continuity between ignition coil terminal 2 and ground.

OK or NG
OK
>> GO TO 15.
NG
15. CHECK IGNITION COIL OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.

Check harness continuity between ECM terminals 60, 61, 79, 80 and ignition coil terminal 3.

OK or NG
OK
>> GO TO 16.
NG
EC-447
http://vnx.su
IGNITION SIGNAL
16. CHECK IGNITION COIL WITH POWER TRANSISTOR

OK or NG
OK
>> GO TO 17.
NG
>> Replace ignition coil with power transistor.

>> INSPECTION END
EBS010V9
ECM RELAY
1.
2.

Condition
Continuity
Yes
OFF
No
3.

PBIB0077E
CONDENSER
1.
2.
3.

Check resistance between condenser terminals 1 and 2.
Resistance: Above 1 M at 25C (77F)
MBIB0031E
EC-448
http://vnx.su
IGNITION SIGNAL
IGNITION COIL WITH POWER TRANSISTOR
1.
2.
3.

Check resistance between ignition coil terminals as follows.
Terminal No.
2 and 3
Except 0 or
EC
1 and 2
1 and 3
Except 0
MBIB0032E
EBS010VA

Refer to EM-31, "IGNITION COIL" .
EC-449
http://vnx.su
INJECTOR CIRCUIT
INJECTOR CIRCUIT
PFP:16600
EBS010VB
The fuel injector is a small, precise solenoid valve. When the ECM
supplies a ground to the injector circuit, the coil in the injector is
energized. The energized coil pulls the ball valve back and allows
fuel to flow through the injector into the intake manifold. The amount
of fuel injected depends upon the injection pulse duration. Pulse
duration is the length of time the injector remains open. The ECM
controls the injection pulse duration based on engine fuel needs.
SEF375Z
EBS010VC

MONITOR ITEM
B/FUEL SCHDL
INJ PULSE-B1
CONDITION
SPECIFICATION

(M/T)
No load
Idle
2.0 - 3.0 msec
2,000 rpm
1.9 - 2.9 msec
EC-450
http://vnx.su
INJECTOR CIRCUIT
Wiring Diagram
EBS010VD
EC
TBWA0630E
EC-451
http://vnx.su
INJECTOR CIRCUIT
CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)

BATTERY VOLTAGE
[Engine is running]
22
23
41
42
G/B
R/B
L/B
Y/B
Warm-up condition
Idle speed
(11 - 14V)
NOTE:
at idle
Injector No. 3
Injector No. 1
Injector No. 4
Injector No. 2
PBIB0529E
BATTERY VOLTAGE
(11 - 14V)
[Engine is running]
Warm-up condition
PBIB0530E
EBS010VE
1. INSPECTION START
Turn ignition switch to START.
Is any cylinder ignited?
Yes or No
Yes
>> GO TO 2.
No
>> GO TO 3.
EC-452
http://vnx.su
INJECTOR CIRCUIT
With CONSULT-II
Start engine.
CONSULT-II.
speed drop.
1.
2.
EC
E
PBIB0133E
Without CONSULT-II
1. Start engine.
I
PBIB1986E
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 3.
EC-453
http://vnx.su
INJECTOR CIRCUIT
3. CHECK INJECTOR POWER SUPPLY CIRCUIT

1.
2.
3.

Disconnect injector harness connector.
PBIB1970E
4.
Check voltage between injector terminal 1 and ground with

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
PBIB0582E

Harness connectors F1, F101
10A fuse
Harness for open or short between injector and fuse
5. CHECK INJECTOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1.
2.
3.

Check harness continuity between injector terminal 2 and ECM terminals 22, 23, 41, 42.

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.
EC-454
http://vnx.su
INJECTOR CIRCUIT
6. DETECT MALFONCTIONING PART
Harness for open or short between injector and ECM
EC
7. CHECK INJECTOR
OK or NG
OK
>> GO TO 8.
NG
>> Replace injector.

F

>> INSPECTION END
EBS010VF
INJECTOR
1.
2.

Check resistance between terminals as shown in the figure.
Resistance: 13.5 - 17.5 [at 10 - 60C (50 - 140F)]

I
K
PBIB1727E
EBS010VG
INJECTOR

M
EC-455
http://vnx.su
VIAS
VIAS
Description
PFP:14956
EBS011HT
SYSTEM DESCRIPTION
Sensor
Input Signal to ECM

Engine speed*
Throttle position
Battery
Battery voltage*
ECM function
VIAS control
Actuator
*: The ECM determines the start signal status by the signals of engine speed and battery voltage.
PBIB0843E
When the engine is running at low or medium speed, the power valve is fully closed. Under this condition, the
effective suction port length is equivalent to the total length of the intake manifold collector's suction port
including the intake valve. This long suction port provides increased air intake which results in improved suction efficiency and higher torque generation.
The surge tank and one-way valve are provided. When engine is running at high speed, the ECM sends the
signal to the VIAS control solenoid valve. This signal introduces the intake manifold vacuum into the power
valve actuator and therefore opens the power valve to two suction passages together in the collector.
Under this condition, the effective port length is equivalent to the length of the suction port provided independently for each cylinder. This shortened port length results in enhanced engine output with reduced suction
resistance under high speeds.
Power Valve
The power valve is installed in intake manifold collector and used to
control the suction passage of the variable induction air control system. It is set in the fully closed or fully opened position by the power
valve actuator operated by the vacuum stored in the surge tank. The
vacuum in the surge tank is controlled by the VIAS control solenoid
valve.
PBIB0946E
EC-456
http://vnx.su
VIAS
VIAS Control Solenoid Valve
A
The VIAS control solenoid valve cuts the intake manifold vacuum
signal for power valve control. It responds to ON/OFF signals from
the ECM. When the solenoid is off, the vacuum signal from the
intake manifold is cut. When the ECM sends an ON signal the coil
pulls the plunger downward and feeds the vacuum signal to the
power valve actuator.
EC
PBIB0947E

MONITOR ITEM
VIAS S/V
EBS011HU
CONDITION
SPECIFICATION
Idle
OFF
More than 5,000 rpm
ON
EC-457
http://vnx.su
VIAS
Wiring Diagram
EBS011HW
TBWA0651E
EC-458
http://vnx.su
VIAS
CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
[Engine is running]

valve
Idle speed
[Engine is running]
DATA (DC Voltage)

BATTERY VOLTAGE
(11 - 14V)
0 - 1.0V
EC-459
http://vnx.su
VIAS
EBS011HX

With CONSULT-II
2. Perform VIAS SOL VALVE in ACTIVE TEST mode with CONSULT-II.
PBIB0844E
3.
Turn VIAS control solenoid valve ON and OFF, and make sure
that power valve actuator rod moves.
PBIB0949E
Without CONSULT-II
2. Rev engine quickly up to above 5,000 rpm and make sure that
power valve actuator rod moves.
PBIB0949E
OK or NG
OK
>> INSPECTION END
NG (With CONSULT-II) >>GO TO 2.
NG (Without CONSULT-II) >>GO TO 3.
EC-460
http://vnx.su
VIAS
2. CHECK VACUUM EXISTENCE
With CONSULT-II
Stop engine and disconnect vacuum hose connected to power valve actuator.
Perform VIAS SOL VALVE in ACTIVE TEST mode with CONSULT-II.
4. Turn VIAS control solenoid valve ON and OFF, and check vacuum existence under the following conditions.
1.
2.
3.
VIAS SOL VALVE
EC
Vacuum
ON
Should exist
OFF
Should not exist
E
PBIB0844E
OK or NG
OK
>> Repair or replace power valve actuator.
NG
>> GO TO 4.

Without CONSULT-II
Disconnect VIAS control solenoid valve harness connector.
Apply 12V of direct current between VIAS control solenoid valve
terminals 1 and 2.
5. Check vacuum existence under the following conditions.
1.
2.
3.
4.
Condition
12V direct current supply
No supply
Vacuum
Should exist
Should not exist
OK or NG
OK
NG
>> GO TO 4.
L
PBIB0845E
4. CHECK VACUUM HOSE
1.
2.
Stop engine.
Check hoses and tubes between intake manifold and power
valve actuator for crack, clogging, improper connection or disconnection. Refer to EC-32, "Vacuum Hose Drawing" .
OK or NG
OK
>> GO TO 5.
NG
>> Repair hoses or tubes.
SEF109L
EC-461
http://vnx.su
VIAS
5. CHECK VACUUM TANK

OK or NG
OK
>> GO TO 6.
NG
>> Replace vacuum tank.
6. CHECK VIAS CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT

1.
2.

PBIB0947E
3.
Check voltage between VIAS control solenoid valve terminal 1

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.
PBIB0173E

Check harness for open or short between VIAS control solenoid valve and ECM relay
8. CHECK VIAS CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Check harness continuity between VIAS control solenoid valve terminal 2 and ECM terminal 6.

OK or NG
OK
>> GO TO 9.
NG
EC-462
http://vnx.su
VIAS
9. CHECK VIAS CONTROL SOLENOID VALVE

OK or NG
OK
>> GO TO 10.
NG
>> Replace VIAS control solenoid valve.
EC

D
>> INSPECTION END
EBS011HY
VIAS CONTROL SOLENOID VALVE

With CONSULT-II
1.
2.
3.
4.
Reconnect harness connectors disconnected.

Perform VIAS SOL VALVE in ACTIVE TEST mode.
Check air passage continuity and operation delay time under the
Condition
VIAS SOL VALVE

between A and B

between A and C
ON
Yes
No
OFF
No
Yes
Operation takes less than 1 second.

PBIB0177E
Without CONSULT-II
Check air passage continuity and operation delay time under the following conditions.
Condition

between A and B

between A and C

between terminals 1 and 2
Yes
No
No supply
No
Yes

MEC488B
VACUUM TANK
1.
2.
3.
Disconnect vacuum hose connected to vacuum tank.

Connect a vacuum pump to the port A of vacuum pump.
Apply vacuum and make sure that vacuum exists at the port B .
PBIB0846E
EC-463
http://vnx.su
VIAS
EBS011HZ

EC-464
http://vnx.su
FUEL PUMP CIRCUIT

FUEL PUMP CIRCUIT

Description
PFP:17042
A
EBS010VH
SYSTEM DESCRIPTION
Sensor
Input Signal to ECM

Engine speed*
Battery
Battery voltage*
ECM Function
Actuator
Fuel pump control
EC
Fuel pump relay
*: ECM determines the start signal status by the signals of engine speed and battery voltage.
The ECM activates the fuel pump for several seconds after the ignition switch is turned ON to improve engine
startability. If the ECM receives a engine speed signal from the crankshaft position sensor (POS) and camshaft position sensor (PHASE), it knows that the engine is rotating, and causes the pump to operate. If the
engine speed signal is not received when the ignition switch is ON, the engine stalls. The ECM stops pump
operation and prevents battery discharging, thereby improving safety. The ECM does not directly drive the fuel
pump. It controls the ON/OFF fuel pump relay, which in turn controls the fuel pump.
Condition
Fuel pump operation
Ignition switch is turned to ON
Operates for 1 second
Engine running and cranking
Operates
When engine is stopped
Stops in 1.5 seconds
Stops
A turbine type design fuel pump is used in the fuel tank.
K
PBIB0513E
EBS010VI

MONITOR ITEM
FUEL PUMP RLY
CONDITION
SPECIFICATION
ON
OFF
EC-465
http://vnx.su
FUEL PUMP CIRCUIT

Wiring Diagram
EBS010VJ
LHD MODELS
TBWA0632E
EC-466
http://vnx.su
FUEL PUMP CIRCUIT

CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
DATA (DC Voltage)
114
B/OR
Fuel pump relay
C
0 - 1.0V
[Engine is running]

switch ON
D
BATTERY VOLTAGE
(11 - 14V)
EC-467
http://vnx.su
FUEL PUMP CIRCUIT

RHD MODELS
TBWA0633E
EC-468
http://vnx.su
FUEL PUMP CIRCUIT

CAUTION:
TERMINAL
NO.
EC
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
114
B/OR
Fuel pump relay
C
0 - 1.0V
[Engine is running]

switch ON
D
BATTERY VOLTAGE
(11 - 14V)
EBS010VK

1.
2.

Pinch fuel feed hose with two fingers.
Fuel pressure pulsation should be felt on the fuel hose
for 1 second after ignition switch is turned ON.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
I
PBIB1983E
2. CHECK FUEL PUMP RELAY POWER SUPPLY CIRCUIT
1.
2.
3.

Disconnect fuel pump relay.
PBIB1974E
4.
Check voltage between fuel pump relay terminals 1, 5 and

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.
MBIB0191E
EC-469
http://vnx.su
FUEL PUMP CIRCUIT


Harness connectors M17, B1
15A fuse
Harness for open or short between fuel pump relay and fuse
4. CHECK CONDENSER CIRCUIT FOR OPEN AND SHORT

1.
2.
3.

Check harness continuity between fuel pump relay terminal 3 and condenser terminal 1, condenser terminal 2 and ground.

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

Harness connectors B22, B128 (RHD models)
Harness for open or short between fuel pump relay and condenser
Harness for open or short between condenser and ground
>> Repair open circuit or short to ground or short to power in harness connectors.
6. CHECK CONDENSER
OK or NG
OK
>> GO TO 7.
NG
7. CHECK FUEL PUMP POWER SUPPLY AND GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
Disconnect fuel level sensor unit and fuel pump harness connector.
Check harness continuity between fuel pump relay terminal 3
and fuel level sensor unit and fuel pump terminal 5, fuel level
sensor unit and fuel pump terminal 3 and ground.

OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.
EC-470
http://vnx.su
PBIB0506E
FUEL PUMP CIRCUIT

Harness for open or short between fuel pump relay and fuel level sensor unit and fuel pump
Harness for open or short between fuel level sensor unit and fuel pump and ground
9. CHECK FUEL PUMP RELAY OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.

Check harness continuity between fuel pump relay terminal 2 and ECM terminal 114.
EC

OK or NG
OK
>> GO TO 11.
NG
>> GO TO 10.

Harness connectors B1, M17 (LHD models)
Harness connectors B2, M18 (RHD models)
Harness for open or short between fuel pump relay and ECM
11. CHECK FUEL PUMP RELAY

OK or NG
OK
>> GO TO 12.
NG
>> Replace fuel pump relay.
12. CHECK FUEL PUMP

M

OK or NG
OK
>> GO TO 13.
NG
>> Replace fuel pump.

>> INSPECTION END
EC-471
http://vnx.su
FUEL PUMP CIRCUIT

EBS010VL
FUEL PUMP RELAY

Check continuity between terminals 3 and 5 under the following conditions.
Conditions
Continuity

1 and 2
Yes
No current supply
No
PBIB0098E
FUEL PUMP
1.
2.
Check resistance between fuel level sensor unit and fuel pump
terminals 3 and 5.
Resistance: Approximately 0.2 - 5.0 [at 25C
(77F)]
PBIB0658E
CONDENSER
1.
2.
3.

Check resistance between condenser terminal 1 and 2.
Resistance: Above 1M [at 25C (77F)]
MBIB0031E
EBS010VM
FUEL PUMP
Refer to FL-4, "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY" .
EC-472
http://vnx.su
REFRIGERANT PRESSURE SENSOR


PFP:92136
A
EBS010VN
The refrigerant pressure sensor is installed at the condenser of the

air conditioner system. The sensor uses an electrostatic volume
pressure transducer to convert refrigerant pressure to voltage. The
voltage signal is sent to ECM, and ECM controls cooling fan system.
EC
D
PBIB0503E
H
PBIB2657E
EC-473
http://vnx.su

Wiring Diagram
EBS010VO
TBWA0634E
EC-474
http://vnx.su

CAUTION:
TERMINAL
NO.
46
WIRE
COLOR
EC
ITEM
Sensor power supply
CONDITION
DATA (DC Voltage)
C
Approximately 5V
[Engine is running]
57
Sensor ground
Warm-up condition
Idle speed
D
Approximately 0V
[Engine is running]
69
Warm-up condition
Both A/C switch and blower switch are ON
E
1.0 - 4.0V
EBS010VP
1. CHECK REFRIGERANT PRESSURE SENSOR OVERALL FUNCTION

1.
2.
3.

Turn A/C switch and blower switch ON.
Check voltage between ECM terminal 69 and ground with CONSULT-II or tester.
Voltage: 1.0 - 4.0V
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
K
MBIB0035E
EC-475
http://vnx.su


1.
2.
3.
Turn A/C switch and blower switch OFF.

Stop engine.
PBIB2021E
OK or NG
OK
>> GO TO 3.
NG
EC-476
http://vnx.su

3. CHECK REFRIGERANT PRESSURE SENSOR POWER SUPPLY CIRCUIT

1.
2.
Disconnect refrigerant pressure sensor harness connector.

EC
D
PBIB0503E
3.
Check voltage between refrigerant pressure sensor terminal 3

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
SEF479Y

Harness for open or short between refrigerant pressure sensor and ECM
5. CHECK REFRIGERANT PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Check harness continuity between refrigerant pressure sensor terminal 1 and ECM terminal 57.

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

EC-477
http://vnx.su

7. CHECK REFRIGERANT PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.


OK or NG
OK
>> Replace refrigerant pressure sensor.
NG
EBS010VQ

Refer to ATC-141, "REFRIGERANT LINES" .
EC-478
http://vnx.su
ELECTRICAL LOAD SIGNAL


PFP:25350
A
EBS01FF9

MONITOR ITEM
LOAD SIGNAL
HEATER FAN SW
CONDITION
Ignition switch: ON
Ignition switch: ON
SPECIFICATION
Rear window defogger switch is ON and/or lighting

switch is in 2nd position (placed in LOW position for
models with Xenon headlamp).
ON
Rear window defogger switch is OFF and lighting switch

is OFF.
OFF
ON
Heater fan is not operating.
OFF
EC
EC-479
http://vnx.su

Wiring Diagram
EBS01FFA
LHD MODELS WITHOUT XENON HEADLAMP
TBWB0468E
EC-480
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
84
L/Y

(Headlamp signal)
Lighting switch: 2nd position
[Engine is running]
96
LG/B
Heater fan switch
[Engine is running]
DATA (DC Voltage)

BATTERY VOLTAGE
(11 - 14V)
Approximately 0V
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
EC-481
http://vnx.su

TBWA0636E
EC-482
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
93
BR

signal)
DATA (DC Voltage)

BATTERY VOLTAGE
(11 - 14V)
Approximately 0V
EC-483
http://vnx.su

LHD MODELS WITH XENON HEADLAMP
TBWB0469E
EC-484
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
84
L/Y

(Headlamp signal)
Lighting switch: 2nd position (placed in LOW

position)
[Engine is running]
96
LG/B
Heater fan switch
[Engine is running]
DATA (DC Voltage)
BATTERY VOLTAGE
(11 - 14V)
Approximately 0V
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
EC-485
http://vnx.su

TBWB0470E
EC-486
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
93
BR

signal)
DATA (DC Voltage)

BATTERY VOLTAGE
(11 - 14V)
Approximately 0V
EC-487
http://vnx.su

RHD MODELS
TBWB0471E
EC-488
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
84
L/Y

(Headlamp signal)

[Engine is running]
96
LG/B
Heater fan switch
[Engine is running]
DATA (DC Voltage)
BATTERY VOLTAGE
(11 - 14V)
Approximately 0V
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
EC-489
http://vnx.su

TBWB0472E
EC-490
http://vnx.su

CAUTION:
TERMINAL
NO.
EC
WIRE
COLOR
ITEM
CONDITION
93

signal)
BR
DATA (DC Voltage)
BATTERY VOLTAGE
(11 - 14V)
Approximately 0V
D
EBS01FFB
1. INSPECTION START
Yes or No
Yes
>> GO TO 2.
No
>> GO TO 3.
2. CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCITION-I

H
With CONSULT-II
2. Check LOAD SIGNAL in DATA MONITOR mode with CONSULT-II under the following conditions.
Condition
LOAD SIGNAL
Lighting switch: ON at 2nd position
ON
OFF
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 8.
PBIB0103E
3. CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCTION-I

M
Without CONSULT-II
2. Check voltage between ECM terminal 84 and ground under the
Condition
Voltage
BATTERY VOLTAGE
0V
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 8.
MBIB0158E
EC-491
http://vnx.su

4. CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCTION-II

With CONSULT-II
Check LOAD SIGNAL in DATA MONITOR mode with CONSULTII under the following conditions.
Condition
LOAD SIGNAL
ON
OFF
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 11.
PBIB0103E

Without CONSULT-II
Condition
Voltage
BATTERY VOLTAGE
0V
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 11.
PBIB1773E
6. CHECK HEATER FAN SIGNAL CIRCUIT OVERALL FUNCTION

With CONSULT-II
Check HEATER FAN SW in DATA MONITOR mode with CONSULT-II under the following conditions.
Condition
LOAD SIGNAL
Heater fan control switch: ON
ON
Heater fan control switch: OFF
OFF
OK or NG
OK
>> INSPECTION END.
NG
>> GO TO 14.
PBIB1995E

Without CONSULT-II
Condition
Voltage
0V
BATTERY VOLTAGE
OK or NG
OK
>> INSPECTION END.
NG
>> GO TO 14.
PBIB1219E
EC-492
http://vnx.su

8. CHECK HEADLAMP FUNCTION
A
1. Start engine.
2. Turn the lighting switch ON at 2nd position.
EC
3. Check that headlamps are illuminated.
OK or NG
OK
>> GO TO 9.
NG
>> Refer to LT-25, "HEADLAMP - CONVENTIONAL TYPE -" or LT-51, "HEADLAMP (WITH DAY- C
TIME) - CONVENTIONAL TYPE -" .
9. CHECK HEADLAMP INPUT SIGNAL CIRCUIT FOR OPEN OR SHORT
1.
2.
3.
4.
Stop engine.
Disconnect lighting switch harness connectors.
Check harness continuity between lighting switch terminal 9, 10 and ECM terminal 84 under the following
conditions.
I
PBIB1994E
Condition
Continuity
Should exist
Should not exist

OK or NG
OK
>> GO TO 16.
NG
>> GO TO 10.

Diode E123
Diode E124
Harness for open and short between lighting switch and ECM
EC-493
http://vnx.su

11. CHECK REAR WINDOW DEFOGGER FUNCTION

1.
2.
3.
Start engine.
Turn ON the rear window defogger switch.
Check the rear windshield.
Is the rear windshield heated up?
Yes or No
Yes
>> GO TO 12.
No
>> Refer to GW-17, "REAR WINDOW DEFOGGER" .
12. CHECK REAR WINDOW DEFOGGER INPUT SIGNAL CIRCUIT FOR OPEN OR SHORT
1.
2.
3.
4.
Stop engine.
Disconnect rear window defogger relay.
Check harness continuity between rear window defogger relay 3 (models without door mirror defogger), 5
(models with door mirror defogger) and ECM terminal 93.

OK or NG
OK
>> GO TO 16.
NG
>> GO TO 13.

Harness connectors B1, M17
Harness for open and short between rear window defogger relay and ECM
14. CHECK HEATER FAN CONTROL FUNCTION

1.
2.
3.
Start engine.
Turn ON the fan control switch.
Check the blower fan motor.
Does the blower fan motor activate?
Yes or No
Yes
>> GO TO 15.
No
>> Refer to ATC-34, "TROUBLE DIAGNOSIS" or MTC-3, "TROUBLE DIAGNOSIS" .
EC-494
http://vnx.su

15. CHECK HEATER FAN SIGNAL CIRCUIT FOR OPEN OR SHORT

1.
2.
3.
4.
Stop engine.
Disconnect A/C AUTO AMP. harness connector.
Check harness continuity between A/C AUTO AMP. terminal 19 and ECM terminal 96.
EC

OK or NG
OK
>> GO TO 16.
NG

>> INSPECTION END
1. INSPECTION START
H

Yes or No
Yes
>> GO TO 2.
No
>> GO TO 3.

J
With CONSULT-II
Condition
LOAD SIGNAL
Lighting switch: ON at 2nd position and

placed in LOW position
ON
OFF
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 8.
PBIB0103E
EC-495
http://vnx.su


Without CONSULT-II
Condition
Voltage

BATTERY VOLTAGE
0V
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 8.
MBIB0158E

With CONSULT-II
Condition
LOAD SIGNAL
ON
OFF
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 11.
PBIB0103E

Without CONSULT-II
Condition
Voltage
BATTERY VOLTAGE
0V
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 11.
PBIB1773E
EC-496
http://vnx.su

With CONSULT-II
Condition
EC
LOAD SIGNAL
ON
OFF
OK or NG
OK
>> INSPECTION END.
NG
>> GO TO 14.
D
PBIB1995E

Without CONSULT-II
Condition
Voltage
0V
BATTERY VOLTAGE
OK or NG
OK
>> INSPECTION END.
NG
>> GO TO 14.
I
PBIB1219E
1. Start engine.
2. Turn the lighting switch ON at 2nd position and placed in LOW position.
OK or NG
OK
>> GO TO 9.
NG
>> Refer to LT-5, "HEADLAMP - XENON TYPE -" or LT-41, "HEADLAMP (WITH DAYTIME) XENON TYPE -" .

1.
2.
3.
4.
Stop engine.
Disconnect daytime light relay LH or HID relay LH.
Check harness continuity between ECM terminal 84 and daytime light relay LH terminal 3 or HID relay LH
terminal 3.
OK or NG
OK
>> GO TO 16.
NG
>> GO TO 10.
EC-497
http://vnx.su


Harness for open and short between ECM and daytime light relay LH or HID relay LH

1.
2.
3.
Start engine.
Yes or No
Yes
>> GO TO 12.
No
1.
2.
3.
4.
Stop engine.

OK or NG
OK
>> GO TO 16.
NG
>> GO TO 13.


1.
2.
3.
Start engine.
Yes or No
Yes
>> GO TO 15.
No
EC-498
http://vnx.su


1.
2.
3.
4.
Stop engine.
EC

OK or NG
OK
>> GO TO 16.
NG

>> INSPECTION END
RHD MODELS
1. INSPECTION START
H

Yes or No
Yes
>> GO TO 2.
No
>> GO TO 3.

J
With CONSULT-II
Condition
LOAD SIGNAL
Lighting switch: ON at 2nd position (placed in

LOW position for models with Xenon headlamp)
ON
OFF
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 8.
PBIB0103E
EC-499
http://vnx.su


Without CONSULT-II
Condition
Voltage
BATTERY VOLTAGE
0V
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 8.
MBIB0158E

With CONSULT-II
Condition
LOAD SIGNAL
ON
OFF
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 13.
PBIB0103E

Without CONSULT-II
Condition
Voltage
BATTERY VOLTAGE
0V
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 13.
PBIB1773E
EC-500
http://vnx.su

With CONSULT-II
Condition
EC
LOAD SIGNAL
ON
OFF
OK or NG
OK
>> INSPECTION END.
NG
>> GO TO 16.
D
PBIB1995E

Without CONSULT-II
Condition
Voltage
0V
BATTERY VOLTAGE
OK or NG
OK
>> INSPECTION END.
NG
>> GO TO 16.
I
PBIB1219E
1. Start engine.
2. Turn the lighting switch ON at 2nd position (placed in LOW position for models with Xenon headlamp).
OK or NG
OK (Models without Xenon headlamp)>>GO TO 9.
OK (Models with Xenon headlamp)>>GO TO 11.
NG
>> Refer to LT-5, "HEADLAMP - XENON TYPE -" , LT-25, "HEADLAMP - CONVENTIONAL TYPE -"
, LT-41, "HEADLAMP (WITH DAYTIME) - XENON TYPE -" or LT-51, "HEADLAMP (WITH DAYTIME) - CONVENTIONAL TYPE -" .
EC-501
http://vnx.su


1.
2.
3.
4.
Stop engine.
conditions.
PBIB1994E
Condition
Continuity
Should exist
Should not exist

OK or NG
OK
>> GO TO 18.
NG
>> GO TO 10.

Diode E123
Diode E124
Harness for open and short between ECM and combination switch

1.
2.
3.
4.
Stop engine.
Disconnect HID relay LH.
Check harness continuity between ECM terminal 84 and HID relay LH terminal 3.
OK or NG
OK
>> GO TO 18.
NG
>> GO TO 12.
EC-502
http://vnx.su

Harness for open and short between ECM and HID relay LH
EC

1.
2.
3.
Start engine.
Yes or No
Yes
>> GO TO 14.
No
1.
2.
3.
4.
Stop engine.

OK or NG
OK
>> GO TO 18.
NG
>> GO TO 15.


1.
2.
3.
Start engine.
Yes or No
Yes
>> GO TO 17.
No
EC-503
http://vnx.su


1.
2.
3.
4.
Stop engine.

OK or NG
OK
>> GO TO 18.
NG

>> INSPECTION END
EC-504
http://vnx.su
ASCD BRAKE SWITCH

ASCD BRAKE SWITCH

PFP:25320
A
EBS01FAN

EC
D
SEC009D
EBS01FAO

MONITOR ITEM
CONDITION
BRAKE SW1
(ASCD brake switch)
BRAKE SW2
(Stop lamp switch)
Ignition switch: ON
Ignition switch: ON
SPECIFICATION

Fully released
ON

Slightly depressed
OFF
OFF
ON
EC-505
http://vnx.su
ASCD BRAKE SWITCH

Wiring Diagram
EBS01FAP
TBWA0763E
EC-506
http://vnx.su
ASCD BRAKE SWITCH

CAUTION:
TERMINAL
NO.
EC
WIRE
COLOR
ITEM
CONDITION
101
Stop lamp switch
DATA (DC Voltage)
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
108
GY/L
ASCD brake switch

Slightly depressed

Fully released
Approximately 0V
E
BATTERY VOLTAGE
(11 - 14V)
F
EBS01FAR
With CONSULT-II
A/T models
I
CONDITION
INDICATION
OFF
ON
M/T models
CONDITION
INDICATION
OFF
ON
SEC011D
1.
2.
Without CONSULT-II
A/T models
CONDITION
VOLTAGE
Approximately 0V
Battery voltage
M/T models
CONDITION
VOLTAGE
Approximately 0V
Battery voltage
OK or NG
OK
>> GO TO 2.
NG
>> GO TO 3.
EC-507
http://vnx.su
MBIB0061E
ASCD BRAKE SWITCH


1.
2.
With CONSULT-II
CONDITION
INDICATION
OFF
ON
SEC013D
Without CONSULT-II
CONDITION
VOLTAGE
Approximately 0V
Battery voltage
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 11.
MBIB0060E

1.
2.
3.

SEC009D
4.

OK or NG
OK
>> GO TO 9.
PBIB0857E
EC-508
http://vnx.su
ASCD BRAKE SWITCH

10A fuse
EC

1.
2.
3.
4.


OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.
H
PBIB0799E
10A fuse
1.
2.


OK or NG
OK
>> GO TO 8.
NG

OK or NG
OK
>> GO TO 15.
NG
EC-509
http://vnx.su
ASCD BRAKE SWITCH

1.
2.
3.


OK or NG
OK
>> GO TO 10.
NG

OK or NG
OK
>> GO TO 15.
NG

1.
2.

PBIB0498E
3.
PBIB2284E

OK or NG
OK
>> GO TO 13.
NG
>> GO TO 12.
EC-510
http://vnx.su
ASCD BRAKE SWITCH

15A fuse
1.
2.

EC

OK or NG
OK
>> GO TO 14.
NG

H

OK or NG
OK
>> GO TO 15.
NG

>> INSPECTION END
EC-511
http://vnx.su
ASCD BRAKE SWITCH

EBS01FAS
ASCD BRAKE SWITCH

1.
2.
3.

Condition

Continuity
Should exist
Should not exist

SEC023D
ASCD CLUTCH SWITCH

1.
2.
3.

Condition

Continuity
Should exist
Should not exist

SEC024D
STOP LAMP SWITCH

1.
2.
3.

PBIB2285E
Condition
Continuity
Should not exist
Should exist
EC-512
http://vnx.su
ASCD INDICATOR
ASCD INDICATOR
PFP:24814
A
EBS01FAT
ASCD indicator lamp illuminates to indicate ASCD operation status. Lamp has two indicators, CRUISE, SET,
and is integrated in combination meter.
EC
CRUISE indicator illuminates when MAIN switch on ASCD steering switch is turned ON to indicated that
ASCD system is ready for operation.
SET indicator illuminates when following conditions are met.
C
CRUISE indicator is illuminated.
SET/COAST switch on ASCD steering switch is turned ON while vehicle speed is within the range of
ASCD setting.
D
SET indicator remains lit during ASCD control.
EBS01FAU
Specification data are reference value.

MONITOR ITEM
CRUISE LAMP
SET LAMP
CONDITION
SPECIFICATION
Ignition switch: ON

at the 2nd time
ON OFF
MAIN switch: ON
ASCD: Operating
ON
Vehicle speed is between 40 km/h

(25 MPH) and 144 km/h (89 MPH)
ASCD: Not operating
OFF
EC-513
http://vnx.su
ASCD INDICATOR
Wiring Diagram
EBS01FAV
TBWA0764E
EC-514
http://vnx.su
ASCD INDICATOR
EBS01FAW
Check ASCD indicator under the following conditions.

ASCD INDICATOR
CRUISE LAMP
SET LAMP
CONDITION
SPECIFICATION
Ignition switch: ON

at the 2nd time
ON OFF
MAIN switch: ON
ASCD: Operating
ON
When vehicle speed is between 40 km/h

(25 MPH) and 144 km/h (130 MPH)
ASCD: Not operating
OFF
EC
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
2. CHECK DTC
Check that DTC U1000 or U1001 is not displayed.
OK or NG
OK
>> GO TO 3.
NG
>> Perform trouble diagnoses for DTC U1000, U1001. Refer to EC-132, "DTC U1000, U1001 CAN
COMMUNICATION LINE" .
3. CHECK COMBINATION METER FUNCTION

OK or NG
OK
>> GO TO 4.
NG
>> Replace combination meter.

K
>> INSPECTION END

L
EC-515
http://vnx.su
MI & DATA LINK CONNECTORS


Wiring Diagram
PFP:24814
EBS010VV
LHD MODELS
TBWA0639E
EC-516
http://vnx.su

A
EC
TBWA0640E
EC-517
http://vnx.su

RHD MODELS
TBWA0641E
EC-518
http://vnx.su

A
EC
TBWA0642E
EC-519
http://vnx.su
EVAPORATIVE EMISSION SYSTEM


Description
PFP:14950
EBS010VX
SYSTEM DESCRIPTION
PBIB0491E
The evaporative emission system is used to reduce hydrocarbons emitted into the atmosphere from the fuel
system. This reduction of hydrocarbons is accomplished by activated charcoals in the EVAP canister.
The fuel vapor in the sealed fuel tank is led into the EVAP canister which contains activated carbon and the
vapor is stored there when the engine is not operating or when refueling to the fuel tank.
The vapor in the EVAP canister is purged by the air through the purge line to the intake manifold when the
engine is operating. EVAP canister purge volume control solenoid valve is controlled by ECM. When the
engine operates, the flow rate of vapor controlled by EVAP canister purge volume control solenoid valve is
proportionally regulated as the air flow increases.
EVAP canister purge volume control solenoid valve also shuts off the vapor purge line during decelerating and
idling.
EC-520
http://vnx.su

EVAPORATIVE EMISSION LINE DRAWING
QR20DE Engine Models
EC
PBIB0490E
EC-521
http://vnx.su

PBIB1998E
EC-522
http://vnx.su

EBS010VY
EVAP CANISTER
Check EVAP canister as follows:
1. Block port B . Orally blow air through port A .
Check that air flows freely through port C .
2. Block port A . Orally blow air through port B .
EC
D
PBIB0663E
FUEL CHECK VALVE

1.
2.
3.
Blow air through connector on fuel tank side.

A considerable resistance should be felt and a portion of air flow
should be directed toward the EVAP canister side.
Blow air through connector on EVAP canister side.
Air flow should be smoothly directed toward fuel tank side.
If fuel check valve is suspected of not properly functioning in
steps 1 and 2 above, replace it.
H
SEF552Y
FUEL TANK VACUUM RELIEF VALVE (BUILT INTO FUEL FILLER CAP)
1.
Wipe clean valve housing.
SEF989X
2.
Check valve opening pressure and vacuum.

Pressure:
Vacuum:
3.
15.3 - 20.0 kPa (0.153 - 0.200 bar,

0.156 - 0.204 kg/cm2 , 2.22 - 2.90 psi)
6.0 to 3.4 kPa (0.060 to 0.034 bar,
0.061 to 0.035 kg/cm2 , 0.87 to 0.49 psi)
If out of specification, replace fuel filler cap as an assembly.
SEF943S
EC-523
http://vnx.su

WATER SEPARATOR
1.
2.
3.
4.
5.
Check visually for insect nests in the water separator air inlet.
Check visually for cracks or flaws in the appearance.
Check visually for cracks or flaws in the hose.
Check that A and C are not clogged by blowing air into B with
A , and then C plugged.
In case of NG in items 2 - 4, replace the parts.
NOTE:
Do not disassemble water separator.
PBIB1032E

EC-524
http://vnx.su
POSITIVE CRANKCASE VENTILATION


Description
PFP:11810
A
EBS010VZ
SYSTEM DESCRIPTION
EC
G
PBIB0492E
This system returns blow-by gas to the intake manifold.

The positive crankcase ventilation (PCV) valve is provided to conduct crankcase blow-by gas to the intake
manifold. During partial throttle operation of the engine, the intake manifold sucks the blow-by gas through the
PCV valve. Normally, the capacity of the valve is sufficient to handle any blow-by and a small amount of ventilating air. The ventilating air is then drawn from the air inlet tubes into the crankcase. In this process the air
passes through the hose connecting air inlet tubes to rocker cover. Under full-throttle condition, the manifold
vacuum is insufficient to draw the blow-by flow through the valve. The flow goes through the hose connection
in the reverse direction.
On vehicles with an excessively high blow-by, the valve does not
meet the requirement. This is because some of the flow will go
through the hose connection to the air inlet tubes under all conditions.
PBIB1588E
EBS010W0
PCV (POSITIVE CRANKCASE VENTILATION) VALVE

With engine running at idle, remove PCV valve from rocker cover. A
properly working valve makes a hissing noise as air passes through
it. A strong vacuum should be felt immediately when a finger is
placed over valve inlet.
PBIB1589E
EC-525
http://vnx.su

PCV VALVE VENTILATION HOSE
1.
2.
Check hoses and hose connections for leaks.

Disconnect all hoses and clean with compressed air. If any hose
cannot be freed of obstructions, replace.
S-ET277
EC-526
http://vnx.su
AUTOMATIC SPEED CONTROL DEVICE (ASCD)


System Description
PFP:18930
A
EBS01FAX

Sensor
Input signal to ECM
ASCD brake switch
Brake pedal operation
Stop lamp switch
ASCD clutch switch (M/T)
Clutch pedal operation
ASCD steering switch operation
Park/Neutral position (PNP)

switch
Gear position
wheel sensor*
Vehicle speed
ECM function
Actuator
EC
C
ASCD vehicle speed control

actuator
BASIC ASCD SYSTEM

Refer to Owner's Manual for ASCD operating instructions.
Automatic Speed Control Device (ASCD) allows a driver to keep vehicle at predetermined constant speed
without depressing accelerator pedal. Driver can set vehicle speed in advance between approximately 40 km/
h (25 MPH) and 144 km/h (89 MPH).
ECM controls throttle angle of electric throttle control actuator to regulate engine speed.
Operation status of ASCD is indicated by CRUISE indicator and SET indicator in combination meter. If any
malfunction occurs in ASCD system, it automatically deactivates control.
NOTE:
Always drive vehicle in safe manner according to traffic conditions and obey all traffic laws.
SET OPERATION
Press ASCD MAIN switch. (The CRUISE indicator in combination meter illuminates.)
When vehicle speed reaches a desired speed between approximately 40 km/h (25 MPH) and 144 km/h (89
MPH), press SET/COAST switch. (Then SET indicator in combination meter illuminates.)
ACCEL OPERATION
If the RESUME/ACCELERATE switch is pressed during cruise control driving, increase the vehicle speed until
the switch is released or vehicle speed reaches maximum speed controlled by the system.
And then ASCD will keep the new set speed.
CANCEL OPERATION
When any of following conditions exist, cruise operation will be canceled.
CANCEL switch is pressed
More than 2 switches at ASCD steering switch are pressed at the same time (Set speed will be cleared)
Brake pedal is depressed
Clutch pedal is depressed or gear position is changed to the neutral position (M/T models)
Vehicle speed decreased to 13 km/h (8 MPH) lower than the set speed
ESP/TCS system is operated

When the ECM detects any of the following conditions, the ECM will cancel the cruise operation and inform
the driver by blinking indicator lamp.
Engine coolant temperature is slightly higher than the normal operating temperature, CRUISE lamp may
blink slowly.
When the engine coolant temperature decreases to the normal operating temperature, CRUISE lamp will
stop blinking and the cruise operation will be able to work by pressing SET/COAST switch or RESUME/
ACCELERATE switch.
Malfunction for some self-diagnoses regarding ASCD control: SET lamp will blink quickly.
If MAIN switch is turned to OFF during ASCD is activated, all of ASCD operations will be canceled and vehicle
speed memory will be erased.
EC-527
http://vnx.su

COAST OPERATION
When the SET/COAST switch is pressed during cruise control driving, decrease vehicle set speed until the
switch is released. And then ASCD will keep the new set speed.
RESUME OPERATION
When the RESUME/ACCELERATE switch is pressed after cancel operation other than pressing MAIN switch
is performed, vehicle speed will return to last set speed. To resume vehicle set speed, vehicle condition must
meet following conditions.
Brake pedal is fully released
Clutch pedal is fully released (M/T models)
A/T selector lever is in other than P and N position (A/T models)
Vehicle speed is greater than 40 km/h (25 MPH) and less than 144 km/h (89 MPH)
EBS01FAY

Refer to EC-376 .
ASCD BRAKE SWITCH

Refer to EC-386 and EC-505 .
ASCD CLUTCH SWITCH

Refer to EC-386 and EC-505
STOP LAMP SWITCH

Refer to EC-386 , EC-404 and EC-505 .

Refer to EC-293 , EC-295 , EC-305 and EC-313 .
ASCD INDICATOR
Refer to EC-513 .
EC-528
http://vnx.su


Fuel Pressure
PFP:00030
A
EBS010W1
Approximately 350 kPa (3.5bar, 3.57kg/cm2 , 51psi)
Fuel pressure at idle
EC
Idle Speed and Ignition Timing

QR20DE
Target idle speed
QR25DE
QR20DE
Air conditioner: ON
QR25DE
QR20DE
Ignition timing
QR25DE
EBS010W2
M/T
No load* (in Neutral position)
65050 rpm
A/T
No load* (in P or N position)
M/T
A/T
M/T
In Neutral position
A/T
In P or N position
M/T
In Neutral position
750 rpm or more
A/T
In P or N position
700 rpm or more
M/T
In Neutral position
A/T
In P or N position
M/T
In Neutral position
A/T
In P or N position
C
70050 rpm
D
725 rpm or more
F
155 BTDC
*: Under the following conditions:
Electric load: OFF (Lights, heater fan & rear window defogger)
Steering wheel: Kept in straight-ahead position
Calculated Load Value
EBS010W3
Calculated load value% (Using CONSULT-II or GST)

At idle
10 - 35
At 2,500 rpm
10 - 35
Mass Air Flow Sensor
EBS010W4
Supply voltage
Battery voltage (11 - 14V)

0.7 - 1.1*V (QR20DE)
0.8 - 1.2*V (QR25DE)
Output voltage at idle
1.0 - 4.0 gm/sec at idle*

4.0 - 10.0 gm/sec at 2,500 rpm*
Mass air flow (Using CONSULT-II or GST)
*: Engine is warmed up to normal operating temperature and running under no-load.
Intake Air Temperature Sensor
EBS010W5
Temperature C (F)
Resistance k
25 (77)
1.800 - 2.200
80 (176)
0.283 - 0.359
Engine Coolant Temperature Sensor

Temperature C (F)
EBS010W6
Resistance k
20 (68)
2.1 - 2.9
50 (122)
0.68 - 1.00
90 (194)
0.236 - 0.260
Heated Oxygen Sensor 1 Heater
EBS010W7
3.3 - 4.0
EC-529
http://vnx.su

Heated Oxygen sensor 2 Heater
EBS010W8
5.0 - 7.0
Crankshaft Position Sensor (POS)
EBS010W9
Camshaft Position Sensor (PHASE)
EBS010WA
Throttle Control Motor
EBS010WB
Approximately 1 - 15
Injector
EBS010WC
Resistance [at 10 - 60C (50 - 140F)]
13.5 - 17.5
Fuel Pump
EBS010WD
Approximately 0.2 - 5.0
EC-530
http://vnx.su
INDEX FOR DTC

[QR (WITHOUT EURO-OBD)]
INDEX FOR DTC

Alphabetical Index
PFP:00024
A
EBS010WE
EC
NOTE:
C
DTC*1
Trip
MI lighting
up
Reference page
2122
EC-812
P2123
2123
EC-812
APP SEN 2/CIRC
P2127
2127
EC-819
APP SEN 2/CIRC
P2128
2128
EC-819
APP SENSOR
P2138
2138
EC-835
ASCD BRAKE SW*7
P1572
1572
EC-787
ASCD SW *7
P1564
1564
EC-777
P1574
1574
EC-797
BRAKE SW/CIRCUIT
P1805
1805
EC-806
CAN COMM CIRCUIT
U1000
1000*5
EC-630
CAN COMM CIRCUIT
U1001
1001*
EC-630
CKP SEN/CIRCUIT
P0335
0335
EC-690
CMP SEN/CIRC-B1
P0340
0340
EC-698
CTP LEARNING
P1225
1225
EC-768
CTP LEARNING
P1226
1226
EC-770
ECM
P0605
0605
1 or 2
or
EC-713
ECM BACK UP/CIRCUIT
P1065
1065
EC-716
ECT SEN/CIRC
P0117
0117
EC-649
ECT SEN/CIRC
P0118
0118
EC-649
ENG OVER TEMP
P1217
1217
EC-752
ETC ACTR
P1121
1121
EC-720
Items
CONSULT-II*2
ECM*3
APP SEN 1/CIRC
P2122
APP SEN 1/CIRC
ASCD VHL SPD
SEN*7
ETC FUNCTION/CIRC
P1122
1122
EC-723
ETC MOT
P1128
1128
EC-742
ETC MOT PWR
P1124
1124
EC-734
ETC MOT PWR
P1126
1126
EC-734
HO2S1 (B1)
P0132
0132
EC-663
HO2S1 (B1)
P0134
0134
EC-670
INT/V TIM CONT-B1
P0011
0011
EC-633
KNOCK SEN/CIRC-B1
P0327
0327
EC-685
KNOCK SEN/CIRC-B1
P0328
0328
EC-685
MAF SEN/CIRCUIT
P0102
0102
EC-641
MAF SEN/CIRCUIT
P0103
0103
EC-641
P1610 - P1615
1610 - 1615
EC-564
No DTC
Flashing*4
Flashing*4
EC-566
NATS MALFUNCTION
NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.
EC-531
http://vnx.su
INDEX FOR DTC

DTC*1
Trip
MI lighting
up
Reference page
0000
P0550
0550
EC-708
P-N POS SW/CIRCUIT
P1706
1706
EC-799
SENSOR POWER/CIRC
P1229
1229
EC-772
TCS C/U FUNCTN*6
P1211
1211
EC-750
TCS/CIRC*6
P1212
1212
EC-751
TP SEN 1/CIRC
P0222
0222
EC-677
TP SEN 1/CIRC
P0223
0223
EC-677
TP SEN 2/CIRC
P0122
0122
EC-655
TP SEN 2/CIRC
P0123
0123
EC-655
TP SENSOR
P2135
2135
EC-827
VEH SPEED SEN/CIRC
P0500
0500
EC-706
V/SP SEN (A/T OUT)
P1720
1720
EC-804
Items
CONSULT-II*2
ECM*3
NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.
P0000
PW ST P SEN/CIRC

*4: When engine is running.
*6: For models with ESP system.
*7: For QR25DE engine models.
EC-532
http://vnx.su
INDEX FOR DTC

DTC No. Index
EBS010WF
NOTE:
EC
DTC*1
Items
Trip
MI lighting
up
Reference page
Flashing*4
EC-566
CONSULT-II*2
ECM*3
No DTC
Flashing*4
U1000
1000*5
CAN COMM CIRCUIT
EC-630
U1001
1001*
CAN COMM CIRCUIT
EC-630
P0000
0000
NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.
P0011
0011
INT/V TIM CONT-B1
EC-633
P0102
0102
MAF SEN/CIRCUIT
EC-641
P0103
0103
MAF SEN/CIRCUIT
EC-641
P0117
0117
ECT SEN/CIRC
EC-649
P0118
0118
ECT SEN/CIRC
EC-649
P0122
0122
TP SEN 2/CIRC
EC-655
P0123
0123
TP SEN 2/CIRC
EC-655
P0132
0132
HO2S1 (B1)
EC-663
P0134
0134
HO2S1 (B1)
EC-670
P0222
0222
TP SEN 1/CIRC
EC-677
P0223
0223
TP SEN 1/CIRC
EC-677
P0327
0327
KNOCK SEN/CIRC-B1
EC-685
P0328
0328
KNOCK SEN/CIRC-B1
EC-685
NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.
P0335
0335
CKP SEN/CIRCUIT
EC-690
P0340
0340
CMP SEN/CIRC-B1
EC-698
P0500
0500
VEH SPEED SEN/CIRC
EC-706
P0550
0550
PW ST P SEN/CIRC
EC-708
P0605
0605
ECM
1 or 2
or
EC-713
P1065
1065
ECM BACK UP/CIRCUIT
EC-716
P1121
1121
ETC ACTR
EC-720
P1122
1122
ETC FUNCTION/CIRC
EC-723
P1124
1124
ETC MOT PWR
EC-734
P1126
1126
ETC MOT PWR
EC-734
P1128
1128
ETC MOT
EC-742
P1211
1211
TCS C/U FUNCTN*6
EC-750
P1212
1212
TCS/CIRC*6
EC-751
P1217
1217
ENG OVER TEMP
EC-752
P1225
1225
CTP LEARNING
EC-768
P1226
1226
CTP LEARNING
EC-770
P1229
1229
SENSOR POWER/CIRC
EC-772
P1564
1564
ASCD SW*
EC-777
P1572
1572
ASCD BRAKE SW*7
EC-787
EC-533
http://vnx.su
INDEX FOR DTC

DTC*1
Trip
MI lighting
up
Reference page
ASCD VHL SPD SEN*7
EC-797
1610 - 1615
NATS MALFUNCTION
EC-564
P1706
1706
P-N POS SW/CIRCUIT
EC-799
P1720
1720
V/SP SEN (A/T OUT)
EC-804
P1805
1805
BRAKE SW/CIRCUIT
EC-806
P2122
2122
APP SEN 1/CIRC
EC-812
P2123
2123
APP SEN 1/CIRC
EC-812
P2127
2127
APP SEN 2/CIRC
EC-819
P2128
2128
APP SEN 2/CIRC
EC-819
P2135
2135
TP SENSOR
EC-827
P2138
2138
APP SENSOR
EC-835
CONSULT-II*2
ECM*3
P1574
1574
P1610 - P1615
Items

*4: When engine is running.
*6: For models with ESP system.
*7: For QR25DE engine models.
EC-534
http://vnx.su
PRECAUTIONS
PRECAUTIONS
PFP:00001
BELT PRE-TENSIONER
EBS010WG
The Supplemental Restraint System such as AIR BAG and SEAT BELT PRE-TENSIONER, used along EC
C
WARNING:
in the event of a collision which would result in air bag inflation, all maintenance must be perD
formed by an authorized NISSAN/INFINITI dealer.
E
harness connectors.
F
On Board Diagnostic (OBD) System of Engine
EBS010WH
CAUTION:
Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM.
Precaution
EBS010WI

running.
EC-535
SEF289H
http://vnx.su
PRECAUTIONS

If battery cable is disconnected, the memory will return to
the initial ECM values.
The ECM will now start to self-control at its initial values.
Engine operation can vary slightly when the cable is disconnected. However, this is not an indication of a malfunction. Do not replace parts because of a slight variation.
PBIB1164E

figure.
PBIB1512E

break).
damage to ICs.
Keep engine control system harness at least 10 cm (4 in)
PBIB0090E
operation of ICs, etc.
Before replacing ECM, perform ECM Terminals and Reference Value inspection and make sure ECM functions properly. Refer to EC-592, "ECM Terminals and Reference Value"
.
Do not disassemble electric throttle control actuator.
Even a slight leak in the air intake system can cause seriMEF040D
ous incidents.
Do not shock or jar the camshaft position sensor (PHASE), crankshaft position sensor (POS).
EC-536
http://vnx.su
PRECAUTIONS

EC
C
SAT652J
When measuring ECM signal with a circuit tester, connect

break-out box (SST) and Y-cable adapter (SST) between the
ECM and ECM harness connector.
the ground.
SEF348N
Do not operate fuel pump when there is no fuel in lines.

Tighten fuel hose clamps to the specified torque.
PBIB0513E
EC-537
http://vnx.su
PRECAUTIONS
Do not depress accelerator pedal when starting.

Immediately after starting, do not rev up engine unnecessarily.
SEF709Y

control units.
Adjust the antenna and feeder line so that the standingwave radio can be kept smaller.


EC-538
http://vnx.su
SEF708Y
EBS010WJ
PREPARATION
PREPARATION
PFP:00002
A
EBS010WK
Tool number
Tool name
Description
KV10117100
Heated oxygen
sensor wrench
EC

with 22 mm (0.87 in) hexagon nut
D
S-NT379
KV10114400
Heated oxygen
sensor wrench

a: 22 mm (0.87 in)
F
S-NT636
EG17650301
Radiator cap tester
adapter

a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
S-NT564
KV109E0010
Break-out box
NT825
KV109E0080
Y-cable adapter
M
NT826
EC-539
http://vnx.su
PREPARATION

Tool name
EBS010WL
Description
Description
Quick connector
release
Removing fuel tube quick connectors in engine

room
(Available in SEC. 164 of PARTS CATALOG: Part
No. 16441 6N210)
PBIC0198E
Fuel filler cap adapter
Checking fuel tank vacuum relief valve opening

pressure
S-NT653
Socket wrench

temperature sensor
S-NT705
Oxygen sensor thread

cleaner

before installing a new oxygen sensor. Use with
anti-seize lubricant shown below.
a: 18 mm diameter with pitch 1.5 mm for
Zirconia Oxygen Sensor
b: 12 mm diameter with pitch 1.25 mm for
Titania Oxygen Sensor
AEM488
Lubricating oxygen sensor thread cleaning tool

when reconditioning exhaust system threads.
Anti-seize lubricant
i.e.: (PermatexTM
133AR or equivalent
meeting MIL
specification MIL-A907)
S-NT779
EC-540
http://vnx.su


System Diagram
PFP:23710
A
EBS010WM

EC
PBIB2455E
EC-541
http://vnx.su

PBIB2456E
EC-542
http://vnx.su

Vacuum Hose Drawing
EBS010WN
EC
PBIB0489E
EC-543
http://vnx.su

PBIB1445E
EC-544
http://vnx.su

System Chart
EBS010WO
A
Input (Sensor)
ECM Function
Output (Actuator)
Fuel injection & mixture ratio control
Fuel injector
Electronic ignition system
Power transistor
Fuel pump control
Fuel pump relay
MI (On the instrument panel)*3
EVAP canister purge flow control

solenoid valve
Ignition switch
Power valve control*6
Battery voltage
ASCD vehicle speed control*6
Knock sensor
Stop lamp switch
TCM (Transmission control module)*2
ESP/TCS/ABS control unit*2 *4
ABS actuator and electric unit

(control unit)*2 *5
Wheel sensor*2
ASCD brake switch*6
switch*6
ASCD clutch
EC
Cooling fan control
Cooling fan relay
*2: This input signal is sent to the ECM through CAN communication line.
*3: This output signal is sent from the ECM through CAN communication line.
*4: With ESP models.
*5: Without ESP models.
EC-545
http://vnx.su

Multiport Fuel Injection (MFI) System
EBS010WP

Sensor
Input Signal to ECM
ECM function
Actuator
Throttle position
Gear position
Knock sensor
Engine knocking condition
Battery
Battery voltage*3
Wheel sensor*2
Vehicle speed
Fuel injection & mixture

ratio control
Fuel injector
SYSTEM DESCRIPTION
The amount of fuel injected from the fuel injector is determined by the ECM. The ECM controls the length of
time the valve remains open (injection pulse duration). The amount of fuel injected is a program value in the
ECM memory. The program value is preset by engine operating conditions. These conditions are determined
by input signals (for engine speed and intake air) from both the crankshaft position sensor and the mass air
flow sensor.
VARIOUS FUEL INJECTION INCREASE/DECREASE COMPENSATION

In addition, the amount of fuel injected is compensated to improve engine performance under various operating conditions as listed below.
<Fuel increase>
During warm-up
During acceleration
Hot-engine operation
When selector lever is changed from N to D (A/T models)

<Fuel decrease>
During deceleration
During high engine speed operation
EC-546
http://vnx.su

MIXTURE RATIO FEEDBACK CONTROL (CLOSED LOOP CONTROL)
A
EC
PBIB0121E
The mixture ratio feedback system provides the best air-fuel mixture ratio for driveability and emission control.
The three way catalyst (manifold) can then better reduce CO, HC and NOx emissions. This system uses
heated oxygen sensor 1 in the exhaust manifold to monitor whether the engine operation is rich or lean. The
ECM adjusts the injection pulse width according to the sensor voltage signal. For more information about
heated oxygen sensor 1, refer to EC-663, "DTC P0132 HO2S1" . This maintains the mixture ratio within the
range of stoichiometric (ideal air-fuel mixture).
This stage is referred to as the closed loop control condition.
Heated oxygen sensor 2 is located downstream of the three way catalyst (manifold). Even if the switching
characteristics of heated oxygen sensor 1 shift, the air-fuel ratio is controlled to stoichiometric by the signal
from heated oxygen sensor 2.
Open Loop Control

The open loop system condition refers to when the ECM detects any of the following conditions. Feedback
control stops in order to maintain stabilized fuel combustion.
Deceleration and acceleration
Malfunction of heated oxygen sensor 1 or its circuit
Insufficient activation of heated oxygen sensor 1 at low engine coolant temperature
High engine coolant temperature
During warm-up
After shifting from N to D (A/T models)
MIXTURE RATIO SELF-LEARNING CONTROL

The mixture ratio feedback control system monitors the mixture ratio signal transmitted from heated oxygen
sensor 1. This feedback signal is then sent to the ECM. The ECM controls the basic mixture ratio as close to
the theoretical mixture ratio as possible. However, the basic mixture ratio is not necessarily controlled as originally designed. Both manufacturing differences (i.e., mass air flow sensor hot wire) and characteristic
changes during operation (i.e., injector clogging) directly affect mixture ratio.
Accordingly, the difference between the basic and theoretical mixture ratios is monitored in this system. This is
then computed in terms of injection pulse duration to automatically compensate for the difference between
the two ratios.
Fuel trim refers to the feedback compensation value compared against the basic injection duration. Fuel trim
includes short term fuel trim and long term fuel trim.
Short term fuel trim is the short-term fuel compensation used to maintain the mixture ratio at its theoretical
value. The signal from heated oxygen sensor 1 indicates whether the mixture ratio is RICH or LEAN compared
to the theoretical value. The signal then triggers a reduction in fuel volume if the mixture ratio is rich, and an
increase in fuel volume if it is lean.
Long term fuel trim is overall fuel compensation carried out long-term to compensate for continual deviation
of the short term fuel trim from the central value. Such deviation will occur due to individual engine differences,
wear over time and changes in the usage environment.
EC-547
http://vnx.su

FUEL INJECTION TIMING
SEF337W
Two types of systems are used.
Sequential Multiport Fuel Injection System

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

Fuel is injected simultaneously into all four cylinders twice each engine cycle. In other words, pulse signals of
the same width are simultaneously transmitted from the ECM.
The four injectors will then receive the signals two times for each engine cycle.
This system is used when the engine is being started and/or if the fail-safe system (CPU) is operating.
FUEL SHUT-OFF
Fuel to each cylinder is cut off during deceleration or operation of the engine at excessively high speeds.
Electronic Ignition (EI) System
EBS010WQ

Sensor
Input Signal to ECM
ECM function
Actuator
Throttle position
Knock sensor
Engine knocking
Gear position
Battery
Battery voltage*2
Wheel sensor*1
Vehicle speed
Ignition timing
control
Power transistor
SYSTEM DESCRIPTION
The ignition timing is controlled by the ECM to maintain the best airfuel ratio for every running condition of the engine. The ignition timing data is stored in the ECM. This data forms the map shown.
The ECM receives information such as the injection pulse width and
camshaft position sensor signal. Computing this information, ignition
signals are transmitted to the power transistor.
e.g., N: 1,800 rpm, Tp: 1.50 msec
A BTDC
During the following conditions, the ignition timing is revised by the
ECM according to the other data stored in the ECM.
At starting
During warm-up
EC-548
http://vnx.su
SEF742M

At idle
A
At low battery voltage
During acceleration
The knock sensor retard system is designed only for emergencies. The basic ignition timing is programmed
within the anti-knocking zone, if recommended fuel is used under dry conditions. The retard system does not EC
operate under normal driving conditions. If engine knocking occurs, the knock sensor monitors the condition.
The signal is transmitted to the ECM. The ECM retards the ignition timing to eliminate the knocking condition.
C
EBS010WR

Sensor
Input Signal to ECM
Throttle valve opening angle

Engine speed*2
Battery
Battery voltage*2
ECM function
Actuator
E
Air conditioner
cut control
Vehicle speed
Wheel sensor*
SYSTEM DESCRIPTION
This system improves engine operation when the air conditioner is used.
Under the following conditions, the air conditioner is turned off.
When the accelerator pedal is fully depressed.
When cranking the engine.
At high engine speeds.
When the engine coolant temperature becomes excessively high.
When operating power steering during low engine speed or low vehicle speed.
When engine speed is excessively low.
When refrigerant pressure is excessively low or high.
Fuel Cut Control (at No Load and High Engine Speed)
EBS010WS

Sensor
Input Signal to ECM
Neutral position

Engine speed
Wheel sensor*
Vehicle speed
ECM function
Fuel cut control
Actuator
Fuel injector
SYSTEM DESCRIPTION
based on engine speed.
Fuel cut will be operated until the engine speed reaches 1,500 rpm, then fuel cut will be cancelled.
NOTE:
This function is different from deceleration control listed under EC-546, "Multiport Fuel Injection (MFI) System"
.
EC-549
http://vnx.su

CAN Communication Unit
EBS010WT
SYSTEM DESCRIPTION
M/T MODELS WITHOUT ESP

System Diagram
PKIA6458E

Signals
ECM
ABS actuator and

electric unit
(control unit)

4WD control unit
Combination meter
Engine speed signal
MI signal
R
R
R
R
R
R

EC-550
http://vnx.su

A/T MODELS WITHOUT ESP
System Diagram
EC
PKIA6457E

ABS actuator
and electric unit
(control unit)
4WD control
unit
Combination
meter
Signals
ECM

TCM
Engine speed signal
MI signal

R
R
R
R
R
PN range signal
R
R

R
T
R
R
T
T
T
R
T
EC-551
http://vnx.su

Signals
ECM
TCM
ABS actuator
and electric unit
(control unit)
4WD control
unit
Combination
meter
M/T MODELS WITH ESP

System Diagram
PKIA6459E

4WD control
unit
Combination
meter
Signals
ECM
R
T
Engine speed signal

MI signal
Steering angle
sensor

ESP/TCS/ABS
control unit
R
R

R
T
R
R
T
EC-552
http://vnx.su

A/T MODELS WITH ESP
System Diagram
EC
PKIA6460E

ESP/TCS/
ABS control
unit
4WD control
unit
Combination
meter
Signals
ECM
Engine speed signal
M
R
R
R
R
PN range signal
T
T
R
T
T
T
EC-553
http://vnx.su
MI signal

R
T

Steering
angle sensor

TCM

Signals
ECM
TCM
ESP/TCS/
ABS control
unit
T
Steering
angle sensor
4WD control
unit
Combination
meter
EC-554
http://vnx.su


Idle Speed and Ignition Timing Check
PFP:00018
A
EBS010WU
IDLE SPEED
With CONSULT-II
EC
Check idle speed in DATA MONITOR mode with CONSULT-II.

C
E
SEF058Y
Without CONSULT-II
Check the idle speed by installing the pulse type tachometer clamp on the loop wire or on suitable high-tension
wire which installed between No.1 ignition coil and No.1 spark plug.
NOTE:
For the method of installing the tachometer, refer to EC-555, "IGNITION TIMING" .
IGNITION TIMING
Any of following two methods may be used.
Method A
1.
2.
Slide the harness protector of ignition coil No.1 to clear the

wires.
Attach timing light to the wire as shown in the figure.
K
PBIB1975E
3.

M
PBIB0514E
EC-555
http://vnx.su

Method B
1.
Remove No. 1 ignition coil.
PBIB1982E
2.
Connect No. 1 ignition coil and No. 1 spark plug with suitable
high-tension wire as shown, and attach timing light clamp to this
wire.
PBIB1976E
SEF166Y
3.
PBIB0514E
Accelerator Pedal Released Position Learning
EBS010WV
DESCRIPTION
Accelerator Pedal Released Position Learning is an operation to learn the fully released position of the accelerator pedal by monitoring the accelerator pedal position sensor output signal. It must be performed each time
harness connector of accelerator pedal position sensor or ECM is disconnected.
OPERATION PROCEDURE
1.
2.

EC-556
http://vnx.su

3.
4.
5.

Throttle Valve Closed Position Learning
EBS010WW
DESCRIPTION
Throttle Valve Closed Position Learning is an operation to learn the fully closed position of the throttle valve by
monitoring the throttle position sensor output signal. It must be performed each time harness connector of
electric throttle control actuator or ECM is disconnected.
EC
OPERATION PROCEDURE
1.
2.
3.

Make sure that throttle valve moves during above 10 seconds by confirming the operating sound.
Idle Air Volume Learning
E
EBS010WX
DESCRIPTION
Idle Air Volume Learning is an operation to learn the idle air volume that keeps each engine within the specific
range. It must be performed under any of the following conditions:
Each time electric throttle control actuator or ECM is replaced.
Idle speed or ignition timing is out of specification.
PREPARATION
Before performing Idle Air Volume Learning, make sure that all of the following conditions are satisfied.
Learning will be cancelled if any of the following conditions are missed for even a moment.
Battery voltage: More than 12.9V (At idle)
PNP switch: ON
Electric load switch: OFF

(Air conditioner, head lamp, rear window defogger)
only small lamps.
Steering wheel: Neutral (Straight-ahead position)
Vehicle speed: Stopped
Transmission: Warmed-up
For A/T models with CONSULT-II, drive vehicle until FLUID TEMP SE in DATA MONITOR mode of A/
T system indicates less than 0.9V.
For A/T models without CONSULT-II and M/T models, drive vehicle for 10 minutes.
OPERATION PROCEDURE
With CONSULT-II
1.
2.
3.
4.
5.

Check that all items listed under the topic PREPARATION (previously mentioned) are in good order.
Select IDLE AIR VOL LEARN in WORK SUPPORT mode.
SEF217Z
EC-557
http://vnx.su

6.
Touch START and wait 20 seconds.
SEF454Y
7.
8.
Make sure that CMPLT is displayed on CONSULT-II screen. If

CMPLT is not displayed, Idle Air Volume Learning will not be
carried out successfully. In this case, find the cause of the incident by referring to the DIAGNOSTIC PROCEDURE below.
Rev up the engine two or three times and make sure that idle
speed and ignition timing are within the specifications.
ITEM
SPECIFICATION
Idle speed

Ignition timing

MBIB0238E
Without CONSULT-II
NOTE:
has a malfunction.
1. Perform EC-556, "Accelerator Pedal Released Position Learning" .
2. Perform EC-557, "Throttle Valve Closed Position Learning" .
4. Check that all items listed under the topic PREPARATION (previously mentioned) are in good order.
6. Confirm that accelerator pedal is fully released, turn ignition switch ON and wait 3 seconds.
7. Repeat the following procedure quickly five times within 5 seconds.
a. Fully depress the accelerator pedal.
b. Fully release the accelerator pedal.
8. Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 20 seconds until the MI stops
blinking and turned ON.
9. Fully release the accelerator pedal within 3 seconds after the MI turned ON.
11. Wait 20 seconds.
PBIB0665E
EC-558
http://vnx.su

12. Rev up the engine two or three times and make sure that idle speed and ignition timing are within the
specifications.
ITEM
SPECIFICATION
Idle speed

Ignition timing

EC
13. If idle speed and ignition timing are not within the specification, Idle Air Volume Learning will not be carried
out successfully. In this case, find the cause of the incident by referring to the DIAGNOSTIC PROCEDURE below.
If idle air volume learning cannot be performed successfully, proceed as follows:
1. Check that throttle valve is fully closed.
2. Check PCV valve operation.
3. Check that downstream of throttle valve is free from air leakage.
4. When the above three items check out OK, engine component parts and their installation condition are questionable. Check and eliminate the cause of the incident.
It is useful to perform EC-617, "TROUBLE DIAGNOSIS - SPECIFICATION VALUE" .
5. If any of the following conditions occur after the engine has started, eliminate the cause of the
incident and perform Idle Air Volume Learning all over again:
Engine stalls.
Erroneous idle.
Fuel Pressure Check
3.
4.
5.
EBS010WY

With CONSULT-II
1.
2.

Perform FUEL PRESSURE RELEASE in WORK SUPPORT
mode with CONSULT-II.
Start engine.
pressure.
SEF214Y
Without CONSULT-II
1.
2.
3.
4.
5.
Remove fuel pump fuse located in fuse box.

Start engine.
pressure.
Reinstall fuel pump fuse after servicing fuel system.
PBIB0508E
FUEL PRESSURE CHECK

CAUTION:
Before disconnecting fuel line, release fuel pressure from fuel line to eliminate danger.
EC-559
http://vnx.su

NOTE:
Prepare pans or saucers under the disconnected fuel line because the fuel may spill out. The fuel pressure cannot be completely released because T30 models do not have fuel return system.
CAUTION:
The fuel hose connection method used when taking fuel pressure check must not be used for
other purposes.
Be careful not to scratch or put debris around connection area when servicing, so that the quick
connector maintains sealability with O-rings inside.
When installing fuel hose quick connector, refer to EM-18, "INTAKE MANIFOLD" .
1. Release fuel pressure to zero. Refer to EC-559, "FUEL PRESSURE RELEASE" .
2. Prepare fuel hose and fuel hose clamp for fuel pressure check, and connect fuel pressure gauge.
Use suitable fuel hose for fuel pressure check (genuine NISSAN fuel hose without quick connector).
To avoid unnecessary force or tension to hose, use moderately long fuel hose for fuel pressure check.
Do not use the fuel hose for checking fuel pressure with damage or cracks on it.
Use Pressure Gauge to check fuel pressure.
3. Remove fuel hose. Refer to EM-18, "INTAKE MANIFOLD" .
Do not twist or kink fuel hose because it is plastic hose.
Do not remove fuel hose from quick connector.
Keep the original fuel hose to be free from intrusion of dust or foreign substances with a suitable cover.
4. Install the fuel pressure gauge as shown in the figure.
Wipe off oil or dirt from hose insertion part using cloth moistened with gasoline.
Apply proper amount of gasoline between top of the fuel tube
and No.1 spool.
Insert fuel hose for fuel pressure check until it touches the
No.1 spool on fuel tube.
Use NISSAN genuine hose clamp (part number: 16439
N4710 or 16439 40U00).
When reconnecting fuel line, always use new clamps.
PBIB0669E
When reconnecting fuel hose, check the original fuel hose for
damage and abnormality.
Use a torque driver to tighten clamps.
Install hose clamp to the position within 1 - 2 mm (0.04 - 0.08
in).
Tightening
torque:
1 - 1.5 Nm (0.1 - 0.15 kg-m, 9 - 13 in-lb)
Make sure that clamp screw does not contact adjacent parts.
After connecting fuel hose for fuel pressure check, pull the hose
with a force of approximately 98 N (10 kg, 22 lb) to confirm fuel
tube does not come off.
Turn ignition switch ON, and check for fuel leakage.
PBIB1977E
Start engine and check for fuel leakage.
Read the indication of fuel pressure gauge.
Do not perform fuel pressure check with system operating. Fuel pressure gauge may indicate false
readings.
During fuel pressure check, confirm for fuel leakage from fuel connection every 3 minutes.
5.
6.
7.
8.
At idling:
Approximately 350 kPa (3.5 bar, 3.57 kg/cm2 , 51 psi)
9. If result is unsatisfactory, go to next step.

10. Check the following.
Fuel hoses and fuel tubes for clogging
EC-560
http://vnx.su

Fuel pump
Fuel pressure regulator for clogging
If OK, replace fuel pressure regulator.
If NG, repair or replace.
EC
EC-561
http://vnx.su


Introduction
PFP:00028
EBS010WZ
Freeze Frame data
1st Trip Diagnostic Trouble Code (1st Trip DTC)
1st Trip Freeze Frame data
: Applicable
: Not applicable
DTC
1st trip DTC
Freeze Frame data
1st trip Freeze Frame

data
CONSULT-II
ECM
*1: When DTC and 1st trip DTC simultaneously appear on the display, they cannot be clearly distinguished from each other.
The malfunction indicator (MI) on the instrument panel lights up when the same malfunction is detected in two
consecutive trips (Two trip detection logic), or when the ECM enters fail-safe mode. (Refer to EC-574, "Failsafe Chart" .)
Two Trip Detection Logic
EBS010X0
When a malfunction is detected for the first time, 1st trip DTC and 1st trip Freeze Frame data are stored in the
ECM memory. The MI will not light up at this stage. <1st trip>
If the same malfunction is detected again during the next drive, the DTC and Freeze Frame data are stored in
the ECM memory, and the MI lights up. The MI lights up at the same time when the DTC is stored. <2nd trip>
The trip in the Two Trip Detection Logic means a driving mode in which self-diagnosis is performed during
vehicle operation. When the ECM enters fail-safe mode (Refer to EC-574, "Fail-safe Chart" .), the DTC is
stored in the ECM memory even in the 1st trip.
trouble on engine control system. Therefore, when Electrical controlled throttle and part of the ECM related
diagnoses are continuously detected as NG for 5-trips, ECM warns the driver that engine control system has
trouble and MI circuit is open by means of operating fail-safe function.
EBS010X1
DTC AND 1ST TRIP DTC

The 1st trip DTC (whose number is the same as the DTC number) is displayed for the latest self-diagnostic
result obtained. If the ECM memory was cleared previously, and the 1st trip DTC did not reoccur, the 1st trip
DTC will not be displayed.
If a malfunction is detected during the 1st trip, the 1st trip DTC is stored in the ECM memory. The MI will not
light up (two trip detection logic). If the same malfunction is not detected in the 2nd trip (meeting the required
driving pattern), the 1st trip DTC is cleared from the ECM memory. If the same malfunction is detected in the
2nd trip, both the 1st trip DTC and DTC are stored in the ECM memory and the MI lights up. In other words,
the DTC is stored in the ECM memory and the MI lights up when the same malfunction occurs in two consecutive trips. If a 1st trip DTC is stored and a non-diagnostic operation is performed between the 1st and 2nd
trips, only the 1st trip DTC will continue to be stored. For fail-safe items, DTC is stored in the ECM memory
even in the 1st trip.
Procedures for clearing the DTC and the 1st trip DTC from the ECM memory are described in EC-563, "HOW
TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" .
When a 1st trip DTC is detected, check, print out or write down and erase (1st trip) DTC and Freeze Frame
data as specified in Work Flow procedure Step II, refer to EC-570, "WORK FLOW" . Then perform DTC Confirmation Procedure or Overall Function Check to try to duplicate the malfunction. If the malfunction is duplicated, the item requires repair.
EC-562
http://vnx.su

How to Read DTC and 1st Trip DTC
A
With CONSULT-II
CONSULT-II displays the DTC in SELF-DIAG RESULTS mode. Examples: P0117, P0340, P1065, etc.
EC
Without CONSULT-II
Example: 0117, 0340, 1065 etc.
C
Output of a DTC indicates a malfunction. However, the Diagnostic Test Mode II do not indicate
whether the malfunction is still occurring or has occurred in the past and has returned to normal. D
CONSULT-II can identify malfunction status as shown below. Therefore, using CONSULT-II (if available) is recommended.
A sample of CONSULT-II display for DTC and 1st trip DTC is shown below. DTC or 1st trip DTC of a malfuncE
tion is displayed in SELF-DIAGNOSTIC RESULTS mode of CONSULT-II. Time data indicates how many
times the vehicle was driven after the last detection of a DTC.
If the DTC is being detected currently, the time data will be [0].
If a 1st trip DTC is stored in the ECM, the time data will be [1t].
F
I
PBIB0911E
FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA

The ECM records the driving conditions such as fuel system status, calculated load value, engine coolant temperature, short term fuel trim, long term fuel trim, engine speed, vehicle speed, base fuel schedule and intake
air temperature at the moment a malfunction is detected.
Data which are stored in the ECM memory, along with the 1st trip DTC, are called 1st trip freeze frame data.
The data, stored together with the DTC data, are called freeze frame data and displayed on CONSULT-II. For
details, see EC-604, "Freeze Frame Data and 1st Trip Freeze Frame Data" .
Only one set of freeze frame data (either 1st trip freeze frame data or freeze frame data) can be stored in the
longer stored. Remember, only one set of freeze frame data can be stored in the ECM.
Both 1st trip freeze frame data and freeze frame data (along with the DTCs) are cleared when the ECM memory is erased. Procedures for clearing the ECM memory are described in EC-563, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" .

How to Erase DTC
With CONSULT-II
2. Touch ENGINE.
EC-563
http://vnx.su

4.
Touch ERASE. (The DTC in the ECM will be erased.)
PBIB2454E
Without CONSULT-II
If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once.
Change the diagnostic test mode from Mode II to Mode I by depressing the accelerator pedal. Refer to
hours.
Freeze frame data

1.
2.
3.
EBS010X2

the ON position or NATS MALFUNCTION is displayed on
SELF-DIAG RESULTS screen, perform self-diagnostic
Refer to BL-108, "NATS (NISSAN ANTI-THEFT SYSTEM)" .
before touching ERASE in SELF-DIAG RESULTS mode
with CONSULT-II.
SEF515Y
Regarding the procedures of NATS initialization and all NATS ignition key ID registration, refer to
CONSULT-II Operation Manual, NATS.
EC-564
http://vnx.su

EBS010X3
DESCRIPTION
If the MI does not light up, refer to DI-33, "WARNING LAMPS"
or see EC-954, "MI & DATA LINK CONNECTORS" .
EC
D
SAT652J
The on board diagnostic system has the following four functions.

Diagnostic Test
Mode
KEY and ENG.

Status
Function
Mode I
Ignition switch in
ON position
BULB CHECK

circuit, etc.).
If the MI does not come on, check MI circuit.
Engine stopped
Engine running
MALFUNCTION
WARNING
This is a usual driving condition. When a malfunction is

detected twice in two consecutive driving cycles (two trip
detection logic), the MI will light up to inform the driver that
a malfunction has been detected.
The following malfunctions will light up or blink the MI in
the 1st trip.
Mode II
Ignition switch in
ON position
SELF-DIAGNOSTIC
RESULTS
This function allows DTCs and 1st trip DTCs to be read.
L
Engine stopped
M
Engine running

MONITOR
This function allows the fuel mixture condition (lean or

rich), monitored by heated oxygen sensor 1, to be read.
When there is an open circuit on MI circuit, the ECM can not warn the driver by lighting MI up when there is
EC-565
http://vnx.su

MI Flashing without DTC
If the ECM is in Diagnostic Test Mode II, MI may flash when engine is running. In this case, check ECM diagnostic test mode. EC-566, "HOW TO SWITCH DIAGNOSTIC TEST MODE" .
How to switch the diagnostic test (function) modes, and details of the above functions are described later, EC566, "HOW TO SWITCH DIAGNOSTIC TEST MODE" .
The following emission-related diagnostic information is cleared when the ECM memory is erased.
Freeze frame data

NOTE:
has a malfunction.

1.
2.
a.
b.
3.
4.
blinking.
PBIB0092E
How to Set Diagnostic Test Mode II (Heated Oxygen Sensor 1 Monitor)

1.
2.
Set the ECM in Diagnostic Test Mode II (Self-diagnostic results). Refer to EC-566, "How to Set Diagnostic
Start Engine.
ECM has entered to Diagnostic Test Mode II (Heated oxygen sensor 1 monitor).

1.
2.
3.
Set ECM in Diagnostic Test Mode II (Self-diagnostic results). Refer to EC-566, "How to Set Diagnostic

In this mode, the MI on the instrument panel should stay ON. If it remains OFF, check the bulb. Refer to DI-33,
"WARNING LAMPS" or see EC-954, "MI & DATA LINK CONNECTORS" .
EC-566
http://vnx.su

MI
Condition
ON
OFF
No malfunction.
EC

In this mode, the DTC and 1st trip DTC are indicated by the number of blinks of the MI as shown below.
The DTC and 1st trip DTC are displayed at the same time. If the MI does not illuminate in diagnostic test mode
I (Malfunction warning), all displayed items are 1st trip DTCs. If only one code is displayed when the MI illuminates in diagnostic test mode II (SELF-DIAGNOSTIC RESULTS), it is a DTC; if two or more codes are displayed, they may be either DTCs or 1st trip DTCs. DTC No. is same as that of 1st trip DTC. These unidentified
codes can be identified by using the CONSULT-II. A DTC will be used as an example for how to read a code.
J
PBIA3905E

The DTC can be erased from the back up memory in the ECM by depressing accelerator pedal. Refer to EC566, "HOW TO SWITCH DIAGNOSTIC TEST MODE" .
DIAGNOSTIC TEST MODE II HEATED OXYGEN SENSOR 1 MONITOR

In this mode, the MI displays the condition of the fuel mixture (lean or rich) which is monitored by the heated
oxygen sensor 1.
MI
Fuel mixture condition in the exhaust gas
ON
Lean
OFF
Rich
*Remains ON or OFF
Any condition
*: Maintains conditions just before switching to open loop.
EC-567
http://vnx.su
Air fuel ratio feedback control condition

Closed loop system
Open loop system

To check the heated oxygen sensor 1 function, start engine in the Diagnostic Test Mode II and warm it up until
engine coolant temperature indicator points to the middle of the gauge.
Next run engine at about 2,000 rpm for about 2 minutes under no load conditions. Then make sure that the MI
comes ON more than 5 times within 10 seconds with engine running at 2,000 rpm under no load.
EC-568
http://vnx.su
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS
PFP:00004
A
EBS010X4
INTRODUCTION
The engine has an ECM to control major systems such as fuel control, ignition control, idle air control system, etc. The ECM accepts
input signals from sensors and instantly drives actuators. It is essential that both input and output signals are proper and stable. At the
same time, it is important that there are no malfunctions such as vacuum leaks, fouled spark plugs, or other malfunctions with the engine.
It is much more difficult to diagnose a incident that occurs intermittently rather than continuously. Most intermittent incidents are
test with CONSULT-II or a circuit tester connected should be performed. Follow EC-570, "WORK FLOW" .
what conditions they occur. A Diagnostic Worksheet like EC-572,
"Worksheet Sample" should be used.
Start your diagnosis by looking for conventional malfunctions first.
This will help troubleshoot driveability malfunctions on an electronically controlled engine vehicle.
EC
MEF036D
H
SEF233G
SEF234G
EC-569
http://vnx.su
TROUBLE DIAGNOSIS
WORK FLOW
Flow Chart
MBIB0178E
*1

RESULTS is other than [0] or [1t],
perform EC-621, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
*2

INCIDENT" .
*4

*5
EC-617, "TROUBLE DIAGNOSIS SPECIFICATION VALUE"
EC-570
http://vnx.su

Refer to EC-622, "POWER SUPPLY
AND GROUND CIRCUIT" .
TROUBLE DIAGNOSIS
STEP
DESCRIPTION
STEP I
Get detailed information about the conditions and the environment when the incident/symptom occurred using EC572, "DIAGNOSTIC WORKSHEET" .
STEP II
Before confirming the concern, check and write down (print out using CONSULT-II) the (1st trip) DTC and the (1st
trip) freeze frame data, then erase the DTC and the data. (Refer to EC-563, "HOW TO ERASE EMISSION-RELATED
DIAGNOSTIC INFORMATION" .) The (1st trip) DTC and the (1st trip) freeze frame data can be used when duplicating the incident at STEP III & IV.
Study the relationship between the cause, specified by (1st trip) DTC, and the symptom described by the customer.
(The Symptom Matrix Chart will be useful. See EC-581, "Symptom Matrix Chart" .)
STEP III
STEP IV
Try to detect the (1st trip) DTC by driving in (or performing) the DTC Confirmation Procedure. Check and read the (1st
trip) DTC and (1st trip) freeze frame data by using CONSULT-II.
During the (1st trip) DTC verification, be sure to connect CONSULT-II to the vehicle in DATA MONITOR (AUTO
In case the DTC Confirmation Procedure is not available, perform the Overall Function Check instead. The (1st trip)
DTC cannot be displayed by this check, however, this simplified check is an effective alternative.
The NG result of the Overall Function Check is the same as the (1st trip) DTC detection.
STEP V
If the normal code is indicated, proceed to the BASIC INSPECTION. (Refer to EC-575, "Basic Inspection" .) Then
perform inspections according to the Symptom Matrix Chart. (Refer to EC-581, "Symptom Matrix Chart" .)
STEP VI
(AUTO TRIG) mode.
Refer to EC-592, "ECM Terminals and Reference Value" , EC-612, "CONSULT-II Reference Value in Data Monitor
Mode" .
STEP VII
Before returning the vehicle to the customer, be sure to erase the unnecessary (already fixed) (1st trip) DTC in ECM.
(Refer to EC-563, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" .)
EC-571
http://vnx.su
EC
TROUBLE DIAGNOSIS
Description
In general, each customer feels differently about a incident. It is
Utilize a diagnostic worksheet like the one on the next page in order
to organize all the information for troubleshooting.
Some conditions may cause the MI to come on steady or blink and
DTC to be detected. Examples:
Vehicle ran out of fuel, which caused the engine to misfire.
SEF907L
Worksheet Sample
MTBL0017
EC-572
http://vnx.su
TROUBLE DIAGNOSIS
EBS010X5
A
chart.
NOTE:
If DTC U1000 and/or U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC EC
U1000 and U1001. Refer to EC-630, "DTC U1000, U1001 CAN COMMUNICATION LINE" .
Priority
1
U1000 U1001 CAN communication line
P0122 P0123 P0222 P0223 P1225 P1226 P2135 Throttle position sensor
P0327 P0328 Knock sensor
P0335 Crankshaft position sensor (POS)
P0340 Camshaft position sensor (PHASE)
P0605 ECM
P1229 Sensor power supply
P1610-P1615 NATS
P1706 Park/Neutral position (PNP) switch
P0132 P0134 Heated oxygen sensor 1
P0550 Power steering pressure sensor
P1065 ECM power supply
P1122 Electric throttle control function
P1124 P1126 Throttle control motor relay
P1128 Throttle control motor
P1805 Brake switch
P0011 Intake valve timing control
P1121 Electric throttle control actuator
P1564 ASCD steering switch*
P1572 ASCD brake switch*
P1574 ASCD vehicle speed sensor*
EC-573
http://vnx.su
TROUBLE DIAGNOSIS
Fail-safe Chart
EBS010X6
When the DTC listed bellow is detected, the ECM enters fail-safe mode and the MI lights up.
DTC No.
Detected items
P0102
P0103
P0122
P0123
P0221
P0222
P2135
condition.
P1121

actuator
(When electric throttle control actuator does not function properly due to the return spring
malfunction:)
ECM controls the electric throttle actuator by regulating the throttle opening around the
idle position. The engine speed will not rise more than 2,000 rpm.
(When throttle valve opening angle in fail-safe mode is not in specified range:)
ECM controls the electric throttle control actuator by regulating the throttle opening to 20
degrees or less.
(ECM detect the throttle valve is stuck open:)
While the vehicle is driving, it slows down gradually by fuel cut. After the vehicle stops, the
engine stalls.
The engine can restart in N or P position (A/T models), neutral position (M/T models), and
engine speed will not exceed 1,000 rpm or more.
P1122

function
P1124
P1126
P1128
P1229
Sensor power supply
P1805
Brake switch
ECM controls the electric throttle control actuator by regulating the throttle opening to a
small range.
Therefore, acceleration will be poor.
P2122
P2123
P2127
P2128
P2138

sensor
Vehicle condition
Driving condition
Normal
When accelerating
Poor acceleration
condition.
EC-574
http://vnx.su
TROUBLE DIAGNOSIS
Basic Inspection
EBS010X7
1. INSPECTION START
1.
2.
3.
4.
Check service records for any recent repairs that may indicate a related malfunction, or a current need for
scheduled maintenance.
EC
C
Wiring harness for improper connections, pinches and cut
Vacuum hoses for splits, kinks and improper connections
Hoses and ducts for leaks
D
Air cleaner clogging
Gasket
Confirm that electrical or mechanical loads are not applied.
E
SEF983U
Rear window defogger switch is OFF.
F
Start engine and warm it up until engine coolant temperature
G
indicator points the middle of gauge.
Ensure engine stays below 1,000 rpm.
H
I
SEF976U
5.
Run engine at about 2,000 rpm for about 2 minutes under no

load.
6. Make sure that no DTC is displayed.
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
M
SEF977U
2. REPAIR OR REPLACE
Repair or replace components as necessary according to corresponding Diagnostic Procedure.
>> GO TO 3
EC-575
http://vnx.su
TROUBLE DIAGNOSIS
3. CHECK TARGET IDLE SPEED

1.
2.
With CONSULT-II
Rev engine (2,000 to 3,000 rpm) two or three times under no
load, then run engine at idle speed for about 1 minute.
PBIA8513J
3.

Except above
SEF058Y
Without CONSULT-II
Rev engine (2,000 to 3,000 rpm) two or three times under no load, then run engine at idle speed for about
1 minute.
1.
2.

Except above
OK or NG
OK
>> GO TO 10.
NG
>> GO TO 4.

1.
2.
Stop engine.
>> GO TO 5.

>> GO TO 6.
EC-576
http://vnx.su
TROUBLE DIAGNOSIS

Yes or No
Yes
>> GO TO 7.
No
2. GO TO 4.
EC

D
With CONSULT-II
2. Read idle speed in DATA MONITOR mode with CONSULT-II.

Except above
Without CONSULT-II
SEF058Y

Except above
OK or NG
OK
>> GO TO 10.
NG
>> GO TO 8.
Check the Following.
(PHASE)" .
.
OK or NG
OK
>> GO TO 9.
NG
2. GO TO 4.

1.
2.
>> GO TO 4.
EC-577
http://vnx.su
TROUBLE DIAGNOSIS

1.
2.
Run engine at idle.

PBIB0514E

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 11.

1.
2.
Stop engine.
>> GO TO 12.

>> GO TO 13.

Yes or No
Yes
>> GO TO 14.
No
2. GO TO 4.
EC-578
http://vnx.su
TROUBLE DIAGNOSIS

1.
2.
With CONSULT-II
EC

Except above
Without CONSULT-II
E
SEF058Y

Except above
OK or NG
OK
>> GO TO 15.
NG
>> GO TO 17.
15. CHECK IGNITION TIMING AGAIN

1.
2.
Run engine at idle.

L
PBIB0514E

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 16.
16. CHECK TIMING CHAIN INSTALLATION

Check timing chain installation. Refer to EM-46, "TIMING CHAIN" .
OK or NG
OK
>> GO TO 17.
NG
>> 1. Repair the timing chain installation.
2. GO TO 4.
EC-579
http://vnx.su
TROUBLE DIAGNOSIS

(PHASE)" .
.
OK or NG
OK
>> GO TO 18.
NG
2. GO TO 4.

1.
2.
>> GO TO 4.
EC-580
http://vnx.su
TROUBLE DIAGNOSIS
EBS010X8
SYSTEM BASIC ENGINE CONTROL SYSTEM
Fuel pressure regulator system
Injector circuit
Evaporative emission system
Air
Positive crankcase ventilation system
Incorrect idle speed adjustment
Incorrect ignition timing adjustment
Ignition circuit
Main power supply and ground circuit
Ignition
Throttle position sensor circuit
AF
AG
AH
AJ
AK
AL
AM
HA
3
4
C
Reference
page
F
EC-903
EC-559
EC-888
EC-958
EC-575
EC-720,
EC-723 ,
EC-734 ,
EC-742
EC-575
EC-870
EC-622
EC-641
EC-649
EC-655,
EC-677 ,
EC-768 ,
EC-770 ,
EC-827
Knock sensor circuit
EC371,EC812 , EC819 , EC835
EC-663,
EC-670 ,
EC-858
EC-685
Crankshaft position sensor (POS) circuit
EC-690
Camshaft position sensor (PHASE) circuit
EC-698
Power steering pressure sensor circuit
3
3
EC-581
http://vnx.su
EC-963
EC
Heated oxygen sensor 1 circuit
Fuel pump circuit
Fuel
AE
AD
AC
IDLING VIBRATION
AB
ROUGH IDLE/HUNTING
ENGINE STALL
AA
HIGH IDLE/LOW IDLE
SYMPTOM
EC-706
EC-708
TROUBLE DIAGNOSIS
ENGINE STALL
HIGH IDLE/LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SYMPTOM
AA
AB
AC
AD
AE
AF
AG
AH
AJ
AK
AL
AM
HA
ECM
EC-713,
EC-716
Intake valve timing control solenoid valve circuit
EC-633
EC-799,
MT-13
EC-911
PNP switch circuit

Refrigerant pressure sensor circuit
Electrical load signal circuit

Air conditioner circuit
ESP/TCS/ABS CONTROL UNIT

(models with ESP)

EC-582
http://vnx.su
Reference
page
EC-917
3
ATC-34,
MTC-3
BRC-11,
BRC-58
TROUBLE DIAGNOSIS
SYSTEM ENGINE MECHANICAL & OTHER
A
Fuel
ENGINE STALL
HIGH IDLE/LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SYMPTOM
AA
AB
AC
AD
AE
AF
AG
AH
AJ
AK
AL
AM
HA
EC
Fuel tank
Fuel piping
Vapor lock
FL-3, EM34
Valve deposit
Air
Reference
page
FL-11
5
Poor fuel (Heavy weight gasoline, Low octane)
Air duct
Air cleaner
EM-16
Air leakage from air duct

(Mass air flow sensor electric
throttle control actuator)
5
5
5
5
EM-18
Air leakage from intake manifold/

Collector/Gasket
Cranking
Battery
Alternator circuit
Engine
SC-3
SC-12
Starter circuit
SC-22
Signal plate/Flywheel/Drive plate
EM-86
MT-13 or
AT-408
PNP switch
Cylinder head
5
4
EM-70
3
Cylinder block
Piston
Piston ring
4
6
Connecting rod
Bearing
Crankshaft
EC-583
http://vnx.su
EM-86
TROUBLE DIAGNOSIS
Valve
mechanism
ENGINE STALL
HIGH IDLE/LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SYMPTOM
AA
AB
AC
AD
AE
AF
AG
AH
AJ
AK
AL
AM
HA
Reference
page
Timing chain
EM-46
Camshaft
EM-56
EM-46
Intake valve
3
Exhaust valve
Exhaust
Exhaust manifold/Tube/Muffler/
Gasket
EM-25, EX2
Three way catalyst

Lubrication
Cooling
Oil pan/Oil strainer/Oil pump/Oil

filter/Oil gallery
EM-70
EM-27, LU13 , LU-10 ,

LU-5
Oil level (Low)/Filthy oil
LU-7
Radiator/Hose/Radiator filler cap
CO-12
Thermostat
CO-23
Water pump
Water gallery
CO-21
5
Cooling fan
2
5
Coolant level (low)/Contaminated

coolant
CO-7
CO-19
CO-9
EC-564 or
BL-108
EC-584
http://vnx.su
TROUBLE DIAGNOSIS
EBS010X9
EC
PBIB1978E
EC-585
http://vnx.su
TROUBLE DIAGNOSIS
PBIB1979E
EC-586
http://vnx.su
TROUBLE DIAGNOSIS
A
EC
PBIB1980E
EC-587
http://vnx.su
TROUBLE DIAGNOSIS
PBIB1997E
EC-588
http://vnx.su
TROUBLE DIAGNOSIS
A
EC
PBIB2887E
EC-589
http://vnx.su
TROUBLE DIAGNOSIS
Circuit Diagram
EBS010XA
TBWA0592E
EC-590
http://vnx.su
TROUBLE DIAGNOSIS
A
EC
TBWB0462E
EC-591
http://vnx.su
TROUBLE DIAGNOSIS
EBS010XB
MBIB0045E
ECM Terminals and Reference Value
EBS010XC
PREPARATION
1.
2.

remove glove box.
PBIB1973E
3.
4.

levers as far as they will go as shown at right.
PBIB1512E

CAUTION:
TERMINAL
NO.
1
WIRE
COLOR
B
ITEM
ECM ground
CONDITION
[Engine is running]
Idle speed
EC-592
http://vnx.su
DATA (DC Voltage)
Body ground
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running]
Warm-up condition
Engine speed is below 3,600 rpm after the

following conditions are met
PU/R

heater
EC
0 - 1.0V

and 4,000 rpm for 1 minute and at idle for
1 minute under no load
Engine stopped
[Engine is running]
W/B

power supply
D
BATTERY VOLTAGE
(11 - 14V)
BATTERY VOLTAGE
(11 - 14V)
0 - 14V
4

(Close)
Engine stopped
PBIB1104E
0 - 14V

5

(Open)
Engine stopped
J
PBIB1105E
[Engine is running]
6*1
Idle speed
[Engine is running]
[Engine is running]
12

sensor
[Engine is running]
EC-593
http://vnx.su
BATTERY VOLTAGE
(11 - 14V)
0 - 1.0V
0.5 - 4.0V
M
0.4 - 0.8V
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
[Engine is running]
Warm-up condition
Idle speed
DATA (DC Voltage)
1.0 - 4.0V
NOTE:
The pulse cycle changes depending on
rpm at idle
13
L/W
PBIB0525E

(PHASE)
1.0 - 4.0V
[Engine is running]
PBIB0526E
[Engine is running]
Warm-up condition
Idle speed
Approximately 3.0V
NOTE:
rpm at idle
14
PU/R
PBIB0527E
Crankshaft position
sensor (POS)
Approximately 3.0V
[Engine is running]
PBIB0528E
15
Knock sensor
[Engine is running]
Idle speed
Approximately 2.5V
[Engine is running]
16
OR/B
Warm-up condition

quickly after the following conditions are
met

and 4,000 rpm for 1 minute and at idle for
1 minute under no load
EC-594
http://vnx.su
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
BATTERY VOLTAGE
EC
(11 - 14V)
[Engine is running]
19
Idle speed
PBIB0050E
Approximately 10V
[Engine is running]
Engine speed is about 2,000 rpm (More

than 100 seconds after starting engine)
F
PBIB0520E
BATTERY VOLTAGE
[Engine is running]
22
23
41
42
G/B
R/B
L/B
Y/B
Warm-up condition
Idle speed
(11 - 14V)
NOTE:
rpm at idle
Injector No. 3
Injector No. 1
Injector No. 4
Injector No. 2
I
PBIB0529E
BATTERY VOLTAGE
(11 - 14V)
[Engine is running]
Warm-up condition
PBIB0530E
Approximately 7.0V
[Engine is running]
24
G/W

heater
Warm-up condition
PBIB0519E
[Engine is running]
BATTERY VOLTAGE
(11 - 14V)
[Engine is running]
29
30
34
Y/G
Sensor ground
Warm-up condition
Idle speed
Approximately 0V
[Engine is running]
Sensor ground
Warm-up condition
Idle speed
[Engine is running]
EC-595
http://vnx.su
Approximately 0V
air temperature.
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running]
35
P/L
Warm-up condition
46
Sensor power supply

Approximately 5V
47
Sensor power supply

Approximately 5V
49
Engine stopped
More than 0.36V
Engine stopped
Less than 4.75V
Approximately 0.4V
[Engine is running]
50
OR
Warm-up condition
Idle speed

[Engine is running]
Warm-up condition
Engine is revving from idle to about 4,000

rpm
0.7 - 1.1V (QR20DE)

0.8 - 1.2V (QR25DE)
0.7 - 1.1 to approximately 4.0V
(QR20DE)
0.8 - 1.2 to approximately 4.0V
(QR25DE)
increased to about 4,000 rpm)
[Engine is running]
54
Sensor ground
(Knock sensor)
Warm-up condition
Idle speed
Approximately 0V
[Engine is running]
57
Sensor ground
Warm-up condition
Idle speed
[Engine is running]
60
61
79
80
L/R
BR
GY/R
PU
Warm-up condition
Idle speed
Approximately 0V
0 - 0.1V
NOTE:
rpm at idle

PBIB0521E
0 - 0.2V
[Engine is running]
Warm-up condition
PBIB0522E
EC-596
http://vnx.su
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running]
Warm-up condition
Idle speed
BATTERY VOLTAGE
(11 - 14V)
EC
62
Intake valve timing

VOLTAGE (11 - 14V)

[Engine is running]
Warm-up condition
PBIB1790E
65
Sensor power supply

sensor)
Approximately 5V
F
[Engine is running]
66
Sensor ground
Warm-up condition
Idle speed
Approximately 0V
[Engine is running]
67
B/P
Sensor ground
Warm-up condition
Idle speed
Approximately 0V
68
Less than 4.75V
More than 0.36V
[Engine is running]
69
Warm-up condition
Both A/C switch and blower switch ON
K
1.0 - 4.0V
72
73
BR/Y
Sensor ground
(Engine coolant temperature sensor)
[Engine is running]
Output voltage varies with engine
coolant temperature.
[Engine is running]
Warm-up condition
Idle speed
Approximately 0V
[Engine is running]
74
82
83
R/Y
Sensor ground
Warm-up condition
Idle speed
Approximately 0V
[Engine is running]
Sensor ground
sensor 1)
Warm-up condition
Idle speed
Sensor ground
sensor 2)
Warm-up condition
Idle speed
Approximately 0V
[Engine is running]
EC-597
http://vnx.su
Approximately 0V
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
84
L/Y

(Headlamp signal)
Lighting switch: 2ND position (placed in

LOW position for models with Xenon
headlamp)
85
LG
DATA link connector
86
GY/R
CONSULT-II is disconnected
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
1.0 - 2.5V
[Engine is running]
BATTERY VOLTAGE
(11 - 14V)
89
BATTERY VOLTAGE
(11 - 14V)
[Engine is running]
0 - 1.0V
90
Sensor power supply

sensor 1)
Approximately 5V
91
BR/Y
Sensor power supply

sensor 2)
Approximately 5V
BATTERY VOLTAGE
(11 - 14V)
BR

(Rear window defogger signal)
93
94
G/R

[Engine is running]
96
LG/B
Heater fan switch
[Engine is running]
97
PU
Approximately 0V
2.5 - 4.0V
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
BATTERY VOLTAGE
(11 - 14V)
0 - 1.0V
98
B/W

sensor 2
Engine stopped
0.15 - 0.6V
Engine stopped
EC-598
http://vnx.su
1.95 - 2.4V
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
99*1
W/R
101
Stop lamp switch
W/B
C
Approximately 1V
Approximately 3V
Approximately 2V
E
Approximately 0V
A/T models
BATTERY VOLTAGE
(11 - 14V)
M/T models
Approximately 5V
BATTERY VOLTAGE
(11 - 14V)
0 - 1.0V

106

sensor 1
Engine stopped
0.5 - 1.0V
Engine stopped
3.9 - 4.7V
108*1
109
GY/L
B/R
ASCD brake switch
Ignition switch
Clutch pedal: Slightly depressed (M/T)
Clutch pedal: Fully released (M/T)
G/W
M
BATTERY VOLTAGE
(11 - 14V)
0V
BATTERY VOLTAGE
(11 - 14V)
111
Approximately 0V
[Engine is running]
ECM relay
(Self shut-off)
104
Approximately 0V
Approximately 0V
PNP switch
EC
G/OR
Approximately 4V
BATTERY VOLTAGE
(11 - 14V)
102
DATA (DC Voltage)
For a few seconds after turning ignition

switch OFF
More than a few seconds after turning ignition switch OFF
EC-599
http://vnx.su
0 - 1.0V
BATTERY VOLTAGE
(11 - 14V)
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
114
B/OR
Fuel pump relay
For 1 second after turning ignition switch

ON
0 - 1.0V
[Engine is running]

switch ON
[Engine is running]
BATTERY VOLTAGE
(11 - 14V)
115
116
B
B
ECM ground
119
120
SB
GY
BATTERY VOLTAGE
(11 - 14V)
121
W/L

(Back-up)
BATTERY VOLTAGE
(11 - 14V)
Idle speed
EC-600
http://vnx.su
Body ground
TROUBLE DIAGNOSIS
EBS010XD
FUNCTION
Function
Work support
This mode enables a technician to adjust some devices faster and more accurately by following the
indications on the CONSULT-II unit.
Self-diagnostic results such as 1st trip DTC, DTCs and 1st trip freeze frame data or freeze frame data
can be read and erased quickly.*
Data monitor
Data monitor (SPEC)
Input/Output of the specification for Basic fuel schedule, AFM, A/F feedback control value and the
other data monitor items can be read.

monitor
Active test
Function test
ECM part number
EC
Freeze frame data
EC-601
http://vnx.su
TROUBLE DIAGNOSIS
SELF-DIAGNOSTIC
RESULTS
Item
WORK
SUPPORT
DTC*1
FREEZE
FRAME
DATA
MONITOR
DATA
MONITOR
(SPEC)
ACTIVE
TEST
DATA*2
Closed throttle position switch (accelerator

pedal position sensor signal)

INPUT
Knock sensor
Stop lamp switch
Battery voltage
ASCD brake switch*3
ASCD clutch switch*3
Fuel injectors
Power transistor (Ignition timing)
OUTPUT

Fuel pump relay
Cooling fan relay

VIAS control solenoid valve*3
X: Applicable
*1: This item includes 1st trip DTCs.
EC-602
http://vnx.su
TROUBLE DIAGNOSIS
*2: This mode includes 1st trip freeze frame data or freeze frame data. The items appear on CONSULT-II screen in freeze frame data
mode only if a 1st trip DTC or DTC is detected. For details, refer to EC-563, "FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME
DATA" .
1.
2.
3.
EC

link connector, which is located under driver side dash panel.
E
PBIB0376E
4.
Touch START(NISSAN BASED VHCL).
I
BCIA0029E
5.
Touch ENGINE.
BCIA0030E
6.

procedure.
BCIA0031E
EC-603
http://vnx.su
TROUBLE DIAGNOSIS
WORK SUPPORT MODE
Work Item
WORK ITEM
CONDITION
USAGE
FUEL PUMP WILL STOP BY TOUCHING START DURING IDLING.

CRANK A FEW TIMES AFTER ENGINE STALLS.
When releasing fuel pressure

from fuel line
IDLE AIR VOL LEARN
THE IDLE AIR VOLUME THAT KEEPS THE ENGINE

WITHIN THE SPECIFIED RANGE IS MEMORIZED IN
ECM.
When learning the idle air volume
SELF-LEARNING CONT
THE COEFFICIENT OF SELF-LEARNING CONTROL

MIXTURE RATIO RETURNS TO THE ORIGINAL COEFFICIENT.
When clearing the coefficient of

self-learning control value
TARGET IDLE RPM ADJ*
IDLE CONDITION
When setting target idle speed
TARGET IGN TIM ADJ*
IDLE CONDITION
When adjusting target ignition timing
*: This function is not necessary in the usual service procedure.
SELF-DIAG RESULTS MODE

Regarding items of DTC and 1st trip DTC, refer to EC-531, "INDEX FOR DTC" .

Freeze frame data
item*
DIAG TROUBLE
CODE
[PXXXX]
Description
The engine control component part/control system has a trouble code, it is displayed as PXXXX. (Refer to
EC-531, "INDEX FOR DTC" .)
Fuel injection system status at the moment a malfunction is detected is displayed.
One mode in the following is displayed.

Mode2: Open loop due to detected system malfunction
Mode3: Open loop due to driving conditions (power enrichment, deceleration enleanment)
Mode4: Closed loop - using oxygen sensor(s) as feedback for fuel control
Mode5: Open loop - has not yet satisfied condition to go to closed loop
Long-term fuel trim at the moment a malfunction is detected is displayed.
The long-term fuel trim indicates much more gradual feedback compensation to the base fuel schedule
than short-term fuel trim.
FUEL SYS-B1
COOLANT TEMP
[C] or [F]
L-FUEL TRM-B1 [%]
Short-term fuel trim at the moment a malfunction is detected is displayed.
S-FUEL TRM-B1 [%]
The short-term fuel trim indicates dynamic or instantaneous feedback compensation to the base fuel
schedule.
ENGINE SPEED
[rpm]
VHCL SPEED
[km/h] or [mph]
B/FUEL SCHDL
[msec]
The base fuel schedule at the moment a malfunction is detected is displayed.
INT/A TEMP SE
[C] or [F]
*: The items are the same as those of 1st trip freeze frame data.
EC-604
http://vnx.su
TROUBLE DIAGNOSIS
DATA MONITOR MODE
Monitored Item
ECM
INPUT
SIGNALS
A
: Applicable
MAIN
SIGNALS
ENG SPEED [rpm]
MAS A/F SE-B1 [V]
B/FUEL SCHDL
[msec]
Indicates the engine speed computed from the

signals of the crankshaft position sensor
(POS) and camshaft position sensor (PHASE).
The signal voltage of the mass air flow sensor

is displayed.
Base fuel schedule indicates the fuel injection pulse width programmed into ECM, prior
to any learned on board correction.
A/F ALPHA-B1 [%]
Remarks
EC
Accuracy becomes poor if engine

speed drops below the idle rpm.
If the signal is interrupted while the

engine is running, an abnormal
value may be indicated.

Description
The mean value of the air-fuel ratio feedback

correction factor per cycle is indicated.

This data also includes the data

for the air-fuel ratio learning control.
COOLAN TEMP/S
[C] or [F]
HO2S1 (B1) [V]
HO2S2 (B1) [V]
The engine coolant temperature (determined

by the signal voltage of the engine coolant
temperature sensor) is displayed.
Display of heated oxygen sensor 1 signal during air-fuel ratio feedback control:
RICH: means the mixture became rich, and
control is being affected toward a leaner mixture.
LEAN: means the mixture became lean, and
control is being affected toward a rich mixture.
HO2S2 MNTR (B1)

[RICH/LEAN]
VHCL SPEED SE
[km/h] or [mph]
BATTERY VOLT [V]
ACCEL SEN 1 [V]
ACCEL SEN 2 [V]
THRTL SEN 1 [V]
THRTL SEN 2 [V]
INT/A TEMP SE
[C] or [F]
Display of heated oxygen sensor 2 signal:

RICH: means the amount of oxygen after three
way catalyst is relatively small.
LEAN: means the amount of oxygen after
three way catalyst is relatively large.

speed signal is displayed.
The accelerator pedal position sensor signal

voltage is displayed.
The throttle position sensor signal voltage is

displayed.
The intake air temperature (determined by the

signal voltage of the intake air temperature
sensor) is indicated.
EC-605
http://vnx.su
When the engine coolant temperature sensor is open or short-circuited, ECM enters fail-safe mode.
The engine coolant temperature
determined by the ECM is displayed.
HO2S1 MNTR (B1)

[RICH/LEAN]
After turning ON the ignition

switch, RICH is displayed until
air-fuel mixture ratio feedback
control begins.
When the air-fuel ratio feedback is
clamped, the value just before the
clamping is displayed continuously.

ACCEL SEN 2 signal is converted

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

by ECM internally. Thus, it differs
from ECM terminal voltage signal.
TROUBLE DIAGNOSIS
ECM
INPUT
SIGNALS
MAIN
SIGNALS
START SIGNAL
[ON/OFF]
CLSD THL POS

[ON/OFF]
AIR COND SIG

[ON/OFF]
P/N POSI SW
[ON/OFF]
PW/ST SIGNAL
[ON/OFF]
Description
Indicates start signal status [ON/OFF] computed by the ECM according to the signals of
engine speed and battery voltage.
Indicates idle position [ON/OFF] computed by

ECM according to the accelerator pedal position sensor signal.
Indicates [ON/OFF] condition of the air conditioner switch as determined by the air conditioner signal.
Indicates [ON/OFF] condition from the park/

neutral position (PNP) switch signal.
[ON/OFF] condition of the power steering

pressure sensor as determined by the power
steering pressure sensor signal is indicated.
Indicates [ON/OFF] condition from the electrical load signal.

ON: Rear window defogger switch is ON and/
or lighting switch is in 2nd position (placed in
LOW position for models with Xenon headlamp).
OFF: Both rear window defogger switch and
lighting switch are OFF.
Remarks
After starting the engine, [OFF] is

displayed regardless of the starter
signal.
LOAD SIGNAL
[ON/OFF]
IGNITION SW
[ON/OFF]
Indicates [ON/OFF] condition from ignition

switch.
HEATER FAN SW
[ON/OFF]
Indicates [ON/OFF] condition from the heater

fan switch signal.
BRAKE SW
[ON/OFF]
Indicates [ON/OFF] condition from the stop

lamp switch signal.
Indicates the actual fuel injection pulse width

compensated by ECM according to the input
signals.

certain computed value is indicated.
Indicates the ignition timing computed by ECM


Indicates the EVAP canister purge volume

control solenoid valve control value computed
by the ECM according to the input signals.
The opening becomes larger as the value

increases.
Indicates [CA] of intake camshaft advanced

angle.
The control value of the intake valve timing

control solenoid valve (determined by ECM
according to the input signal) is indicated.
The advance angle becomes larger as the

value increases
The control condition of the VIAS control solenoid valve (determined by ECM according to
the input signals) is indicated.
ON: VIAS control solenoid valve is operating.
OFF: VIAS control solenoid valve is not operating.
The air conditioner relay control condition

signals) is indicated.
INJ PULSE-B1
[msec]
IGN TIMING [BTDC]
PURG VOL C/V [%]
INT/V TIM (B1)

[CA]
INT/V SOL (B1) [%]
VIAS S/V*
[ON/OFF]
AIR COND RLY

[ON/OFF]
EC-606
http://vnx.su
TROUBLE DIAGNOSIS
ECM
INPUT
SIGNALS
MAIN
SIGNALS
Description
FUEL PUMP RLY

[ON/OFF]
THRTL RELAY
[ON/OFF]
COOLING FAN
[HI/LOW/OFF]
HO2S1 HTR (B1)

[ON/OFF]
HO2S2 HTR (B1)
[ON/OFF]
AC PRESS SEN [V]

VHCL SPEED SE*
[km/h] or [mph]
SET VHCL SPD*
[km/h] or [mph]
EC
Indicates the throttle control motor relay control condition determined by the ECM according to the input signals.
Indicates the condition of the cooling fan

signals).
HI: High speed operation
LOW: Low speed operation
OFF: Stop

Display the condition of Idle Air Volume Learning

YET: Idle Air Volume Learning has not been
performed yet.
CMPLT: Idle Air Volume Learning has already
been performed successfully.
The signal voltage from the refrigerant pressure sensor is displayed.

speed signal sent from TCM is displayed.
MAIN SW*
[ON/OFF]

switch signal.
CANCEL SW*
[ON/OFF]
Indicates [ON/OFF] condition from CANCEL

switch signal.
RESUME/ACC SW*
[ON/OFF]
Indicates [ON/OFF] condition from RESUME/

ACCELERATE switch signal.
SET SW*
[ON/OFF]

BRAKE SW1*
[ON/OFF]
Indicates [ON/OFF] condition from ASCD

brake switch signal.
BRAKE SW2*
[ON/OFF]
Indicates [ON/OFF] condition of stop lamp

switch signal.

ASCD set speed.
CUT: Vehicle speed increased to excessively
high compared with the ASCD set speed, and

ASCD set speed.
CUT: Vehicle speed decreased to excessively
low compared with the ASCD set speed, and
VHCL SPD CUT*

[NON/CUT]
LO SPEED CUT*
[NON/CUT]
Indicates the fuel pump relay control condition

determined by ECM according to the input signals.
IDL A/V LEARN

[YET/CMPLT]
Remarks
EC-607
http://vnx.su
TROUBLE DIAGNOSIS
ECM
INPUT
SIGNALS
MAIN
SIGNALS
Description
Remarks
AT OD MONITOR*
[ON/OFF]
Indicates [ON/OFF] condition of A/T O/D

according to the input signal from the TCM.

displayed.
AT OD CANCEL*
[ON/OFF]
Indicates [ON/OFF] condition of A/T O/D cancel signal sent from the TCM.

displayed.
Indicates [ON/OFF] condition of CRUISE lamp

signals.
Indicates [ON/OFF] condition of SET lamp

signals.


ones. They are the same figures
as an actual piece of data which
was just previously measured.
CRUISE LAMP*
[ON/OFF]
SET LAMP*
[ON/OFF]
Voltage [V]
Frequency
[msec], [Hz] or [%]
DUTY-HI
DUTY-LOW
Voltage, frequency, duty cycle or pulse width

measured by the probe.
PLS WIDTH-HI
PLS WIDTH-LOW
NOTE:
DATA MONITOR (SPEC) MODE

Monitored Item
ECM
INPUT
SIGNALS
ENG SPEED [rpm]
MAS A/F SE-B1 [V]
MAIN
SIGNALS
Description
Indicates the engine speed computed

from the signals of the crankshaft position sensor (POS) and camshaft position
sensor (PHASE).

sensor specification is displayed.
Base fuel schedule indicates the fuel

injection pulse width programmed into
ECM, prior to any learned on board correction.
B/FUEL SCHDL
[msec]
A/F ALPHA-B1 [%]
The mean value of the air-fuel ratio feedback correction factor per cycle is indicated.
Remarks

range is indicated.

range is indicated.

range is indicated.
This data also includes the data for

the air-fuel ratio learning control.
NOTE:
EC-608
http://vnx.su
TROUBLE DIAGNOSIS
ACTIVE TEST MODE
Test Item
TEST ITEM
CONDITION
FUEL INJECTION
IGNITION TIMING
POWER BALANCE
COOLING FAN*
FUEL PUMP
RELAY
PURG VOL
CONT/V
Change the amount of fuel injection using CONSULT-II.

trouble condition
Timing light: Set
Retard the ignition timing using

CONSULT-II.

the engine.
JUDGEMENT
If trouble symptom disappears, see
CHECK ITEM.
CHECK ITEM (REMEDY)
Fuel injector
EC
C
CHECK ITEM.
Perform Idle Air Volume Learning.
Compression
Fuel injector
Power transistor
Air conditioner switch OFF
Shift lever: N (A/T), Neutral (M/T)

a time using CONSULT-II.
Spark plug
Ignition coil
Ignition switch: ON
Turn the cooling fan LOW, HI,

OFF with CONSULT-II.
Cooling fan relay
Cooling fan motor
Fuel injector
Fuel pump relay

trouble condition

stopped)
Turn the fuel pump relay ON and

OFF using CONSULT-II and listen to operating sound.
Engine: After warming up, run

engine at 1,500 rpm.
Change the EVAP canister purge

volume control solenoid valve
opening percent using CONSULT-II.
V/T ASSIGN
ANGLE

trouble condition
ENG COOLANT
TEMP

trouble condition
Change intake valve timing using
CONSULT-II.
Cooling fan moves and stops.

CHECK ITEM.
Fuel pump relay makes the operating sound.
K
Engine speed changes according to
the opening percent.

CHECK ITEM.
Solenoid valve
*:Leaving cooling fan OFF with CONSULT-II while engine is running may cause the engine to overheat.
EC-609
http://vnx.su
TROUBLE DIAGNOSIS
REAL TIME DIAGNOSIS IN DATA MONITOR MODE (RECORDING VEHICLE DATA)
Description
mode.
The malfunction will be identified on the CONSULT-II screen
in real time.
In other words, DTC/1st trip DTC and malfunction item will be
displayed if the malfunction is detected by ECM.
At the moment a malfunction is detected by ECM, MONITOR in DATA MONITOR screen is changed to Recording
Data ... xx% as shown at right, and the data after the malfunction detection is recorded. Then when the percentage
reached 100%, REAL-TIME DIAG screen is displayed. If
STOP is touched on the screen during Recording Data ...
xx%, REAL-TIME DIAG screen is also displayed.
SEF705Y
The recording time after the malfunction detection and the
recording speed can be changed by TRIGGER POINT and
Recording Speed. Refer to CONSULT-II Operation Manual.
DTC/1st trip DTC and malfunction item will not be displayed
automatically on CONSULT-II screen even though a malfunction is detected by ECM.
DATA MONITOR can be performed continuously even though
a malfunction is detected.
SEF707X
Operation
1.
2.
AUTO TRIG
While trying to detect the DTC/1st trip DTC by performing the DTC Confirmation Procedure, be sure to
select to DATA MONITOR (AUTO TRIG) mode. You can confirm the malfunction at the moment it is
detected.
When you are inspecting the circuit by gently shaking (or twisting) the suspicious connectors, components and harness in the DTC Confirmation Procedure, the moment a malfunction is found the DTC/
1st trip DTC will be displayed. (Refer to Incident Simulation Tests in GI-23, "How to Perform Efficient
Diagnosis for an Electrical Incident" .)
MANU TRIG
TRIG. By selecting MANU TRIG you can monitor and store the data. The data can be utilized for further diagnosis, such as a comparison with the value for the normal operating condition.
EC-610
http://vnx.su
TROUBLE DIAGNOSIS
A
EC
PBIB0197E
EC-611
http://vnx.su
TROUBLE DIAGNOSIS
EBS010XE
Remarks:
i.e. Adjust ignition timing with a timing light before monitoring IGN TIMING, because the monitor may show the specification data in
spite of the ignition timing not being adjusted to the specification data. This IGN TIMING monitors the data calculated by the ECM
according to the signals input from the camshaft position sensor and other ignition timing related sensors.
MONITOR ITEM
CONDITION
SPECIFICATION
ENG SPEED
MAS A/F SE-B1
B/FUEL SCHDL
A/F ALPHA-B1
COOLAN TEMP/S
HO2S1 (B1)

between 3,500 and 4,000 rpm for
1 minute and at idle for 1 minute
under no load
HO2S2 (B1)
HO2S1 MNTR (B1)

between 3,500 and 4,000 rpm for
1 minute and at idle for 1 minute
under no load
HO2S2 MNTR (B1)
VEH SPEED SE
BATTERY VOLT
ACCEL SEN 1
ACCEL SEN 2*1
THRTL SEN 1
THRTL SEN 2*
CLSD THL POS
AIR COND SIG
P/N POSI SW
PW/ST SIGNAL

rpm
0 - 0.3V Approx. 0.6 - 1.0V

rpm quickly.
0 - 0.3V Approx. 0.6 - 1.0V

rpm
LEAN RICH

rpm quickly.
LEAN RICH

speedometer indication.
11 - 14V
Ignition switch: ON
(Engine stopped)
0.5 - 1.0V
4.0 - 4.7V
Ignition switch: ON
(Engine stopped)
0.3 - 1.2V
3.9 - 4.8V
Ignition switch: ON
(Engine stopped)
More than 0.36V
Less than 4.75V
START SIGNAL

Ignition switch: ON

the engine
Ignition switch: ON

the engine
OFF ON OFF
ON
Accelerator pedal: Slightly

depressed
OFF
OFF

ON
Shift lever:
P or N (A/T), Neutral (M/T)
ON
OFF
OFF
ON
EC-612
http://vnx.su
TROUBLE DIAGNOSIS
MONITOR ITEM
LOAD SIGNAL
IGNITION SW
HEATER FAN SW
BRAKE SW
INJ PULSE-B1
IGN TIMING
PURG VOL C/V
INT/V TIM (B1)
INT/V SOL (B1)
VIAS S/V*2
AIR COND RLY
FUEL PUMP RLY
THRTL RELAY
CONDITION
Ignition switch: ON
Ignition switch: ON

(M/T)
No load

(M/T)
No load

(M/T)
No load

(M/T)
No load

(M/T)
No load

the engine
Rear window defogger switch is ON

and/or lighting switch is in 2nd
(placed in LOW position for models
with Xenon headlamp).
ON
Rear window defogger switch is

OFF and lighting switch is OFF.
OFF
Ignition switch: ON OFF ON

Ignition switch: ON
SPECIFICATION
EC
ON OFF ON
ON
OFF
OFF
ON
Idle
2.0 - 3.0 msec
2,000 rpm
1.9 - 2.9 msec
Idle
13 - 17 BTDC
G
2,000 rpm
25 - 45 BTDC
H
Idle
0%
2,000 rpm
20 - 30%
Idle
5 - 5CA
2,000 rpm
Approx. 0 - 20CA
Idle
0% - 2%
2,000 rpm
Approx. 0% - 50%
M
Idle
OFF
More than 5,000 rpm
ON
OFF

ON
OFF
Ignition switch: ON
ON
EC-613
http://vnx.su
ON
TROUBLE DIAGNOSIS
MONITOR ITEM
CONDITION

the engine
COOLING FAN
SPECIFICATION

(201F) or less
OFF

(210F)
LOW

100C (212F) or more
HIGH
Engine speed is below 3,600 rpm after the following conditions are met.
and at idle for 1 minute under no load.
OFF
Engine coolant temperature when engine started: More than 80C

(176F)
Approx. 50%
Engine speed: below 3,600 rpm
Engine: Idle
Both A/C switch and blower fan seitch: ON (Compressor operates)

SET VHCL SPD*2
Engine: Running
MAIN SW*2
Ignition switch: ON
CANCEL SW*2
HO2S1 HTR (B1)
HO2S2 HTR (B1)
O2SEN HTR DTY
AC PRESS SEN
VEH SPEED SE*2
RESUME/ACC SW*
SET SW
BRAKE
SW1*2
Ignition switch: ON
Ignition switch: ON
Ignition switch: ON
Ignition switch: ON
ON
OFF
ON
ASCD: Operating.
1.0 - 4.0V
ON
OFF
ON
OFF
Pressed
ON
Released
OFF
ON
OFF

Fully released
ON
Clutch pedal (M/T) and/or brake

OFF
OFF
ON
BRAKE SW2*2
CRUISE LAMP*2
Ignition switch: ON
MAIN switch: Pressed at the 1st

time at the 2nd time
ON OFF
MAIN switch: ON
ASCD: Operating
ON
Vehicle speed: Between 40 km/h

(25 MPH) and 144 km/h (89
MPH)
ASCD: Not operating
OFF
SET LAMP*2
Ignition switch: ON
*1: Accelerator pedal position sensor 2 signal and throttle position sensor 2 signal are converted by ECM internally. Thus, they differ
from ECM terminals voltage signals.
EC-614
http://vnx.su
TROUBLE DIAGNOSIS
EBS010XF
CLSD THL POS, ACCEL SEN 1, THRTL SEN 1

Below is the data for CLSD THL POS, ACCEL SEN 1 and THRTL SEN 1 when depressing the accelera- EC
tor pedal with the ignition switch ON and with selector lever in D position (A/T models) or with shift lever in 1st
position (M/T models).
The signal of ACCEL SEN 1 and THRTL SEN 1 should rise gradually without any intermittent drop or rise
C
after CLSD THL POS is changed from ON to OFF.
D
F
PBIB0198E
ENG SPEED, MAS A/F SE-B1, THRTL SEN 1, HO2S2 (B1), HO2S1 (B1), INJ PULSE-B1
Below is the data for ENG SPEED, MAS A/F SE-B1, THRTL SEN 1, HO2S2 (B1), HO2S1 (B1) and
INJ PULSE-B1 when revving engine quickly up to 4,800 rpm under no load after warming up engine sufficiently.
PBIB2445E
EC-615
http://vnx.su
TROUBLE DIAGNOSIS
PBIB0668E
EC-616
http://vnx.su


Description
PFP:00031
A
EBS010XG
The specification (SP) value indicates the tolerance of the value that is displayed in DATA MONITOR (SPEC)
mode of CONSULT-II during normal operation of the Engine Control System. When the value in DATA MONI- EC
TOR (SPEC) mode is within the SP value, the Engine Control System is confirmed OK. When the value in
DATA MONITOR (SPEC) mode is NOT within the SP value, the Engine Control System may have one or
more malfunctions.
The SP value is used to detect malfunctions that may affect the Engine Control System, but will not light the C
MIL.
The SP value will be displayed for the following three items:
B/FUEL SCHDL (The fuel injection pulse width programmed into ECM prior to any learned on board cor- D
rection)
A/F ALPHA-B1 (The mean value of air-fuel ratio feedback correction factor per cycle)
E
MAS A/F SE-B1 (The signal voltage of the mass air flow sensor)
Testing Condition
EBS010XH
Vehicle driven distance: More than 5,000 km (3,017 miles)
F
2
Barometric pressure: 98.3 - 104.3 kPa (0.983 - 1.043 bar, 1.003 - 1.064 kg/cm , 14.25 - 15.12 psi)
Atmospheric temperature: 20 - 30C (68 - 86F)
Transmission: Warmed-up*1
Electrical load: Not applied*2
Engine speed: Idle

*1: For A/T models, after the engine is warmed up to normal operating temperature, drive vehicle until FLUID
TEMP SE (A/T fluid temperature sensor signal) indicates more than 60C (140F).
For M/T models, after the engine is warmed up to normal operating temperature, drive vehicle for 5 minutes.
*2: Rear window defogger switch, air conditioner switch, lighting switch are OFF. Steering wheel is straight
ahead.
Inspection Procedure
EBS010XI
NOTE:
Perform DATA MONITOR (SPEC) mode in maximum scale display.
1. Perform EC-575, "Basic Inspection" .
2. Confirm that the testing conditions indicated above are met.
3. Select B/FUEL SCHDL, A/F ALPHA-B1 and MAS A/F SEB1 in DATA MONITOR (SPEC) mode with CONSULT-II.
4. Make sure that monitor items are within the SP value.
SEF601Z
EC-617
http://vnx.su

EBS010XJ
SEF613ZD
EC-618
http://vnx.su

A
EC
SEF768Z
EC-619
http://vnx.su

SEF615ZA
EC-620
http://vnx.su


Description
PFP:00006
A
EBS010XK
Intermittent incidents may occur. In many cases, the malfunction resolves itself (the part or circuit function
returns to normal without intervention). It is important to realize that the symptoms described in the customer's EC
complaint often do not recur on (1st trip) DTC visits. Realize also that the most frequent cause of intermittent
incident occurrences is poor electrical connections. Because of this, the conditions under which the incident
C
Common Intermittent Incident Report Situations
STEP in Work Flow
Situation
II
The CONSULT-II is used. The SELF-DIAG RESULTS screen shows time data other than [0] or [1t].
III
IV
(1st trip) DTC does not appear during the DTC Confirmation Procedure.
VI
The Diagnostic Procedure for PXXXX does not indicate the malfunctioning area.
EBS010XL
1. INSPECTION START
Erase (1st trip) DTCs. Refer to EC-563, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" .
H
>> GO TO 2.

OK or NG
OK
>> GO TO 3.
NG

Perform GI-23, "How to Perform Efficient Diagnosis for an Electrical Incident" , Incident Simulation Tests.
OK or NG
OK
>> INSPECTION END
NG
EC-621
http://vnx.su


Wiring Diagram
PFP:24110
EBS010XM
TBWA0594E
EC-622
http://vnx.su

CAUTION:
TERMINAL
NO.
1
EC
WIRE
COLOR
B
ITEM
ECM ground
CONDITION
[Engine is running]
109
B/R
Idle speed
G/W
BATTERY VOLTAGE
(11 - 14V)
0 - 1.0V
BATTERY VOLTAGE
(11 - 14V)
Body ground
B
B
ECM ground
119
120
SB
GY
Power supply for

ECM
For a few seconds after turning ignition switch OFF
115
116
Body ground
0V
Ignition switch
ECM relay
(Self shut-off)
DATA (DC Voltage)
[Engine is running]
111
More than a few seconds after turning ignition switch

OFF
[Engine is running]
Idle speed
BATTERY VOLTAGE
(11 - 14V)
EBS010XN
1. INSPECTION START
I
Start engine.
Is engine running?
Yes or No
Yes
>> GO TO 11.
No
>> GO TO 2.
1.
2.
Turn ignition switch OFF and then ON.

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.
MBIB0015E

10A fuse

EC-623
http://vnx.su


1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 5.
NG
5. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-I

1.
2.
3.


OK or NG
OK
>> GO TO 6.
NG
EC-624
http://vnx.su


1.

EC
D
PBIB1973E
2.

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.
SEF420X

20A fuse


1.
Check harness continuity between ECM terminal 111 and ECM relay terminal 2.

OK or NG
OK
>> GO TO 10.
NG
>> GO TO 9.


EC-625
http://vnx.su

10. CHECK ECM RELAY

OK or NG
OK
>> Go to EC-870, "IGNITION SIGNAL" .
NG

1.
2.
3.

Voltage:

drop approximately 0V.
PBIB1630E
OK or NG
OK
>> GO TO 17.
NG (Battery voltage does not exist.)>>GO TO 12.
NG (Battery voltage exists for more than a few seconds.)>>GO TO 14.

1.
PBIB1973E
2.
Check voltage between ECM relay terminal 3 and ground with

OK or NG
OK
>> GO TO 14.
NG
>> GO TO 13.
SEF860T
EC-626
http://vnx.su

10A fuse


1.
2.

Check harness continuity between ECM terminals 119, 120 and ECM relay terminal 5.
EC

OK or NG
OK
>> GO TO 16.
NG
>> GO TO 15.

16. CHECK ECM RELAY

OK or NG
OK
>> GO TO 17.
NG
EC-627
http://vnx.su


PBIB2021E
OK or NG
OK
>> GO TO 18.
NG
18. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-II

1.
2.


OK or NG
OK
>> GO TO 19.
NG

OK or NG
OK
>> INSPECTION END
EC-628
http://vnx.su

EBS010XO
ECM RELAY
1.
2.

EC
Condition
Continuity
Yes
OFF
No
3.

D
PBIB0077E
Ground Inspection
EBS011V7
For detailed ground distribution information, refer to Ground Distribution in PG section.
PBIB1870E
EC-629
http://vnx.su


Description
PFP:23710
EBS010XP
EBS010XQ
The MI will not light up these self-diagnoses.

DTC No.
U1000
1000
U1001
1001
Trouble diagnosis
name
CAN communication
line
ECM cannot communicate to other control

units.
ECM cannot communicate for more than the
specified time.

1.
2.
3.
Possible cause
shorted)
EBS010XR

EC-630
http://vnx.su

Wiring Diagram
EBS010XS
EC
TBWA0595E
EC-631
http://vnx.su

EBS010XT
EC-632
http://vnx.su


Description
PFP:23796
A
EBS010XU
SYSTEM DESCRIPTION
Sensor
Input signal to ECM

Engine speed
Wheel sensor*
Vehicle speed
ECM function
Intake valve
timing control
Actuator
EC

solenoid valve
I
PBIB0540E
This mechanism hydraulically controls cam phases continuously with the fixed operating angle of the intake
valve.
The ECM receives signals such as crankshaft position, camshaft position, engine speed, and engine coolant
temperature. Then, the ECM sends ON/OFF pulse duty signals to the intake valve timing control solenoid
valve depending on driving status. This makes it possible to control the shut/open timing of the intake valve to
increase engine torque in low/mid speed range and output in high-speed range.
COMPONENT DISCRIPTION
Intake valve timing control solenoid valve is activated by ON/OFF

pulse duty (ratio) signals from the ECM.
The intake valve timing control solenoid valve changes the oil
amount and direction of flow through intake valve timing control unit
or stops oil flow.
The longer pulse width advances valve angle.
The shorter pulse width retards valve angle.
When ON and OFF pulse widths become equal, the solenoid valve
stops oil pressure flow to fix the intake valve angle at the control
position.
PBIB1842E
EC-633
http://vnx.su

EBS010XV

MONITOR ITEM
CONDITION

(M/T)
No load

(M/T)
No load
INT/V TIM (B1)
INT/V SOL (B1)
SPECIFICATION
Idle
5 - 5CA
2,000 rpm
Approx. 0 - 20CA
Idle
0% - 2%
2,000 rpm
Approx. 0% - 50%
EBS010XW

Trouble diagnosis
name
DTC No.
P0011
0011
Intake valve timing

control performance
Detecting condition
There is a gap between angle of target and

phase-control angle degree.
Possible cause
(Intake valve timing control solenoid valve
circuit is open or shorted.)
Accumulation of debris to the signal pick-up

portion of the camshaft
FAIL-SAFE MODE
ECM enters in fail-safe mode when the malfunction is detected.
Detected items

The signal is not energized to the solenoid valve and the valve control does not function
EBS010XX
CAUTION:
Always drive at a safe speed.
NOTE:
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is between 10V and 16V at
idle.
WITH CONSULT-II
1.
2.
3.

CONSULT-II.
ENG SPEED
1,200 - 2,000 (A constant rotation is

maintained.)
SEF174Y
EC-634
http://vnx.su

COOLAN TEMP/S
60 - 120C (140 - 248F)
Selector lever
M/T: Neutral position

A/T: P or N position
4.
5.
6.
Stop vehicle with engine running and let engine idle for 10 seconds.
If the 1st trip DTC is not detected, go to next step.
ENG SPEED
COOLAN TEMP/S
80 - 90C (176 - 194F)
Selector lever
1st or 2nd position
Driving location uphill
Driving vehicle uphill

(Increased engine load will help maintain the driving
conditions required for this test.)
7.
EC

F
EC-635
http://vnx.su

EBS011UR
Use this procedure to check the overall function of the intake valve timing control system. During this check, a
1st trip DTC might not be confirmed.
WITHOUT CONSULT-II
1.
2.
3.
4.
5.
6.

Set the tester probe between ECM terminal 62 (IVT control solenoid valve signal) and ground.
Check the voltage under the following conditions.
Verify that the oscilloscope screen shows the signal wave as
shown below.
Conditions
Voltage
AT idle
BATTERY VOLTAGE
(11 - 14V)
Approximately 4V - BATTERY VOLTAGE (11 - 14V)
2,000 rpm
SEF955V
PBIB1790E
7.
EC-636
http://vnx.su

Wiring Diagram
EBS0128E
EC
TBWA0612E
EC-637
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running]
Warm-up condition
Idle speed
BATTERY VOLTAGE
(11 - 14V)
62
Intake valve timing

VOLTAGE (11 - 14V)

[Engine is running]
Warm-up condition
PBIB1790E
EBS010XY
1. CHECK POWER SUPPLY CIRCUIT

1.
2.

PBIB0511E
3.
4.
Check voltage between intake valve timing control solenoid

valve terminal 1 and ground with CONSULT-II or tester.
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
PBIB0285E
2. DETECT MALFUNCTION PART

Check harness for open or short between intake valve timing control solenoid valve and ECM relay.
EC-638
http://vnx.su

3. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR
OPEN AND SHORT
1.
2.
3.

EC
Check harness continuity between intake valve timing control solenoid valve terminal 2 and ECM terminal
C

OK or NG
OK
>> GO TO 4.
NG
4. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE

Refer to .
OK or NG
OK
>> GO TO 5.
NG
>> Replace intake valve timing control solenoid valve.

Refer to .
OK or NG
OK
>> GO TO 6.
NG

J
Refer to .
OK or NG
OK
>> GO TO 7.
NG

L

OK or NG
OK
>> GO TO 8.
NG
PBIB0565E

Refer to .
For wiring diagram refer to CKP sensor (POS) and CMP sensor (PHASE) .
>> INSPECTION END
EC-639
http://vnx.su

EBS0128F

1.
2.

Check resistance between intake valve timing control solenoid
valve terminals 1 and 2 under the following conditions.
Terminals
Resistance
1 and 2
Approximately 8 at 20C (68F)
1 or 2 and ground
MBIB0027E
EBS0128G

Refer to EM-46, "TIMING CHAIN" .
EC-640
http://vnx.su


PFP:22680
A
EBS010XZ
wire is a certain amount. The heat generated by the hot wire is
the heat loss.
EC
D
PBIB1604E
EBS010Y0

MONITOR ITEM
MAS A/F SE-B1
CONDITION
SPECIFICATION
EBS010Y1

DTC No.
P0102
0102
P0103
0103

low input

high input

is sent to ECM when engine is running.
Possible cause
Intake air leaks

is sent to ECM.
FAIL-SAFE MODE
Detected items
EBS010Y2
NOTE:
EC-641
http://vnx.su

With CONSULT-II
1.
2.
3.
4.

SEF058Y
Without CONSULT-II
1.
2.
3.
4.
Start engine and wait 5 seconds at most.

Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.

With CONSULT-II
1.
2.
3.
4.
5.
6.
Turn ignition switch ON

SEF058Y
Without CONSULT-II
1.
2.
3.
4.
5.
6.
7.
8.
9.

EC-642
http://vnx.su

Wiring Diagram
EBS010Y3
EC
TBWA0598E
EC-643
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)

Approximately 0.4V
[Engine is running]
50
OR
Warm-up condition
Idle speed

[Engine is running]
Warm-up condition
0.7 - 1.1V (QR20DE)

0.8 - 1.2V (QR25DE)
(QR20DE)
(QR25DE)
[Engine is running]
67
B/P
Sensor ground
Warm-up condition
Idle speed
Approximately 0V
EBS010Y4
1. INSPECTION START
Which malfunction (P0102 or P0103) is duplicated?
P0102 or P0103
P0102 >> GO TO 2.
P0103 >> GO TO 3.

Check the following for connection.
Air duct
Vacuum hoses
Intake air passage between air duct to intake manifold

OK or NG
OK
>> GO TO 3.
NG
>> Reconnect the parts.
EC-644
http://vnx.su


1.
2.

EC
J
PBIB2021E
OK or NG
OK
>> GO TO 4.
NG
EC-645
http://vnx.su

4. CHECK MAF SENSOR POWER SUPPLY CIRCUIT

1.
2.
Disconnect MAF sensor harness connector.

PBIB0495E
3.
Check voltage between MAF sensor terminals 2 and ground

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.
PBIB1168E

Harness for open or short between mass air flow sensor and ECM relay
6. CHECK MAF SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1.
2.
3.


OK or NG
OK
>> GO TO 7.
NG
EC-646
http://vnx.su

7. CHECK MAF SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
EC

OK or NG
OK
>> GO TO 8.
NG

OK or NG
OK
>> GO TO 9.
NG

>> INSPECTION END
EBS01FFC

With CONSULT-II
1.
2.
3.
4.
Condition
temperature.)
b.
6.
7.
8.
9.
Voltage V
Approx. 0.4
0.7 - 1.1V (QR20DE)
0.8 - 1.2V (QR25DE)
0.7 - 1.1 to 2.4 (QR20DE)*

0.8 - 1.2 to 2.4 (QR25DE)*
4,000 rpm.
5.
a.

Connect CONSULT-II and select DATA MONITOR mode.
Select MAS A/F SE-B1 and check indication under the following conditions.

Crushed air ducts
Perform step 2 to 4 again.
EC-647
http://vnx.su
M
SEF178Y

Without CONSULT-II
1.
2.
3.

signal) and ground.
Condition

temperature.)
Voltage V
Approx. 0.4
0.7 - 1.1V (QR20DE)
0.8 - 1.2V (QR25DE)
0.7 - 1.1 to 2.4 (QR20DE)*
0.8 - 1.2 to 2.4 (QR25DE)*
4,000 rpm.
4.
a.
b.
5.
6.
7.
8.
MBIB0017E

Crushed air ducts
Perform step 2 and 3 again.
EBS010Y6

EC-648
http://vnx.su


PFP:22630
A
EBS010Y7

EC
D
SEF594K
<Reference data>
Engine coolant
temperature C (F)
Voltage* V
10 (14)
4.4
Resistance
7.0 - 11.4
20 (68)
3.5
2.1 - 2.9
50 (122)
2.2
0.68 - 1.00
90 (194)
0.9
0.236 - 0.260
*: This data is reference value and is measured between ECM terminal 72 (Engine
coolant temperature sensor) and ground.
SEF012P
CAUTION:

DTC No.
EBS010Y8
Possible Cause
P0117
0117

sensor circuit low input

is sent to ECM.
P0118
0118

sensor circuit high input

is sent to ECM.
FAIL-SAFE MODE
When this malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Detected items

Engine coolant temperature will be determined by ECM based on the time after turning ignition switch ON
or START. CONSULT-II displays the engine coolant temperature decided by ECM.
Condition
40C (104F)
More than approx. 4 minutes after ignition ON or

START
80C (176F)
40 - 80C (104 - 176F)
When the fail-safe system for engine coolant temperature sensor is activated, the cooling fan operates
while engine is running.
EC-649
http://vnx.su

EBS010Y9
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

.
SEF058Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-650
http://vnx.su

Wiring Diagram
EBS010YA
EC
TBWA0600E
EC-651
http://vnx.su

EBS010YB

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-652
http://vnx.su


1.
2.
Disconnect engine coolant temperature (ECT) sensor harness

connector.
EC
D
PBIB0496E
3.

OK or NG
OK
>> GO TO 3.
NG
PBIB0080E

1.
2.
3.

Check harness continuity between ECT sensor terminal 2 and ECM terminal 73.

OK or NG
OK
>> GO TO 4.
NG

OK or NG
OK
>> GO TO 5.
NG

>> INSPECTION END
EC-653
http://vnx.su

EBS010YC

1.

PBIB2005E
<Reference data>
2.
C (F)
Resistance
20 (68)
2.1 - 2.9
50 (122)
0.68 - 1.00
90 (194)
0.236 - 0.260
SEF012P
EBS010YD

Refer to CO-23, "THERMOSTAT AND WATER CONTROL VALVE" .
EC-654
http://vnx.su


PFP:16119
A
EBS010YE

EC
D
PBIB0145E
EBS010YF

MONITOR ITEM
CONDITION
Ignition switch: ON
(Engine stopped)
More than 0.36V
Less than 4.75V
THRTL SEN 1
THRTL SEN 2*
SPECIFICATION
EBS010YG

DTC No.
P0122
0122
P0123
0123

circuit low input

is sent to ECM.

circuit high input
An excessively high voltage from the TP sensor 2

is sent to ECM.
Possible cause
(TP sensor 2 circuit is open or
shorted.)

(TP sensor 2)

(APP sensor 2)
FAIL-SAFE MODE

degrees.
EBS010YH
NOTE:
TESTING CONDITION:
EC-655
http://vnx.su

WITH CONSULT-II
1.
2.
3.
4.

SEF058Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-656
http://vnx.su

Wiring Diagram
EBS010YI
EC
TBWB0260E
EC-657
http://vnx.su

CAUTION:
TERMINAL NO.
47
WIRE
COLOR
R
ITEM
power supply
CONDITION
DATA (DC Voltage)

Approximately 5V
49
Engine stopped
More than 0.36V
Engine stopped
Less than 4.75V
[Engine is running]
66
Sensor ground
Warm-up condition
Idle speed
Approximately 0V
68
91
BR/Y
Sensor power supply

Less than 4.75V
EC-658
http://vnx.su
More than 0.36V
Approximately 5V

EBS010YJ

1.
2.

EC
J
PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-659
http://vnx.su


1.
PBIB1992E
PBIB1971E
2.
3.

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 3.
PBIB0082E

1.
2.
3.

OK or NG
OK
>> GO TO 4.
NG
EC-660
http://vnx.su

ECM terminal
Sensor terminal
47
EC-657
91
EC-837
OK or NG
OK
>> GO TO 5.
NG
EC
5. CHECK APP SENSOR

OK or NG
OK
>> GO TO 11
NG
>> GO TO 6.

1.
2.
3.
4.

>> INSPECTION END
1.
2.
3.


OK or NG
OK
>> GO TO 8.
NG
1.
Check harness continuity between electric throttle control actuator terminal 2 ECM terminal 68.

OK or NG
OK
>> GO TO 9.
NG
EC-661
http://vnx.su


OK or NG
OK
>> GO TO 11.
NG
>> GO TO 10.

1.
2.
3.

>> INSPECTION END

>> INSPECTION END
EBS010YK

1.
2.
3.
4.
5.

Terminal
Accelerator pedal
Voltage
49
Fully released
More than 0.36V
Fully depressed
Less than 4.75V
68
Fully released
Less than 4.75V
Fully depressed
More than 0.36V
6.
7.
8.

step.
MBIB0022E
EBS010YL

EC-662
http://vnx.su
DTC P0132 HO2S1

DTC P0132 HO2S1

PFP:22690
A
EBS010YM

EC
D
SEF463R
H
SEF288D
EBS010YN

MONITOR ITEM
CONDITION
SPECIFICATION
0 - 0.3V Approx. 0.6 - 1.0V
HO2S1 (B1)
HO2S1 MNTR (B1)
Maintaining engine speed at 2,000 rpm
LEAN RICH
10 seconds.
EBS010YO
To judge the malfunction, the diagnosis checks that the heated oxygen sensor 1 output is not inordinately high.
SEF301UA
DTC No.
P0132
0132

Possible cause

is sent to ECM.
EC-663
http://vnx.su
DTC P0132 HO2S1

EBS010YP
NOTE:
WITH CONSULT-II
1.
2.
3.
4.
5.
6.

.
SEF174Y
WITHOUT CONSULT-II
1.
2.
3.
4.
5.
6.

EC-664
http://vnx.su
DTC P0132 HO2S1

Wiring Diagram
EBS010YQ
EC
TBWA0602E
EC-665
http://vnx.su
DTC P0132 HO2S1

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running]
35
74
P/L
Sensor ground
Warm-up condition
[Engine is running]
Idle speed
Approximately 0V
EBS010YR

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-666
http://vnx.su
DTC P0132 HO2S1


1.

EC
>> GO TO 3.
C
D
PBIB0499E

1.
2.
3.

Check harness continuity between ECM terminal 74 and HO2S1
terminal 3.

OK or NG
OK
>> GO TO 4.
NG
H
PBIB0500E

1.

2.
L

OK or NG
OK
>> GO TO 5.
NG

Check heated oxygen sensor 1 connectors for water.
OK or NG
OK
>> GO TO 6.
NG
EC-667
http://vnx.su
DTC P0132 HO2S1


OK or NG
OK
>> GO TO 7.
NG

>> INSPECTION END
EBS010YS

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

SEF646Y
6.

5 times (cycles) are counted as shown at right.
SEF217YA
SEF648Y
CAUTION:
EC-668
http://vnx.su
DTC P0132 HO2S1

Without CONSULT-II
1.
2.
3.

EC
C
D
1 time: 0 - 0.3V 0.6 - 1.0V 0 - 0.3V
E
2 times: 0 - 0.3V 0.6 - 1.0V 0 - 0.3V 0.6 - 1.0V
0 - 0.3V
MBIB0018E
CAUTION:
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 F
G
EBS010YT

I
EC-669
http://vnx.su
DTC P0134 HO2S1

DTC P0134 HO2S1

PFP:22690
EBS010YU

SEF463R
SEF288D
EBS010YV

MONITOR ITEM
CONDITION
SPECIFICATION
0 - 0.3V Approx. 0.6 - 1.0V
HO2S1 (B1)
HO2S1 MNTR (B1)

rpm
LEAN RICH
EBS010YW
Under the condition in which the heated oxygen sensor 1 signal is

not input, the ECM circuits will read a continuous approximately
0.3V. Therefore, for this diagnosis, the time that output voltage is
within 200 to 400 mV range is monitored, and the diagnosis checks
that this time is not inordinately long.
SEF237U
DTC No.
P0134
0134

circuit no activity detected
Possible cause
The voltage from the sensor is constantly

approx. 0.3V.
EC-670
http://vnx.su
DTC P0134 HO2S1

EBS010YX
WITH CONSULT-II
1.
2.
3.
4.
5.
EC

Select MANU TRIG in DATA MONITOR mode with CONSULT-II, and select H02S1 (B1).
Hold engine speed at 2,000 rpm under no load.
Make sure that the indications do not remain in the range
between 0.2V to 0.4V.
E
SEF646Y
WITHOUT CONSULT-II
1.
2.
3.
4.

The voltage does not remain in the range of 0.2 to 0.4V.
J
MBIB0018E
EC-671
http://vnx.su
DTC P0134 HO2S1

Wiring Diagram
EBS010YY
TBWA0602E
EC-672
http://vnx.su
DTC P0134 HO2S1

CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running]
35
P/L
Warm-up condition
[Engine is running]
74
Sensor ground
Warm-up condition
Idle speed
Approximately 0V
EBS010YZ

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-673
http://vnx.su
DTC P0134 HO2S1


1.
2.
3.


OK or NG
OK
>> GO TO 3.
NG
PBIB0500E

1.

2.

OK or NG
OK
>> GO TO 4.
NG

OK or NG
OK
>> GO TO 5.
NG

>> INSPECTION END
EBS010Z0

With CONSULT-II
1.
2.

EC-674
http://vnx.su
DTC P0134 HO2S1

3.
4.
5.

EC
C
SEF646Y
6.

5 times (cycles) are counted as shown at right.
G
SEF217YA
SEF648Y
CAUTION:
Without CONSULT-II
1.
2.
3.

1 time: 0 - 0.3V 0.6 - 1.0V 0 - 0.3V
2 times: 0 - 0.3V 0.6 - 1.0V 0 - 0.3V 0.6 - 1.0V
0 - 0.3V
MBIB0018E
CAUTION:
EC-675
http://vnx.su
DTC P0134 HO2S1

EBS010Z1

EC-676
http://vnx.su


PFP:16119
A
EBS010Z2

EC
D
PBIB0145E
EBS010Z3

MONITOR ITEM
CONDITION
Ignition switch: ON
(Engine stopped)
More than 0.36V
Less than 4.75V
THRTL SEN 1
THRTL SEN 2*
SPECIFICATION
EBS010Z4

DTC No.
P0222
0222
P0223
0223

circuit low input

is sent to ECM.

circuit high input
Possible cause
(TP sensor 1 circuit is open or shorted.)

(TP sensor 1)

(APP sensor 2)
An excessively high voltage from the TP sensor

1 is sent to ECM.
FAIL-SAFE MODE
degrees.
EBS010Z5
NOTE:
TESTING CONDITION:
EC-677
http://vnx.su

WITH CONSULT-II
1.
2.
3.
4.

SEF058Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-678
http://vnx.su

Wiring Diagram
EBS010Z6
EC
TBWB0261E
EC-679
http://vnx.su

CAUTION:
TERMINAL
NO.
47
WIRE
COLOR
R
ITEM
power supply
CONDITION
DATA (DC Voltage)
Approximately 5V
49
Engine stopped
More than 0.36V
Engine stopped
Less than 4.75V
[Engine is running]
66
Sensor ground
Warm-up condition
Idle speed
Approximately 0V
68
Less than 4.75V
91
BR/Y
Sensor power supply

EC-680
http://vnx.su
More than 0.36V
Approximately 5V

EBS010Z7

1.
2.

EC
J
PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-681
http://vnx.su


1.
PBIB1992E
PBIB1971E
2.
3.

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 3.
PBIB0082E

1.
2.
3.

OK or NG
OK
>> GO TO 4.
NG
EC-682
http://vnx.su

ECM terminal
Sensor terminal
47
EC-679
91
EC-837
OK or NG
OK
>> GO TO 5.
NG
EC
5. CHECK APP SENSOR

OK or NG
OK
>> GO TO 11
NG
>> GO TO 6.

1.
2.
3.
4.

>> INSPECTION END
1.
2.
3.


OK or NG
OK
>> GO TO 8.
NG
1.

OK or NG
OK
>> GO TO 9.
NG
EC-683
http://vnx.su


OK or NG
OK
>> GO TO 11.
NG
>> GO TO10.

1.
2.
3.

>> INSPECTION END

>> INSPECTION END
EBS010Z8

1.
2.
3.
4.
5.

Terminal
Accelerator pedal
Voltage
49
Fully released
More than 0.36V
Fully depressed
Less than 4.75V
68
Fully released
Less than 4.75V
Fully depressed
More than 0.36V
6.
7.
8.

step.
MBIB0022E
EBS010Z9

EC-684
http://vnx.su
DTC P0327, P0328 KS

DTC P0327, P0328 KS

PFP:22060
A
EBS010ZA
The knock sensor is attached to the cylinder block. It senses engine knocking using a piezoelectric element. A
knocking vibration from the cylinder block is sensed as vibrational pressure. This pressure is converted into a EC
voltage signal and sent to the ECM.
C
E
PBIB0512E
EBS010ZB

DTC No.
DTC Detected Condition
Possible Cause
P0327
0327
Knock sensor circuit low

input

sent to ECM.
P0328
0328
Knock sensor circuit high

input

sent to ECM.
Knock sensor
H
EBS010ZC
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.

CONSULT-II.
.
SEF058Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-685
http://vnx.su
DTC P0327, P0328 KS

Wiring Diagram
EBS010ZD
TBWA0606E
EC-686
http://vnx.su
DTC P0327, P0328 KS

CAUTION:
TERMINAL
NO.
15
WIRE
COLOR
W
EC
ITEM
Knock sensor
CONDITION
[Engine is running]
Idle speed
DATA (DC Voltage)
Approximately 2.5V
[Engine is running]
54
Sensor ground
(Knock sensor)
Warm-up condition
Idle speed
Approximately 0V
EBS010ZE
1. CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT-I

1.
2.
3.

Check resistance between ECM terminal 15 and ground. Refer to Wiring Diagram.
NOTE:
It is necessary to use an ohmmeter which can measure more than 10 M.

H

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 2.
2. CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT-II

1.
Disconnect knock sensor harness connector.

K
M
PBIB0512E
2.
Check harness continuity between knock sensor terminal 1 and ECM terminal 15.

OK or NG
OK
>> GO TO 3.
NG
EC-687
http://vnx.su
DTC P0327, P0328 KS

3. CHECK KNOCK SENSOR

OK or NG
OK
>> GO TO 4.
NG
>> Replace knock sensor.

PBIB2021E
OK or NG
OK
>> GO TO 5.
NG
5. CHECK KNOCK SENSOR SHIELD CIRCUIT FOR OPEN AND SHORT

1.
2.
Reconnect knock sensor harness connector.

Check harness continuity between ECM terminal 54 and ground.
Continuity should exist

OK or NG
OK
>> GO TO 6.
NG
EC-688
http://vnx.su
DTC P0327, P0328 KS


EC
>> INSPECTION END
EBS010ZF
KNOCK SENSOR
Check resistance between knock sensor terminal 1 and ground.

NOTE:
It is necessary to use an ohmmeter which can measure more
than 10 M.

E
CAUTION:
Do not use any knock sensors that have been dropped or physically damaged. Use only new ones.
F
SEF227W
EBS010ZG
KNOCK SENSOR
EC-689
http://vnx.su


PFP:23731
EBS010ZH
The crankshaft position sensor (POS) is located on the cylinder

block rear housing facing the gear teeth (cogs) of the signal plate at
the end of the crankshaft. It detects the fluctuation of the engine revolution.
When the engine is running to the high and low parts of the teeth
cause the gap with the sensor to change.
change.
Due to the changing magnetic field, the voltage from the sensor
changes.
The ECM receives the voltage signal and detects the fluctuation of
the engine revolution.
PBIB0562E
EBS010ZI

MONITOR ITEM
ENG SPEED
CONDITION
SPECIFICATION


DTC No.
P0335
0335
Crankshaft position
sensor (POS) circuit
EBS010ZJ
The crankshaft position sensor (POS) signal is not

detected by the ECM during the first few seconds of
engine cranking.
The proper pulse signal from the crankshaft position
sensor (POS) is not sent to ECM while the engine is
running.
The crankshaft position sensor (POS) signal is not in
the normal pattern during engine running.
Possible cause
shorted.)
Signal plate
EBS010ZK
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.
5.

CONSULT-II.
.
.
EC-690
http://vnx.su
SEF058Y

WITHOUT CONSULT-II
1.
2.
3.
4.
5.
6.
7.
8.
9.
Start engine and maintain engine speed at more than 800 rpm for at least 5 seconds.
EC
EC-691
http://vnx.su

Wiring Diagram
EBS010ZL
TBWA0607E
EC-692
http://vnx.su

A
CAUTION:
EC
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
C
Approximately 3V
[Engine is running]
Warm-up condition
Idle speed
NOTE:
The pulse cycle changes depending on rpm at idle
14
PU/R
E
PBIB0527E
Crankshaft position
sensor (POS)
Approximately 3V
F
[Engine is running]
G
PBIB0528E
30
Sensor ground
(Crankshaft position
sensor)
[Engine is running]
Warm-up condition
Idle speed
Approximately 0V
EC-693
http://vnx.su

EBS010ZM

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-694
http://vnx.su

2. CHECK CRANKSHAFT POSITION (CKP) SENSOR (POS) POWER SUPPLY CIRCUIT

1.
Disconnect crankshaft position (CKP) sensor (POS) harness connector.

EC
D
PBIB0512E
2.
3.

Check voltage between CKP sensor (POS) terminal 1 and

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.
H
PBIB0664E
Harness for open or short between crankshaft position sensor (POS) and ECM
Harness for open or short between crankshaft position sensor (POS) and ECM relay
4. CHECK CKP SENSOR (POS) GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

4. Also check harness for and short to power.

OK or NG
OK
>> GO TO 5.
NG
EC-695
http://vnx.su

5. CHECK CKP SENSOR (POS) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

OK or NG
OK
>> GO TO 6.
NG

OK or NG
OK
>> GO TO 7.
NG
7. CHECK GEAR TOOTH

OK or NG
OK
>> GO TO 8.
NG

>> INSPECTION END
EBS010ZN

1.
2.
3.
4.

Disconnect crankshaft position sensor (POS) harness connector.
Remove the sensor.
PBIB0563E
EC-696
http://vnx.su

5.

3 (+) - 1 (-)
3 (+) - 2 (-)
Except 0 or
EC
2 (+) - 1 (-)
6.
If NG, replace crankshaft position sensor (POS).
C
MBIB0024E
EBS010ZO

EC-697
http://vnx.su


PFP:23731
EBS010ZP
The camshaft position sensor (PHASE) senses the retraction of

intake valve camshaft to identify a particular cylinder. The camshaft
position sensor (PHASE) senses the piston position.
When the crankshaft position sensor (POS) system becomes inoperative, the camshaft position sensor (PHASE) provides various controls of engine parts instead, utilizing timing of cylinder identification
signals.
When engine is running, the high and low parts of the teeth cause
the gap with the sensor to change.
change.
Due to the changing magnetic field, the voltage from the sensor changes.
PBIB0562E

DTC No.
P0340
0340

(PHASE) circuit
EBS010ZQ
The cylinder No. signal is not sent to ECM

for the first few seconds during engine
cranking.
Possible cause
Camshaft (Intake)
The cylinder No. signal is not set to ECM

during engine running.
Starter motor (Refer to SC-22, "STARTING SYSTEM" .)
The cylinder No. signal is not in the normal

pattern during engine running.
Starting system circuit (Refer to SC-22,

"STARTING SYSTEM" .)
Dead (Weak) battery
EBS010ZR
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.
5.
6.

.
.
EC-698
http://vnx.su
SEF058Y

WITHOUT CONSULT-II
1.
2.
3.
4.
5.
6.
7.
8.
9.
Start engine and maintain engine speed at more than 800 rpm for at least 5 seconds.
EC
EC-699
http://vnx.su

Wiring Diagram
EBS010ZS
TBWA0608E
EC-700
http://vnx.su

A
CAUTION:
EC
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
C
1.0 - 4.0V
[Engine is running]
Warm-up condition
Idle speed
NOTE:
The pulse cycle changes depending on rpm at idle
13
L/W
E
PBIB0525E
Camshaft position
sensor (PHASE)
1.0 - 4.0V
F
[Engine is running]
G
PBIB0526E
29
Sensor ground
(Camshaft position
sensor)
[Engine is running]
Warm-up condition
Idle speed
Approximately 0V
EBS010ZT


Yes or No
Yes
>> GO TO 2.
No
EC-701
http://vnx.su


1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 3.
NG
EC-702
http://vnx.su

3. CHECK CAMSHAFT POSITION (CMP) SENSOR (PHASE) POWER SUPPLY CIRCUIT

1.
2.
Disconnect camshaft position (CMP) sensor (PHASE) harness

connector.
EC
D
PBIB0496E
3.
Check voltage between CMP sensor (PHASE) terminal 1 and


OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
PBIB0664E

Harness for open or short between camshaft position sensor (PHASE) and ECM
Harness for open or short between camshaft position sensor (PHASE) and ECM relay
5. CHECK CMP SENSOR (PHASE) GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.


OK or NG
OK
>> GO TO 6.
NG
EC-703
http://vnx.su

6. CHECK CMP SENSOR (PHASE) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

OK or NG
OK
>> GO TO 7.
NG

OK or NG
OK
>> GO TO 8.
NG


OK or NG
OK
>> GO TO 9.
NG
PBIB0565E

>> INSPECTION END
EC-704
http://vnx.su

EBS010ZU

1.
2.
3.
4.

Disconnect camshaft position sensor (PHASE) harness connector.
Remove the sensor.
EC
E
PBIB0563E
5.

3 (+) - 1 (-)
3 (+) - 2 (-)
Except 0 or
2 (+) - 1 (-)
I
MBIB0024E
EBS010ZV
Refer to EM-56, "CAMSHAFT" .

K
EC-705
http://vnx.su
DTC P0500 VSS

DTC P0500 VSS

Description
PFP:32702
EBS010ZW
NOTE:
If DTC P0500 is displayed with DTC U1000 or U1001, first perform the trouble diagnosis for DTC U1000,
The vehicle speed signal is sent to the combination meter from the ESP/TCS/ABS control unit (with ESP
models) ABS actuator and electric unit (control unit) (without ESP models) through CAN communication line.
The combination meter then sends a signal to the ECM through CAN communication line.

DTC No.
P0500
0500
EBS010ZX
The almost 0 km/h (0 MPH) signal from

vehicle speed sensor is sent to ECM
even when vehicle is being driven.
Possible cause
shorted.)
ESP/TCS/ABS control unit (with ESP models)

(without ESP models)
Wheel sensor
Combination meter
EBS010ZY
CAUTION:
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.
5.
Start engine.
Read VHCL SPEED SE in DATA MONITOR mode with CONSULT-II. The vehicle speed on CONSULTII should exceed 10 km/h (6 MPH) when rotating wheels with suitable gear position.
Warm engine up to normal operating temperature.
ENG SPEED
M/T: 2,000 - 6,000 rpm

A/T: 1,750 - 6,000 rpm
COOLAN TEMP/S
B/FUEL SCHDL
QR20DE
4.9 - 31.8 msec
QR25DE
M/T: 5.0 - 31.8 msec

A/T: 6.0 - 31.8 msec
Selector lever
Suitable position
PW/ST SIGNAL
OFF
6.
EC-706
http://vnx.su
SEF196Y
DTC P0500 VSS

EBS010ZZ
Use this procedure to check the overall function of the vehicle speed signal circuit. During this check, a 1st trip
WITHOUT CONSULT-II
1.
2.
3.
4.
EC
Lift up drive wheels.

Start engine.
Read vehicle speed with combination meter.
The vehicle speed indication should be able to exceed 10 km/h (6 MPH) when rotating wheels with suitable gear position.
EBS01100
1. CHECK DTC WITH ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) (WITHOUT ESP
MODELS) OR ESP/TCS/ABS CONTROL UNIT (WITH ESP MODELS)
Refer to BRC-11, "TROUBLE DIAGNOSIS" (Models without ESP) or BRC-58, "TROUBLE DIAGNOSIS"
(Models with ESP).
OK or NG
OK
>> GO TO 2.
NG

H

>> INSPECTION END
EC-707
http://vnx.su


PFP:49763
EBS01101
Power steering pressure (PSP) sensor is installed to the power

steering high-pressure tube and detects a power steering load. This
sensor is a potentiometer which transforms the power steering load
into output voltage, and emits the voltage signal to the ECM. The
ECM controls the electric throttle control actuator and adjusts the
throttle valve opening angle to increase the engine speed and
adjusts the idle speed for the increased load.
PBIB0502E
EBS01102

MONITOR ITEM
PW/ST SIGNAL
CONDITION

the engine
SPECIFICATION
OFF
ON
EBS01103

NOTE:
DTC No.
P0550
0550

sensor circuit
Possible cause
An excessively low or high voltage from the

sensor is sent to ECM.
EBS01104
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

.
SEF058Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-708
http://vnx.su

Wiring Diagram
EBS01105
EC
TBWA0610E
EC-709
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
[Engine is running]
12

sensor
[Engine is running]
DATA (DC Voltage)
0.5 - 4.0V
0.4 - 0.8V
[Engine is running]
57
65
Sensor ground
Sensor power supply

(Power steering pressure sensor)
Warm-up condition
Idle speed
Approximately 0V
Approximately 5V
EBS01106

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-710
http://vnx.su

2. CHECK PSP SENSOR POWER SUPPLY CIRCUIT

1.
2.
Disconnect PSP sensor harness connector.

EC
D
PBIB0502E
3.
Check voltage between PSP sensor terminal 3 and ground with

F
OK or NG
OK
>> GO TO 3.
NG
SEF509Y
3. CHECK PSP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1.
2.
3.


OK or NG
OK
>> GO TO 4.
NG
4. CHECK PSP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

OK or NG
OK
>> GO TO 5.
NG
5. CHECK PSP SENSOR

OK or NG
OK
>> GO TO 6.
NG
>> Replace PSP sensor.
EC-711
http://vnx.su


>> INSPECTION END
EBS01107

1.
2.
3.

Condition
Voltage
0.5 - 4.0V
0.4 - 0.8V
MBIB0025E
EBS0128H

EC-712
http://vnx.su
DTC P0605 ECM

DTC P0605 ECM

PFP:23710
A
EBS01108

EC
D
PBIB1164E
EBS01109
This self-diagnosis has one or two trip detection logic.

DTC No.
P0605
0605

A)
B)
ECM EEP-ROM system is malfunctioning.
C)
ECM self shut-off function is malfunctioning.
Possible cause
ECM
FAIL-SAFE MODE
ECM enters fail-safe mode when malfunction A is detected.

Detected items
ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx.
5 degrees) by the return spring.
ECM deactivates ASCD operation.
Malfunction A
EBS0110A
Perform PROCEDURE FOR MALFUNCTION A first. If the DTC cannot be confirmed, perform PROCEDURE FOR MALFUNCTION B. If there is no malfunction on PROCEDURE FOR MALFUNCTION B, perform PROCEDURE FOR MALFUNCTION C.
NOTE:
PROCEDURE FOR MALFUNCTION A

With CONSULT-II
1.
2.
3.

.
SEF058Y
Without CONSULT-II
1.
2.

EC-713
http://vnx.su
DTC P0605 ECM

3.
4.

PROCEDURE FOR MALFUNCTION B

With CONSULT-II
1.
2.
3.
4.

ON.
.
SEF058Y
Without CONSULT-II
1.
2.
3.
4.


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

ON.
.
SEF058Y
Without CONSULT-II
1.
2.
3.
4.
5.

EC-714
http://vnx.su
DTC P0605 ECM

EBS0110B
1. INSPECTION START
1.
2.
3.
4.
5.
With CONSULT-II
Touch ERASE.
Is the 1st trip DTC P0605 displayed again?
Without CONSULT-II
2. Erase the Diagnostic Test Mode II (Self-diagnostic results) memory. Refer to EC-563, "HOW TO ERASE
Yes or No
Yes
>> GO TO 2.
No
>> INSPECTION END
2. REPLACE ECM
1.
2.
3.
4.
5.
EC
Replace ECM.
>> INSPECTION END
EC-715
http://vnx.su


PFP:23710
EBS0110C
Battery voltage is supplied to the ECM even when the ignition switch
is turned OFF for the ECM memory function of the DTC memory, the
air fuel ratio feedback compensation value memory, the Idle Air Volume Learning value memory, etc.
PBIB1164E

DTC No.
P1065
1065
ECM power supply circuit
EBS0110D
Possible cause
[ECM power supply (back-up) circuit is
open or shorted.]
ECM
ECM back-up RAM system does not function

properly.
EBS0110E
NOTE:
WITH CONSULT-II
1.
2.
3.
4.
5.
6.

ON.
.
SEF058Y
WITHOUT CONSULT-II
1.
2.
3.
4.
5.
6.
7.

EC-716
http://vnx.su

Wiring Diagram
EBS0110F
EC
TBWA0611E
EC-717
http://vnx.su

CAUTION:
TERMINAL
NO.
121
WIRE
COLOR
W/L
ITEM
(Back-up)
CONDITION
DATA (DC Voltage)

BATTERY VOLTAGE
(11 - 14V)
EBS0110G
1. CHECK ECM POWER SUPPLY

1.
2.
3.

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
MBIB0026E

10A fuse
Harness for open or short between ECM and battery


OK or NG
OK
>> GO TO 4.
NG
EC-718
http://vnx.su

4. PERFORM DTC CONFIRMATION PROCEDURE

With CONSULT-II
Touch ERASE.
1.
2.
3.
4.
Without CONSULT-II
Erase the Diagnostic Test Mode II (Self-diagnostic results) memory. Refer to EC-563, "HOW TO ERASE
Yes or No
Yes
>> GO TO 5.
No
>> INSPECTION END
EC
1.
2.
5. REPLACE ECM
1.
2.
3.
4.
5.
Replace ECM.
>> INSPECTION END

K
EC-719
http://vnx.su


PFP:16119
EBS0110H
The throttle position sensor detects the throttle valve position, and the opening and closing speed of the throttle valve and feeds the voltage signals to the ECM. The ECM judges the current opening angle of the throttle
valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening
angle properly in response to driving condition.
EBS0110I

DTC No.
P1121
1121

actuator

A)
Electric throttle control actuator does not function

properly due to the return spring malfunction.
B)
Throttle valve opening angle in fail-safe mode is

not in specified range.
C)
ECM detect the throttle valve is stuck open.
Possible cause
FAIL-SAFE MODE
Detected items
Malfunction A
The ECM controls the electric throttle actuator by regulating the throttle opening around the idle position.
The engine speed will not rise more than 2,000 rpm.
Malfunction B
ECM controls the electric throttle control actuator by regulating the throttle opening to 20 degrees or less.
Malfunction C
While the vehicle is driving, it slows down gradually by fuel cut. After the vehicle stops, the engine stalls.
The engine can restart in N or P position, and engine speed will not exceed 1,000 rpm or more.
EBS0110J
NOTE:
Perform PROCEDURE FOR MALFUNCTION A AND B first. If the DTC cannot be confirmed, perform
PROCEDURE FOR MALFUNCTION C.
PROCEDURE FOR MALFUNCTION A AND B

With CONSULT-II
1.
2.
3.
Turn ignition witch ON and wait at least 1 second.

6. Turn ignition switch ON and wait at least 1 second.
7. Shift selector lever to D position (A/T), 1st position (M/T) and
ON.
EC-720
http://vnx.su
SEF058Y

Without CONSULT-II
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Shift selector lever to D position (A/T), 1st position (M/T) and wait at least 3 seconds.
EC

With CONSULT-II
1.
2.
3.
4.
5.
6.

SEF058Y
Without CONSULT-II
1.
2.
3.
4.
5.
6.
7.

Start engine and let it idle for the 3 seconds.
L
EBS0110K
1.
2.

Check if a foreign matter is caught between the throttle valve
and the housing.
OK or NG
OK
>> GO TO 2.
NG
PBIB0518E
EC-721
http://vnx.su


1.
2.
3.

>> INSPECTION END
EBS0110L
EC-722
http://vnx.su


Description
PFP:16119
A
EBS0110M
NOTE:
If DTC P1122 is displayed with DTC P1121 or 1126, first perform the trouble diagnosis for DTC P1121 or EC
P1126. Refer to EC-720, "DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR" or EC-734, "DTC
P1124, P1126 THROTTLE CONTROL MOTOR RELAY" .
Electric Throttle Control Actuator consists of throttle control motor, throttle position sensor, etc.
C
D
EBS0110N

DTC No.
Possible cause
P1122
1122

performance problem
Electric throttle control function does not

operate properly.
(Throttle control motor circuit is open or
shorted.)
(Throttle control motor relay circuit is open or
shorted.)
FAIL-SAFE MODE

spring.
EBS0110O
NOTE:
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 11V when engine
is running.
WITH CONSULT-II
1.
2.
3.
4.
SEF058Y
EC-723

http://vnx.su

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

EC-724
http://vnx.su

Wiring Diagram
EBS0110P
LHD MODELS
EC
TBWA0613E
EC-725
http://vnx.su

CAUTION:
TERMINAL
NO.
3
WIRE
COLOR
W/B
ITEM
relay power supply
CONDITION
DATA (DC Voltage)

BATTERY VOLTAGE
(11 - 14V)
0 - 14V

4

(Close)
Engine stopped

PBIB1104E
0 - 14V
5

(Open)
Engine stopped

PBIB1105E
104
W/B

relay
BATTERY VOLTAGE
(11 - 14V)
0 - 1.0V
EC-726
http://vnx.su

RHD MODELS
A
EC
TBWA0614E
EC-727
http://vnx.su

CAUTION:
TERMINAL
NO.
3
WIRE
COLOR
W/B
ITEM
relay power supply
CONDITION
DATA (DC Voltage)

BATTERY VOLTAGE
(11 - 14V)
0 - 14V

4

(Close)
Engine stopped

PBIB1104E
0 - 14V
5

(Open)
Engine stopped

PBIB1105E
104
W/B

relay
BATTERY VOLTAGE
(11 - 14V)
0 - 1.0V
EC-728
http://vnx.su

EBS0110Q

1.
2.

EC
J
PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
2. CHECK THROTTLE CONTROL MOTOR RELAY SIGNAL CIRCUIT

Check voltage between ECM terminal 3 and ground under the following conditions with CONSULT-II or tester.
Ignition switch
Voltage
OFF
Approximately 0V
ON
Battery voltage
(11 - 14V)
OK or NG
OK
>> GO TO 10.
NG
>> GO TO 3.
MBIB0028E
EC-729
http://vnx.su


1.
2.

PBIB1972E
3.

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
PBIB0575E

15A fuse

1.
2.


OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

EC-730
http://vnx.su


1.
EC

OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.

OK or NG
OK
>> GO TO 13.
NG
1.
2.
3.
4.

actuator terminal
3
ECM terminal
Continuity
Should exist
Should not exist
Should not exist
Should exist
M
PBIB1992E

OK or NG
OK
>> GO TO 11.
NG
PBIB1971E
EC-731
http://vnx.su


1.
2.

the housing.
OK or NG
OK
>> GO TO 12.
NG
PBIB0518E

OK or NG
OK
>> GO TO 13.
NG
>> GO TO 14.

OK or NG
OK
>> GO TO 14.
NG

1.
2.
3.

>> INSPECTION END
EBS0110R

1.
2.

Conditions
Continuity

1 and 2
Yes
No current supply
No
3.
PBIB0098E

1.
EC-732
http://vnx.su

2.

A

3.
4.
5.

step.
EC
C
PBIB0095E
EBS0110S

EC-733
http://vnx.su


PFP:16119
EBS0110T
Power supply for the Throttle Control motor is provided to the ECM via throttle control motor relay. The throttle
control motor relay is ON/OFF controlled by the ECM. When the ignition switch is turned ON, the ECM sends
an ON signal to throttle control motor relay and battery voltage is provided to the ECM. When the ignition
switch is turned OFF, the ECM sends an OFF signal to throttle control motor relay and battery voltage is not
provided to the ECM.
EBS0110U

MONITOR ITEM
THRTL RELAY
CONDITION
SPECIFICATION
Ignition switch: ON
ON
EBS0110V

DTC No.
P1124
1124
P1126
1126

relay circuit short

relay circuit open
Possible cause
(Throttle control motor relay circuit is shorted.)
(Throttle control motor relay circuit is open.)
ECM detect the throttle control motor relay

is stuck ON.
ECM detects a voltage of power source for

throttle control motor is excessively low.
FAIL-SAFE MODE
When the DTC detected, the ECM enters fail-safe mode and the MI lights up.
spring.
EBS0110W
NOTE:

TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 8V.
With CONSULT-II
1.
2.
3.

SEF058Y
EC-734
http://vnx.su

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

EC

With CONSULT-II
1.
2.
3.
4.

F
SEF058Y
Without CONSULT-II
1.
2.
3.
4.
5.

EC-735
http://vnx.su

Wiring Diagram
EBS0110X
LHD MODELS
TBWA0615E
EC-736
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
W/B

relay power supply
104
W/B

relay
CONDITION
EC
DATA (DC Voltage)
BATTERY VOLTAGE
(11 - 14V)
BATTERY VOLTAGE
(11 - 14V)
0 - 1.0V
EC-737
http://vnx.su

RHD MODELS
TBWA0616E
EC-738
http://vnx.su

CAUTION:
TERMINAL
NO.
EC
WIRE
COLOR
ITEM
W/B

relay power supply
104
W/B

relay
CONDITION
DATA (DC Voltage)
BATTERY VOLTAGE
(11 - 14V)
BATTERY VOLTAGE
(11 - 14V)
0 - 1.0V
EBS0110Y

1.
2.

I
PBIB1972E
3.

and ground.

K
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
PBIB0575E

15A fuse
EC-739
http://vnx.su


1.
2.


OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.


1.

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.


OK or NG
OK
>> GO TO 8.
NG

>> INSPECTION END
EC-740
http://vnx.su

EBS0110Z

1.
2.

EC
Conditions
Continuity

1 and 2
Yes
No current supply
No
3.

D
PBIB0098E
EC-741
http://vnx.su


PFP:16119
EBS01110
EBS01111

DTC No.
P1128
1128

circuit short

ECM detects short both circuits between ECM
and throttle control motor.
Possible cause
(Throttle control motor circuit is shorted.)

(Throttle control motor)
FAIL-SAFE MODE
spring.
EBS01112
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF058Y
WITHOUT CONSULT-II
1.
2.
3.
4.
5.

EC-742
http://vnx.su

Wiring Diagram
EBS01113
LHD MODELS
EC
TBWA0617E
EC-743
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
0 - 14V
4

(Close)
Engine stopped

PBIB1104E
0 - 14V
5

(Open)
Engine stopped

PBIB1105E
EC-744
http://vnx.su

RHD MODELS
A
EC
TBWA0618E
EC-745
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
0 - 14V
4

(Close)
Engine stopped

PBIB1104E
0 - 14V
5

(Open)
Engine stopped

PBIB1105E
EC-746
http://vnx.su

EBS01114

1.
2.

EC
J
PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-747
http://vnx.su

1.
2.
3.

actuator terminal
ECM terminal
Continuity
Should exist
Should not exist
Should not exist
Should exist
PBIB1992E

OK or NG
OK
>> GO TO 3.
NG
PBIB1971E

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 5.

OK or NG
OK
>> GO TO 5.
NG

1.
2.
3.

>> INSPECTION END
EBS01115

1.
EC-748
http://vnx.su

2.

A

3.
4.
5.

step.
EC
C
PBIB0095E
EBS01116

EC-749
http://vnx.su


Description
PFP:47850
EBS01117
EBS01118
DTC No.
P1211
1211

TCS control unit

Possible cause
TCS related parts
EBS01119
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.

.
SEF058Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EBS0111A
EC-750
http://vnx.su


Description
PFP:47850
A
EBS0111B
NOTE:
If DTC P1212 is displayed with DTC U1000 or U1001, first perform the trouble diagnosis for DTC U1000, EC
Be sure to erase the malfunction information such as DTC not only for ESP/TCS/ABS control unit but C
EBS0111C
DTC No.
P1212
1212
TCS communication
line
ECM can not receive the information

from ESP/TCS/ABS control unit continuously.
Possible cause
shorted.)
Dead (Weak) battery
EBS0111D
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10.5V at idle.
WITH CONSULT-II
1.
2.
3.
4.

If a 1st trip DTC is detected, go to EC-751, "Diagnostic Procedure" .
L
SEF058Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EBS01FFD
EC-751
http://vnx.su


System Description
PFP:00000
EBS0111F
NOTE:
If DTC P1217 is displayed with DTC U1000, U1001, first perform the trouble diagnosis for DTC U1000,
COOLING FAN CONTROL

Sensor
Wheel
sensor*1
Input Signal to ECM
ECM function
Actuator
Vehicle speed

Engine speed*2
Battery
Battery voltage*2
Cooling fan
control
Cooling fan relay
*1: This signal is sent to ECM through CAN communication line.

The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, refrigerant
pressure, and air conditioner ON signal. The control system has 3-step control [HIGH/LOW/OFF].
OPERATION
PBIB1987E
EC-752
http://vnx.su

EBS0111G

MONITOR ITEM
AIR COND SIG
CONDITION

the engine

the engine
COOLING FAN
SPECIFICATION
OFF

ON

(201F) or less
OFF

(210F) or more
LOW

(212F) or more
HIGH
EC
EBS0111H
If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will
rise. When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction
is indicated.
DTC No.
P1217
1217
Engine over temperature (Overheat)
shorted.)
Cooling fan
Cooling fan relays
Radiator hose

Radiator
Radiator cap

range.
Water pump
Thermostat
Cooling fan system does not operate properly (Overheat).
Possible cause

CAUTION:
When a malfunction is indicated, be sure to replace the coolant. Refer to CO-9, "Changing Engine
Coolant" . Also, replace the engine oil. Refer to LU-8, "Changing Engine Oil" .
1. Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure to
use coolant with the proper mixture ratio. Refer to MA-19, "Engine Coolant Mixture Ratio" .
2. After refilling coolant, run engine to ensure that no water-flow noise is emitted.
EBS0111I
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could be caused by high pressure fluid escaping from the radiator.
Wrap a thick cloth around cap. Carefully remove the cap by turning it a quarter turn to allow built-up
pressure to escape. Then turn the cap all the way off.
EC-753
http://vnx.su

WITH CONSULT-II
1.
2.
3.

SEF621W
4.
5.

MBIB0037E
WITHOUT CONSULT-II
1.

3. Start engine.
CAUTION:
4. Set temperature control dial to full cold position.
CAUTION:
harness connector.
SEF621W
SEC163BA
EC-754
http://vnx.su

CAUTION:
EC
C
MEC475B
EC-755
http://vnx.su

Wiring Diagram
EBS0111J
LHD MODELS
TBWA0619E
EC-756
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
[Engine is running]
89
[Engine is running]
97
PU
DATA (DC Voltage)

BATTERY VOLTAGE
(11 - 14V)
0 - 1.0V
BATTERY VOLTAGE
(11 - 14V)
E
0 - 1.0V
EC-757
http://vnx.su

RHD MODELS
TBWA0620E
EC-758
http://vnx.su

CAUTION:
TERMINAL
NO.
EC
WIRE
COLOR
ITEM
CONDITION
[Engine is running]
89
[Engine is running]
97
PU
DATA (DC Voltage)
BATTERY VOLTAGE
(11 - 14V)
0 - 1.0V
BATTERY VOLTAGE
(11 - 14V)
E
0 - 1.0V
EBS0111K
1. INSPECTION START
Yes or No
Yes
>> GO TO 2.
No
>> GO TO 4.

I
With CONSULT-II
2. Perform COOLING FAN in ACTIVE TEST mode with CONSULT-II and touch LOW on the CONSULT-II screen.
OK or NG
OK
>> GO TO 3.
NG
SEF784Z

With CONSULT-II
Touch HIGHon the CONSULT-II screen.
Make sure that cooling fan-2 operate at higher speed than low
speed.
OK or NG
OK
>> GO TO 6.
NG
1.
2.
SEF785Z
EC-759
http://vnx.su


1.
2.
3.
4.
5.
Without CONSULT-II
PBIB1972E

OK or NG
OK
>> GO TO 5.
NG
SEC163BA

Without CONSULT-II
2. Reconnect cooling fan relay-3.
5. Connect 150 resistor to engine coolant temperature sensor harness connector.
6. Restart engine and make sure that cooling fan-2 operates at
OK or NG
OK
>> GO TO 6.
NG
MEC475B
EC-760
http://vnx.su

EC
CAUTION:
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.
E
SLC756AA

Hose
Radiator
pressure.
Radiator cap
relief pressure:
59 - 98 kPa (0.59 - 0.98 bar, 0.6 - 1.0

kg/cm2 , 9 - 14 psi)
K
OK or NG
OK
>> GO TO 9.
NG
L
SLC755AC
EC-761
http://vnx.su

9. CHECK THERMOSTAT
1.
2.
3.
Remove thermostat.
Valve opening
temperature:
Valve lift:
82 C (180 F) [standard]
More than 8 mm/95 C (0.31 in/203 F)
4.
Check if valve is closed at 5C (9F) below valve opening temperature.

For details, refer to CO-23, "THERMOSTAT AND WATER CONTROL VALVE" .
OK or NG
OK
>> GO TO 10.
NG

OK or NG
OK
>> GO TO 11.
NG

>> INSPECTION END
EC-762
http://vnx.su
SLC343

PROCEDURE A
A

1.
2.
3.

EC
E
PBIB1972E
4.


G
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
PBIB0577E

10A fuse
40A fusible links
M
EC-763
http://vnx.su

1.
2.
3.

2 and ground.
4.
5.

4 and ground.

OK or NG
OK
>> GO TO 4.
NG
1.
2.


OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.


OK or NG
OK
>> GO TO 7.
NG

OK or NG
OK
>> GO TO 8.
NG
EC-764
http://vnx.su
PBIB0504E


EC
>> INSPECTION END
PROCEDURE B
1.
2.
3.

PBIB1972E
4.
Check voltage between cooling fan relay-3 terminals 1, 3 and


OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
J
PBIB0251E

1.
2.
3.

Disconnect cooling fan motor-2 harness connector.
3 and cooling fan relay-3 terminal 6, cooling fan relay-3 terminal
7 and ground.

OK or NG
OK
>> GO TO 4.
NG
EC-765
http://vnx.su
PBIB0504E

1.
2.


OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

6. CHECK COOLING FAN RELAYS-3

OK or NG
OK
>> GO TO 7.
NG

>> INSPECTION END

Engine
Step
OFF
Inspection item
Blocked radiator
Blocked condenser
Blocked bumper
EBS0111L
Equipment
Standard
Reference page
Visual
No blocking
Coolant mixture
Coolant tester
See MA-19 .
Coolant level
Visual

See CO-9 .
Radiator cap
Pressure tester
59 - 98 kPa
(0.59 - 0.98 bar, 0.6 - 1.0
See CO-13 .

ON*2
Coolant leaks
Visual
No leaks
See CO-9 .
ON*2
Thermostat
Touch the upper and

See CO-23 , and CO-12 .
ON*1
Cooling fan
CONSULT-II
Operating

DTC P1217 (EC-752 ).
OFF
Combustion gas leak

Negative
EC-766
http://vnx.su

Engine
Step
ON*3
OFF*4
OFF
10
Inspection item
Equipment
Standard
Reference page
Coolant temperature
gauge
Visual
Gauge less than 3/4

when driving
Coolant overflow to
reservoir tank
Visual

and idling
See CO-9 .
Coolant return from

Visual

reservoir tank
See CO-9 .
EC
11
Cylinder head

gauge
See EM-70 .
12
Visual
walls or piston
See EM-86 .

F
EBS0111M
COOLING FAN RELAYS-1 AND -3

G

Conditions
Continuity
Yes
No current supply
No
SEF745U
COOLING FAN MOTOR-1

1.
2.

check operation.
Terminals
Cooling fan motor
(+)
(-)
PBIB1999E
COOLING FAN MOTOR-2

1.
2.

check operation.
Terminals
Speed
Cooling fan motor
(+)
(-)
Low
High
1, 2
3, 4
SEF734W
EC-767
http://vnx.su
DTC P1225 TP SENSOR

DTC P1225 TP SENSOR

PFP:16119
EBS0111N

PBIB0145E
EBS0111O

DTC No.
P1225
1225

problem
Closed throttle position learning value is excessively

low.
Possible cause

(TP sensor 1 and 2)
EBS0111P
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.
5.

.
SEF058Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-768
http://vnx.su
DTC P1225 TP SENSOR

EBS0111Q
1.
2.
3.

the housing.
OK or NG
OK
>> GO TO 2.
NG
EC
E
PBIB0518E
1.
2.
3.

>> INSPECTION END
EBS0111R

EC-769
http://vnx.su
DTC P1226 TP SENSOR

DTC P1226 TP SENSOR

PFP:16119
EBS0111S

PBIB0145E
EBS0111T

DTC No.
P1226
1226

problem
Closed throttle position learning is not performed

successfully, repeatedly.
Possible cause

(TP sensor 1 and 2)
EBS0111U
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.
5.
6.

.
SEF058Y
WITHOUT CONSULT-II
1.
2.
3.
4.
5.

EC-770
http://vnx.su
DTC P1226 TP SENSOR

EBS0111V
1.
2.
3.

the housing.
OK or NG
OK
>> GO TO 2.
NG
EC
E
PBIB0518E
1.
2.
3.

>> INSPECTION END
EBS0111W

EC-771
http://vnx.su


PFP:16119
EBS0111X

DTC No.
P1229
1229
Sensor power supply circuit

short
ECM detects a voltage of power source

for sensor is excessively low or high.
Possible cause
(PSP sensor circuit is shorted.)
(Refrigerant pressure sensor circuit is
shorted.)

(APP sensor 1)
FAIL-SAFE MODE
spring.
EBS0111Y
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.

SEF058Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-772
http://vnx.su

Wiring Diagram
EBS0111Z
EC
TBWB0262E
EC-773
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
46
Sensor power supply

(Refrigerant pressure
sensor)
Approximately 5V
65
Sensor power supply

(Power steering pressure sensor)
Approximately 5V
90
Sensor power supply

Approximately 5V
EBS01120

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-774
http://vnx.su

2. CHECK ACCELERATOR PEDAL POSITION SENSOR 1 POWER SUPPLY CIRCUIT

1.
2.
Disconnect accelerator pedal position sensor (APP) sensor harness connector.

EC
D
PBIB0498E
3.

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.
PBIB0914E
3. CHECK SENSOR POWER SUPPLY CIRCUIT

Check harness for short to power and short to ground, between the following terminals
ECM terminal
Sensor terminal
90
EC-837
46
Refrigerant pressure sensor terminal 3
EC-912
65
PSP sensor terminal 3
EC-709
OK or NG
OK
>> GO TO 4.
NG
4. CHECK COMPONENTS
Refrigerant pressure sensor (Refer to ATC-94, "COMPONENT INSPECTION" .)
Power steering pressure sensor (Refer to EC-712, "Component Inspection" .)

OK or NG
OK
>> GO TO 7.
NG
5. CHECK APP SENSOR

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.
EC-775
http://vnx.su


1.
2.
3.
4.

>> INSPECTION END

>> INSPECTION END
EC-776
http://vnx.su


PFP:25551
A
EBS01FB3
EC
E
PBIB2877E
1.
2.
4.
SET/COAST switch
5.
MAIN switch
3.
CANCEL switch
EBS01FB4

MONITOR ITEM
MAIN SW
CANCEL SW
RESUME/ACC SW
SET SW
CONDITION
Ignition switch: ON
Ignition switch: ON
Ignition switch: ON
Ignition switch: ON
SPECIFICATION
ON
OFF
ON
OFF
Pressed
ON
Released
OFF
ON
OFF
EBS01FB5

NOTE:
DTC No.
P1564
1564
Trouble Diagnosis
Name
ASCD steering
switch
Possible Cause

ECM detects that input signal from the ASCD

steering switch is out of the specified range.

stuck ON.
ECM
EC-777
http://vnx.su

EBS01FB6
NOTE:
WITH CONSULT-II
1.
2.
3.
4.
5.
6.
7.
8.

WITHOUT CONSULT-II
1.
2.
3.
4.
5.
6.
7.
8.
9.

EC-778
http://vnx.su

Wiring Diagram
EBS01FFE
LHD MODELS
EC
TBWB0463E
EC-779
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running]
57
Sensor ground
Warm-up condition
Idle speed
99
W/R
EC-780
http://vnx.su
Approximately 0V
Approximately 4V
Approximately 0V
Approximately 1V
Approximately 3V
Approximately 2V

RHD MODELS
A
EC
TBWB0464E
EC-781
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running]
57
Sensor ground
Warm-up condition
Idle speed
99
W/R
EC-782
http://vnx.su
Approximately 0V
Approximately 4V
Approximately 0V
Approximately 1V
Approximately 3V
Approximately 2V

EBS01FB8

1.
2.

Loosen and retighten three ground screws on the body. Refer to EC-629, "Ground Inspection" .
EC
J
PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-783
http://vnx.su


With CONSULT-II
Select MAIN SW, RESUME/ACC SW, SET SW and CANCEL SW in DATA MONITOR mode with
CONSULT-II.
1.
2.
Switch
Monitor item
MAIN switch
MAIN SW
CANCEL switch
CANCEL SW
RESUME/ACCELERARE switch
RESUME/ACC SW
Condition
Indication
Pressed
ON
Released
OFF
Pressed
ON
Released
OFF
Pressed
ON
Released
OFF
Pressed
ON
Released
OFF
SEC006D
SET/COAST switch
1.
2.
SET SW
Without CONSULT-II
Check voltage between ECM terminal 99 and ground with pressing each button.
Switch
MAIN switch
CANCEL switch
RESUME/ACCELERATE
switch
SET/COAST switch
Condition
Voltage [V]
Pressed
Approx. 0
Released
Approx. 4
Pressed
Approx. 1
Released
Approx. 4
Pressed
Approx. 3
Released
Approx. 4
Pressed
Approx. 2
Released
Approx. 4
PBIB0311E
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 3.
1.
2.
3.
4.

Disconnect ASCD steering switch (1) harness connector M205.

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
PBIB2879E
EC-784
http://vnx.su

EC
1.

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.


OK or NG
OK
>> GO TO 8.
NG

>> INSPECTION END
EC-785
http://vnx.su

EBS01FB9

1.
2.
Disconnect ASCD steering switch harness connector M205.

Switch
MAIN switch
CANCEL switch
RESUME/ACCELERATE
switch
SET/COAST switch
Condition
Resistance []
Pressed
Approx. 0
Released
Approx. 4,000
Pressed
Approx. 250
Released
Approx. 4,000
Pressed
Approx. 1,480
Released
Approx. 4,000
Pressed
Approx. 660
Released
Approx. 4,000
EC-786
http://vnx.su
PBIB2202E


PFP:25320
A
EBS01FBA

EC
D
SEC009D
EBS01FBB

MONITOR ITEM
CONDITION
BRAKE SW1
(ASCD brake switch)
BRAKE SW2
(Stop lamp switch)
Ignition switch: ON
Ignition switch: ON
SPECIFICATION

Fully released
ON

Slightly depressed
OFF
OFF
ON
H
EBS01FBC

NOTE:
This self-diagnosis has the one trip detection logic. When malfunction A is detected, DTC is not
stored in ECM memory. And in that case, 1st trip DTC and 1st trip freeze frame data are displayed.
1st trip DTC is erased when ignition switch OFF. And even when malfunction A is detected in two
consecutive trips, DTC is not stored in ECM memory.
DTC No.
Trouble Diagnosis
Name
A)
P1572
1572
When the vehicle speed is above 30km/h

(19 MPH), ON signals from the stop lamp
switch and the ASCD brake switch are sent
to ECM at the same time.
ASCD brake switch

B)
ASCD brake switch signal is not sent to

ECM for extremely long time while the vehicle is driving
EC-787
http://vnx.su
Possible Cause
(The stop lamp switch circuit is shorted.)
(The ASCD brake switch circuit is shorted.)
(The ASCD clutch switch circuit is shorted.)
(M/T models)
Stop lamp switch
ASCD brake switch
ASCD clutch switch

(M/T models)

(M/T models)
ECM

EBS01FBD
CAUTION:
NOTE:
Procedure for malfunction B is not described here. It takes extremely long time to complete procedure for
malfunction B. By performing procedure for malfunction A, the incident that causes malfunction B can be
detected.
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.
Start engine (EPS switch OFF).

Press MAIN switch and make sure that CRUISE indicator lights
up.
VHCL SPEED SE
Shift lever
Suitable position
5.

.
If 1st trip DTC is not detected, go to the following step.
Drive the vehicle for at least 5 consecutive seconds under the following condition.
VHCL SPEED SE
Shift lever
Suitable position
Driving location

the above-mentioned vehicle speed.
6.
PBIB2386E
EBS01FHM
Use this procedure to check the overall function of the ASCD brake switch circuit. During this check, a 1st trip
WITHOUT CONSULT-II
1.
2.

Check voltage between ECM terminal 108 (ASCD brake switch
signal) and ground under the following conditions.
A/T models
CONDITION
VOLTAGE
Approximately 0V
Brake pedal: Fully relased
Battery voltege
M/T models
CONDITION
VOLTAGE
MBIB0061E
Approximately 0V
Battery voltage
3.

EC-788
http://vnx.su

4.
Check voltage between ECM terminal 101 (Stop lamp switch

CONDITION
VOLTAGE
Approximately 0V
Brake pedal: Slightly deprassed
Battery voltage
5.
EC

C
PBIB1677E
EC-789
http://vnx.su

Wiring Diagram
EBS01FBE
TBWA0756E
EC-790
http://vnx.su

CAUTION:
TERMINAL
NO.
EC
WIRE
COLOR
ITEM
CONDITION
101
Stop lamp switch
DATA (DC Voltage)
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
108
GY/L
ASCD brake switch

Slightly depressed

Fully released
Approximately 0V
E
BATTERY VOLTAGE
(11 - 14V)
F
EBS01FBG
With CONSULT-II
A/T models
I
CONDITION
INDICATION
OFF
ON
M/T models
CONDITION
INDICATION
OFF
ON
SEC011D
1.
2.
Without CONSULT-II
A/T models
CONDITION
VOLTAGE
Approximately 0V
Battery voltage
M/T models
CONDITION
VOLTAGE
Approximately 0V
Battery voltage
OK or NG
OK
>> GO TO 2.
NG
>> GO TO 3.
EC-791
http://vnx.su
MBIB0061E


1.
2.
With CONSULT-II
CONDITION
INDICATION
OFF
ON
SEC013D
Without CONSULT-II
CONDITION
VOLTAGE
Approximately 0V
Battery voltage
OK or NG
OK
>> GO TO 15.
NG
>> GO TO 11.
MBIB0060E

1.
2.
3.

SEC009D
4.

OK or NG
OK
>> GO TO 9.
PBIB0857E
EC-792
http://vnx.su

10A fuse
EC

1.
2.
3.
4.


OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.
H
PBIB0799E
10A fuse
1.
2.


OK or NG
OK
>> GO TO 8.
NG

OK or NG
OK
>> GO TO 15.
NG
EC-793
http://vnx.su

1.
2.
3.


OK or NG
OK
>> GO TO 10.
NG

OK or NG
OK
>> GO TO 15.
NG

1.
2.

PBIB0498E
3.
PBIB2284E

OK or NG
OK
>> GO TO 13.
NG
>> GO TO 12.
EC-794
http://vnx.su

15A fuse
1.
2.

EC

OK or NG
OK
>> GO TO 14.
NG

H

OK or NG
OK
>> GO TO 15.
NG

>> INSPECTION END
EC-795
http://vnx.su

EBS01FBH
ASCD BRAKE SWITCH

1.
2.
3.

Condition

Continuity
Should exist
Should not exist

SEC023D
ASCD CLUTCH SWITCH

1.
2.
3.

Condition

Continuity
Should exist
Should not exist

SEC024D
STOP LAMP SWITCH

1.
2.
3.

PBIB2285E
Condition
Continuity
Should not exist
Should exist
EC-796
http://vnx.su


PFP:31036
A
EBS01FBI
control unit (models with ESP) or ABS actuator and electric unit (control unit)(models without ESP), and the EC
other is from TCM (Transmission control module).
The ECM uses these signals for ASCD control. Refer to EC-965, "AUTOMATIC SPEED CONTROL DEVICE
(ASCD)" for ASCD functions.
C
EBS01FBJ

NOTE:
If DTC P1574 is displayed with DTC U1000 or U1001, first perform the trouble diagnosis for DTC
U1000, U1001. Refer to EC-630, "DTC U1000, U1001 CAN COMMUNICATION LINE" .
Refer to EC-706, "DTC P0500 VSS" .
Refer to EC-713, "DTC P0605 ECM" .
DTC No.
Trouble Diagnosis
Name
Possible Cause
P1574
1574
ASCD vehicle speed

sensor
ECM detects a difference between two vehicle

speed signals is out of the specified range.
shorted)
TCM

Combination meter
Wheel sensor
Revolution sensor
ECM
L
EBS01FBK
CAUTION:
NOTE:
TESTING CONDITION:
EC-797
http://vnx.su

WITH CONSULT-II
1.
2.
3.
4.

Drive the vehicle at more than 40 km/h (25 MPH).
PBIB2673E
WITHOUT CONSULT-II
1.
2.
3.
4.
5.
6.
Start engine.
Drive the vehicle at more than 40 km/h (25MPH) for at least 5 seconds.
Stop vehicle.
EBS01FBL

Check DTC with TCM.
Refer to AT-242, "ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION" .
OK or NG
OK
>> GO TO 2.
NG
OK or NG
OK
>> GO TO 3.
NG

>> INSPECTION END
EC-798
http://vnx.su


PFP:32006
A
EBS018LJ
When the shift lever position is P or N (A/T), Neutral (M/T), park/neutral position (PNP) switch is ON.
ECM detects the position because the continuity of the line (the ON signal) exists.
EC
EBS018LK

MONITOR ITEM
P/N POSI SW
C
CONDITION
Ignition switch: ON
SPECIFICATION
ON
OFF

DTC No.
P1706
1706
EBS018LL
The signal of the park/neutral position (PNP)

switch is not changed in the process of
engine starting and driving.
Possible cause
(PNP switch circuit is open or shorted.)

EBS018LM
CAUTION:
NOTE:
WITH CONSULT-II
1.
2.
ON
OFF

ENG SPEED
1,500 - 6,375 rpm
COOLAN TEMP/S
B/FUEL SCHDL
3.0 - 31.8 msec
VHCL SPEED SE
Selector lever
Suitable position
6.
Known-good signal
N or P position (A/T)
3.
4.
5.

Select P/N POSI SW in DATA MONITOR mode with CONSULT-II. Then check the P/N POSI SW signal under the following conditions.
Position (Selector lever)

.
L
SEF212Y
SEF213Y
EBS018LN
Use this procedure to check the overall function of the park/neutral position (PNP) switch circuit. During this
check, a 1st trip DTC might not be confirmed.
EC-799
http://vnx.su

WITHOUT CONSULT-II
1.
2.

Check voltage between ECM terminal 102 (PNP switch signal)
and body ground under the following conditions.
Condition (Gear position)
Voltage V (Known-good data)
P or N position (A/T)
Approx. 0
A/T: Battery voltage

M/T: Approximately 5V
3.

MBIB0029E
EC-800
http://vnx.su

Wiring Diagram
EBS018LO
EC
TBWA0622E
EC-801
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
102
G/OR
PNP switch
DATA (DC Voltage)
Approximately 0V
A/T models
BATTERY VOLTAGE
(11 - 14V)
M/T models
Approximately 5V
EBS018LP

1.
2.
3.

Disconnect PNP switch harness connector.
Check harness continuity between PNP switch terminal 2 and ground.

OK or NG
OK
>> GO TO 2.
NG
1.
2.
3.

Disconnect combination meter harness connector.
Check harness continuity between PNP switch terminal 1 and ECM terminal 102, combination meter terminal 55. Refer to Wiring Diagram.

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

Harness for open or short between PNP switch and combination meter
EC-802
http://vnx.su

4. CHECK PNP SWITCH
Refer to AT-408, "Park/Neutral Position (PNP) Switch"

SWITCH" (M/T).
OK or NG
OK
>> GO TO 5.
NG
>> Replace PNP switch.
(A/T) or MT-13, "PARK/NEUTRAL POSITION

EC

>> INSPECTION END

E
EC-803
http://vnx.su
DTC P1720 VSS

DTC P1720 VSS

Description
PFP:31036
EBS018OH
NOTE:
If DTC P1720 is displayed with DTC U1000, first perform the trouble diagnosis for DTC U1000. Refer to
EC-630, "DTC U1000, U1001 CAN COMMUNICATION LINE" .
control unit (models with ESP) or ABS actuator and electric unit (control unit)(models without ESP), and the
other is from TCM (Transmission control module). ECM uses these two signals for engine control.
EBS018OI

MONITOR ITEM
VEH SPEED SE
CONDITION
SPECIFICATION
Turn drive wheels and compare the CONSULT-II value with speedometer
indication

EBS018OJ

DTC No.
P1720
1720

(A/T output)
ECM detects a difference between two

vehicle speed sensor signals is out of the
specified range.
Possible cause
shorted)
TCM

Combination meter
Wheel sensor
Revolution sensor
EBS018OK
CAUTION:
NOTE:
WITH CONSULT-II
1.
2.
3.
4.
5.

Start engine.
WITHOUT CONSULT-II
1.
2.
3.
4.
Start engine.
Stop the vehicle.
EC-804
http://vnx.su
DTC P1720 VSS

5.
6.

A
EBS018OL
EC
Check DTC with TCM. Refer to AT-6, "TROUBLE DIAGNOSIS INDEX" .

OK or NG
OK
>> GO TO 2.
NG

OK or NG
OK
>> GO TO 3.
NG
Check combination meter function. Refer to DI-4, "COMBINATION METERS" .

H
>> INSPECTION END

I
EC-805
http://vnx.su


Description
PFP:25320
EBS01121
Brake switch signal is applied to the ECM through the stop lamp
switch when the brake pedal is depressed. This signal is used
mainly to decrease the engine speed when the vehicle is driving.
PBIB0498E
EBS01122

MONITOR ITEM
BRAKE SW
CONDITION
Ignition switch: ON
SPECIFICATION
OFF
ON
EBS01123

DTC No.
P1805
1805
Brake switch

A brake switch signal is not sent to ECM for
extremely long time while the vehicle is driving.
Possible cause
(Stop lamp switch circuit is open or shorted.)
Stop lamp switch
FALI-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and MI lights up.
ECM controls the electric throttle control actuator by regulating the throttle opening to a small range.
Therefore, acceleration will be poor.
Vehicle condition
Driving condition
Normal
When accelerating
Poor acceleration
EBS01124
WITH CONSULT-II
1.
2.
3.
4.
5.

Fully depress the brake pedal for at least 5 seconds.
Erase the DTC with CONSULT-II.
PBIB1952E
EC-806
http://vnx.su

WITHOUT CONSULT-II
1.
2.
3.
4.
5.
6.
A
Fully depress the brake pedal at least 5 seconds.
Erase the Diagnostic Test Mode II (Self-diagnostic results) memory. Refer to EC-567, "How to Erase DiagEC
nostic Test Mode II (Self-diagnostic Results)" .
C
D
EC-807
http://vnx.su

Wiring Diagram
EBS01125
TBWA0623E
EC-808
http://vnx.su

CAUTION:
TERMINAL
NO.
EC
WIRE
COLOR
ITEM
CONDITION
101
Stop lamp switch
Brake pedal: Slightly fully depressed
DATA (DC Voltage)
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
D
EBS01126
1. CHECK STOP LAMP SWITCH CIRCUIT

1.
2.

Check the stop lamp when depressing and releasing the brake pedal.
Brake pedal
Stop lamp
Fully released
Not illuminated
Slightly depressed
Illuminated
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 2.

1.

J
L
PBIB0498E
2.
Check voltage between stop lamp switch terminal 1 and ground with CONSULT-II or tester.
PBIB2284E

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.
EC-809
http://vnx.su


15A fuse
Harness for open and short between stop lamp switch and battery
1.
2.

Check harness continuity between stop lamp switch terminal 2 and ECM terminal 101.

OK or NG
OK
>> GO TO 5.
NG

OK or NG
OK
>> GO TO 6.
NG

>> INSPECTION END
EBS01FFF
STOP LAMP SWITCH

1.
2.

PBIB0498E
EC-810
http://vnx.su

3.
A
EC
PBIB2285E
Condition
Continuity
Should not exist
Should exist
EC-811
http://vnx.su


PFP:18002
EBS01128

of the accelerator pedal assembly. The sensor detects the accelerator position and sends a signal to the ECM.
signals.
PBIB1741E
EBS01129

MONITOR ITEM
ACCEL SEN 1
ACCEL SEN 2*
CLSD THL POS
CONDITION
SPECIFICATION
Ignition switch: ON
(engine stopped)
0.5 - 1.0V
4.0 - 4.7V
Ignition switch: ON
(engine stopped)
0.3 - 1.2V
3.9 - 4.8V
ON
OFF
Ignition switch: ON
EBS0112A

NOTE:
Refer to EC-772, "DTC P1229 SENSOR POWER SUPPLY" .
DTC No.
P2122
2122


is sent to ECM.
P2123
2123


is sent to ECM.
Possible cause
shorted.)

(APP sensor 1)
FAIL-SAFE MODE
degrees.
EC-812
http://vnx.su

EBS0112B
A
NOTE:
EC
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.

F
SEF058Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-813
http://vnx.su

Wiring Diagram
EBS0112C
TBWA0624E
EC-814
http://vnx.su

CAUTION:
TERMINAL
NO.
82
83
WIRE
COLOR
R/Y
EC
ITEM
CONDITION
Sensor ground
sensor 1)
[Engine is running]
Sensor ground
sensor 2)
[Engine is running]
90
Sensor power supply

sensor 1)
91
BR/Y
Sensor power supply

sensor 2)
Warm-up condition
Idle speed
Warm-up condition
Idle speed
DATA (DC Voltage)
C
Approximately 0V
D
Approximately 0V
E
Approximately 5V
Approximately 5V
98
B/W

sensor 2
Engine stopped
G
0.15 - 0.6V
Engine stopped
1.95 - 2.4V
106

sensor 1
Engine stopped
0.5 - 1.0V
Engine stopped
3.9 - 4.7V
EC-815
http://vnx.su

EBS0112D

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-816
http://vnx.su


1.
2.

connector.
EC
D
PBIB0498E
3.

F
OK or NG
OK
>> GO TO 3.
NG
PBIB0914E

1.
2.
3.


OK or NG
OK
>> GO TO 4.
NG
1.

OK or NG
OK
>> GO TO 5.
NG
5. CHECK APP SENSOR

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.
EC-817
http://vnx.su


1.
2.
3.
4.

>> INSPECTION END

>> INSPECTION END
EBS0112E

1.
2.
3.

conditions.
Terminal
Accelerator pedal
Voltage
106
sensor 1)
Fully released
0.5 - 1.0V
Fully depressed
3.9 - 4.7V
Fully released
0.15 - 0.6V
Fully depressed
1.95 - 2.4V
98
sensor 2)
4.
5.
6.
7.
MBIB0023E

step.
EBS0112F
ACCELERATOR PEDAL
EC-818
http://vnx.su


PFP:18002
A
EBS0112G

C
D
signals.
PBIB1741E
E
EBS0112H

MONITOR ITEM
ACCEL SEN 1
ACCEL SEN 2*
CLSD THL POS
CONDITION
SPECIFICATION
Ignition switch: ON
(engine stopped)
0.5 - 1.0V
4.0 - 4.7V
Ignition switch: ON
(engine stopped)
0.3 - 1.2V
3.9 - 4.8V
ON
OFF
Ignition switch: ON
EBS0112I

DTC No.
P2127
2127
P2128
2128


is sent to ECM.


is sent to ECM.
Possible cause
(APP sensor 2 circuit is open or
shorted.)

(APP sensor 2)

(TP sensor 1 and 2)
FAIL-SAFE MODE
degrees.
The ECM regulates the opening speed of throttle valve to be shower than the normal condition.
EC-819
http://vnx.su

EBS0112J
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.

SEF058Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-820
http://vnx.su

Wiring Diagram
EBS0112K
EC
TBWB0263E
EC-821
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
47
Sensor power supply

82
R/Y
Sensor ground
sensor 1)
Warm-up condition
Idle speed
83
DATA (DC Voltage)
Approximately 5V
[Engine is running]
Approximately 0V
[Engine is running]
Sensor ground
sensor 2)
Warm-up condition
Idle speed
Approximately 0V
90
Sensor power supply

sensor 1)
Approximately 5V
91
BR/Y
Sensor power supply

sensor 2)
Approximately 5V
98
B/W

sensor 2
Engine stopped
0.15 - 0.6V
Engine stopped
1.95 - 2.4V
106

sensor 1
Engine stopped
0.5 - 1.0V
Engine stopped
EC-822
http://vnx.su
3.9 - 4.7V

EBS0112L

1.
2.

EC
J
PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-823
http://vnx.su


1.
2.

connector.
PBIB0498E
3.

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 3.
PBIB0915E

1.
2.
3.

OK or NG
OK
>> GO TO 4.
NG

ECM terminal
Sensor terminal
91
EC-821
47
EC-829
OK or NG
OK
>> GO TO 5.
NG

OK or NG
OK
>> GO TO 11.
NG
>> GO TO 6.
EC-824
http://vnx.su


1.
2.
3.

>> INSPECTION END
EC

1.
2.
3.


OK or NG
OK
>> GO TO 8.
NG
1.

OK or NG
OK
>> GO TO 9.
NG
9. CHECK APP SENSOR

OK or NG
OK
>> GO TO 11.
NG
>> GO TO 10.
1.
2.
3.
4.

>> INSPECTION END

>> INSPECTION END
EC-825
http://vnx.su

EBS0112M

1.
2.
3.

conditions.
Terminal
Accelerator pedal
Voltage
106
sensor 1)
Fully released
0.5 - 1.0V
Fully depressed
3.9 - 4.7V
Fully released
0.15 - 0.6V
Fully depressed
1.95 - 2.4V
98
sensor 2)
4.
5.
6.
7.
MBIB0023E

step.
EBS0112N
ACCELERATOR PEDAL
EC-826
http://vnx.su
DTC P2135 TP SENSOR

DTC P2135 TP SENSOR

PFP:16119
A
EBS0112O

EC
D
PBIB0145E
EBS0112P

MONITOR ITEM
CONDITION
Ignition switch: ON
(Engine stopped)
More than 0.36V
Less than 4.75V
THRTL SEN1
THRTL SEN2*
SPECIFICATION
EBS0112Q

DTC No.
P2135
2135

problem

compared with the signals from TP sensor 1
and TP sensor 2.
Possible cause
(TP sensor 1 and 2 circuit is open or
shorted.)

(TP sensor 1 and 2)

(APP sensor 2)
FAIL-SAFE MODE

degrees.
EBS0112R
NOTE:
TESTING CONDITION:
EC-827
http://vnx.su
DTC P2135 TP SENSOR

WITH CONSULT-II
1.
2.
3.
4.

SEF058Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-828
http://vnx.su
DTC P2135 TP SENSOR

Wiring Diagram
EBS0112S
EC
TBWB0264E
EC-829
http://vnx.su
DTC P2135 TP SENSOR

CAUTION:
TERMINAL NO.
47
WIRE
COLOR
R
ITEM
power supply
CONDITION
DATA (DC Voltage)

Approximately 5V
49
Engine stopped
More than 0.36V
Engine stopped
Less than 4.75V
[Engine is running]
66
Sensor ground
Warm-up condition
Idle speed
Approximately 0V
68
91
BR/Y
Sensor power supply

Less than 4.75V
EC-830
http://vnx.su
More than 0.36V
Approximately 5V
DTC P2135 TP SENSOR

EBS0112T

1.
2.

EC
J
PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-831
http://vnx.su
DTC P2135 TP SENSOR

2. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT-I

1.
2.

PBIB1992E
PBIB1971E
3.

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 3.
PBIB0082E
3. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT-II

1.
2.
3.

OK or NG
OK
>> GO TO 4.
NG
EC-832
http://vnx.su
DTC P2135 TP SENSOR

4. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT-III
ECM terminal
Sensor terminal
47
EC-829
91
EC-837
OK or NG
OK
>> GO TO 5.
NG
EC
5. CHECK APP SENSOR

OK or NG
OK
>> GO TO 11
NG
>> GO TO 6.

1.
2.
3.
4.

>> INSPECTION END
7. CHECK THROTTLE POSITION SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.


OK or NG
OK
>> GO TO 8.
NG
8. CHECK THROTTLE POSITION SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
Check harness continuity between electric throttle control actuator terminal 4 and ECM terminal 49, electric throttle control actuator terminal 2 and ECM terminal 68.

OK or NG
OK
>> GO TO 9.
NG
EC-833
http://vnx.su
DTC P2135 TP SENSOR


OK or NG
OK
>> GO TO 11.
NG
>> GO TO 10.

1.
2.
3.

>> INSPECTION END

>> INSPECTION END
EBS0112U

1.
2.
3.
4.
5.

Terminal
Accelerator pedal
Voltage
49
Fully released
More than 0.36V
Fully depressed
Less than 4.75V
68
Fully released
Less than 4.75V
Fully depressed
More than 0.36V
6.
7.
8.

step.
MBIB0022E
EBS0112V

EC-834
http://vnx.su


PFP:18002
A
EBS0112W

C
D
signals.
PBIB1741E
E
EBS0112X

MONITOR ITEM
ACCEL SEN 1
ACCEL SEN 2*
CLSD THL POS
CONDITION
SPECIFICATION
Ignition switch: ON
(engine stopped)
0.5 - 1.0V
4.0 - 4.7V
Ignition switch: ON
(engine stopped)
0.3 - 1.2V
3.9 - 4.8V
ON
OFF
Ignition switch: ON
EBS0112Y

NOTE:
DTC No.
Possible cause
P2138
2138

circuit range/performance problem

compared with the signals from APP sensor
1 and APP sensor 2.
(APP sensor 1 and 2 circuit is open
or shorted.)

(APP sensor 1 and 2)

(TP sensor 1 and 2)
FAIL-SAFE MODE
degrees.
EC-835
http://vnx.su

EBS0112Z
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.

SEF058Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-836
http://vnx.su

Wiring Diagram
EBS01130
EC
TBWB0265E
EC-837
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
47
Sensor power supply

82
R/Y
Sensor ground
sensor 1)
Warm-up condition
Idle speed
83
DATA (DC Voltage)
Approximately 5V
[Engine is running]
Approximately 0V
[Engine is running]
Sensor ground
sensor 2)
Warm-up condition
Idle speed
Approximately 0V
90
Sensor power supply

sensor 1)
Approximately 5V
91
BR/Y
Sensor power supply

sensor 2)
Approximately 5V
98
B/W

sensor 2
Engine stopped
0.15 - 0.6V
Engine stopped
1.95 - 2.4V
106

sensor 1
Engine stopped
0.5 - 1.0V
Engine stopped
EC-838
http://vnx.su
3.9 - 4.7V

EBS01131

1.
2.

EC
J
PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-839
http://vnx.su


1.
2.

connector.
PBIB0498E
3.

OK or NG
OK
>> GO TO 3.
NG
PBIB0914E

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 4.
PBIB0915E

1.
2.
3.

OK or NG
OK
>> GO TO 5.
NG
EC-840
http://vnx.su

ECM terminal
Sensor terminal
91
EC-837
47
EC-829
OK or NG
OK
>> GO TO 6.
NG
EC

OK or NG
OK
>> GO TO 12.
NG
>> GO TO 7.

1.
2.
3.

>> INSPECTION END
1.
2.
3.


OK or NG
OK
>> GO TO 9.
NG
1.

OK or NG
OK
>> GO TO 10.
NG
EC-841
http://vnx.su

10. CHECK APP SENSOR

OK or NG
OK
>> GO TO 12.
NG
>> GO TO 11.

1.
2.
3.
4.

>> INSPECTION END

>> INSPECTION END
EBS01132

1.
2.
3.

conditions.
Terminal
Accelerator pedal
Voltage
106
sensor 1)
Fully released
0.5 - 1.0V
Fully depressed
3.9 - 4.7V
Fully released
0.15 - 0.6V
Fully depressed
1.95 - 2.4V
98
sensor 2)
4.
5.
6.
7.
MBIB0023E

step.
EBS01133
ACCELERATOR PEDAL
EC-842
http://vnx.su
HO2S1 HEATER
HO2S1 HEATER
Description
PFP:22690
A
EBS01134
SYSTEM DESCRIPTION
Sensor
Input Signal to ECM

Engine speed
ECM function
Actuator

heater control
EC

heater
The ECM performs ON/OFF duty control of the heated oxygen sensor 1 heater corresponding to the engine
speed and engine coolant temperature. The duty percent varies with engine coolant temperature when engine
is started.
OPERATION
Engine speed
rpm
Above 3,600
OFF
Below 3,600
ON
EBS01135

MONITOR ITEM
HO2S1 HTR (B1)
CONDITION
SPECIFICATION
ON
H
OFF
EC-843
http://vnx.su
HO2S1 HEATER
Wiring Diagram
EBS01136
TBWA0643E
EC-844
http://vnx.su
HO2S1 HEATER
A
CAUTION:
EC
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
C
Approximately 7.0V
[Engine is running]
24
G/W
Warm-up condition.
E
PBIB0519E
[Engine is running]
BATTERY VOLTAGE
(11 - 14V)
EBS01137

1.
2.
3.
4.
5.
6.

Set tester prove between ECM terminal 24 (HO2S1 heater signal) and ground.
Verify that the oscilloscope screen shows the signal waves as
shown below.
Conditions
Voltage
Approximately 7.0V
L
At idle
MBIB0038E
PBIB0519E
Engine speed is above 3,600 rpm.
BATTERY VOLTAGE
(11 - 14V)
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
EC-845
http://vnx.su
HO2S1 HEATER

1.
2.
3.

PBIB0500E
4.

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.
PBIB0541E

10A fuse

1.
2.
3.


OK or NG
OK
>> GO TO 5.
NG

OK or NG
OK
>> GO TO 6.
NG
EC-846
http://vnx.su
HO2S1 HEATER

EC
>> INSPECTION END
EBS01138

1.

Terminal No.
Resistance
1 and 4
3.3 - 4.0 at 25C (77F)
2 and 1, 3, 4
3 and 1, 2, 4

CAUTION:


I
PBIB0542E
EBS01139

EC-847
http://vnx.su
HO2S2 HEATER
HO2S2 HEATER
Description
PFP:226A0
EBS0113A
SYSTEM DESCRIPTION
Sensor
Input Signal to ECM

Engine speed
ECM Function

heater control
Actuator
The ECM performs ON/OFF control of the heated oxygen sensor 2 heater corresponding to the engine speed,
amount of intake air and engine coolant temperature.
OPERATION
Engine speed rpm
Above 3,600
OFF
Below 3,600 rpm after the following conditions are met.
Keeping the engine speed between 3,500 and 4,000 rpm for 1
minute and at idle for 1 minute under no load
ON
EBS0113B

MONITOR ITEM
HO2S2 HTR (B1)
CONDITION
Engine speed: Below 3,600 rpm after the following conditions are met.
and at idle for 1 minute under no load
SPECIFICATION
ON
OFF
EC-848
http://vnx.su
HO2S2 HEATER
Wiring Diagram
EBS0113C
EC
TBWA0644E
EC-849
http://vnx.su
HO2S2 HEATER
CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running]
PU/R
Engine speed: Below 3,600 rpm after the following conditions are met
Warm-up condition

under no load

heater
0 - 1.0V
Engine stopped
[Engine is running]
BATTERY VOLTAGE
(11 - 14V)
EBS0113D

1.
2.
3.
4.
5.
6.

Set voltmeter proves between ECM terminal 2 (HO2S2 heater signal) and ground.
Conditions
At idle
Voltage
0 - 1V
Battery voltage
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
PBIB0673E
EC-850
http://vnx.su
HO2S2 HEATER

1.
2.
3.

EC
D
PBIB0500E
4.

F

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.
H
PBIB0541E
10A fuse

1.
2.
3.


OK or NG
OK
>> GO TO 5.
NG

OK or NG
OK
>> GO TO 6.
NG
EC-851
http://vnx.su
HO2S2 HEATER

>> INSPECTION END
EBS0113E

1.

Terminal No.
Resistance
1 and 4
5.0 - 7.0 at 25C (77F)
2 and 1, 3, 4
3 and 1, 2, 4

CAUTION:


PBIB0542E
EBS0113F

EC-852
http://vnx.su
IAT SENSOR
IAT SENSOR
PFP:22630
A
EBS0113G
the ECM.
EC
D
PBIB1604E
<Reference data>
Intake air
temperature C (F)
Voltage*
Resistance
25 (77)
3.32
1.800 - 2.200
80 (176)
1.23
0.283 - 0.359
*: This data is reference value and is measured between ECM terminal 34 (Intake air
temperature sensor) and ground.
CAUTION:
H
SEF012P
EC-853
http://vnx.su
IAT SENSOR
Wiring Diagram
EBS0113H
TBWA0645E
EC-854
http://vnx.su
IAT SENSOR
EBS0113I

1.
2.

Voltage
EC
: Approximately 0 - 4.8V
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
MBIB0041E

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 3.
NG
EC-855
http://vnx.su
IAT SENSOR

1.
2.

PBIB0495E
3.
Check voltage between mass air flow sensor terminal 5 and

ground.
OK or NG
OK
>> GO TO 4.
NG
PBIB1169E
1.
2.
3.

Check harness continuity between mass air flow sensor terminal 6 and ECM terminal 57.

OK or NG
OK
>> GO TO 5.
NG

OK or NG
OK
>> GO TO 6.
NG

>> INSPECTION END
EC-856
http://vnx.su
IAT SENSOR
EBS0113J

1.
2.

Resistance k
25 (77)
1.800 - 2.200
EC
sensor).
D
PBIB1604E
SEF012P
EBS0113K

EC-857
http://vnx.su
HO2S1
HO2S1
PFP:22690
EBS0113L

SEF463R
SEF288D
EBS0113M

MONITOR ITEM
CONDITION
0 - 0.3V Approx. 0.6 - 1.0V
HO2S1 (B1)
HO2S1 MNTR (B1)
SPECIFICATION
Maintaining engine speed at 2,000 rpm
EC-858
http://vnx.su
LEAN RICH
10 seconds.
HO2S1
Wiring Diagram
EBS0113N
EC
TBWA0646E
EC-859
http://vnx.su
HO2S1
CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running]
35
74
P/L
Sensor ground
Warm-up condition
[Engine is running]
Idle speed
Approximately 0V
EBS0113O

1.
2.

PBIB2021E
OK or NG
OK
>> GO TO 2.
NG
EC-860
http://vnx.su
HO2S1
With CONSULT-II
Select HO2S1 MNTR (B1) in DATA MONITOR mode with
CONSULT-II.
3. Keep the engine speed at 2,000 rpm under no load, and make
sure that the monitors fluctuates between LEAN and RICH more
than five times in 10 seconds.
1.
2.
EC
1 time: RICH LEAN RICH

2 times: RICH LEAN RICH LEAN RICH
E
SEF820Y
Without CONSULT-II
Set ECM in Diagnostic test mode - II (Heated oxygen sensor 1 monitor).
Refer to EC-566, "HOW TO SWITCH DIAGNOSTIC TEST MODE" .
4. Keep the engine speed at 2,000 rpm under no load, and make
sure that the MI comes ON more than five times in 10 seconds.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 3.
1.
2.
3.
J
SAT652J

1.
2.
3.
4.

terminal 3.

OK or NG
OK
>> GO TO 4.
NG
EC-861
http://vnx.su
PBIB0500E
HO2S1

1.

2.

OK or NG
OK
>> GO TO 5.
NG

OK or NG
OK
>> GO TO 6.
NG

>> INSPECTION END
EBS0113P

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

SEF646Y
6.

SEF217YA
EC-862
http://vnx.su
HO2S1
A
EC
C
SEF648Y
CAUTION:
Without CONSULT-II
1.
2.
3.

1 time: 0 - 0.3V 0.6 - 1.0V 0 - 0.3V
2 times: 0 - 0.3V 0.6 - 1.0V 0 - 0.3V 0.6 - 1.0V
0 - 0.3V
MBIB0018E
CAUTION:
EBS0113Q

M
EC-863
http://vnx.su
HO2S2
HO2S2
PFP:226A0
EBS0113R

SEF327R
EBS0113S

MONITOR ITEM
HO2S2 (B1)
HO2S2 MNTR (B1)
CONDITION

SPECIFICATION
0 - 0.3V Approx. 0.6 - 1.0V

rpm quickly.
EC-864
http://vnx.su
LEAN RICH
HO2S2
Wiring Diagram
EBS0113T
EC
TBWA0647E
EC-865
http://vnx.su
HO2S2
CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
[Engine is running]
16
OR/B
Warm-up condition


under no load
[Engine is running]
74
Sensor ground
Warm-up condition
Idle speed
Approximately 0V
EBS0113U

1.
2.
3.
4.
5.
6.

Check the voltage while revving up to 4,000 rpm under no load
at least 10 times. (Depress and release the accelerator pedal as
quickly as possible.)
The voltage does not remain in the range of 0.2 - 0.4V
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
MBIB0020E

Keep engine at idle for 10 minutes, then check the voltage between ECM terminal 16 (HO2S2 signal) and
ground, or check voltage when coasting 80 km/h (50 MPH) in 3rd gear (M/T) or D position (A/T) with OD
OFF.
The voltage does not remain in the range of 0.2 - 0.4V
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 3.
EC-866
http://vnx.su
HO2S2

1.
2.

EC
J
PBIB2021E
OK or NG
OK
>> GO TO 4.
NG
1.
2.
3.
4.

terminal 3.

OK or NG
OK
>> GO TO 5.
NG
EC-867
http://vnx.su
PBIB0500E
HO2S2

1.

2.

OK or NG
OK
>> GO TO 6.
NG

OK or NG
OK
>> GO TO 7.
NG

>> INSPECTION END
EBS0113V

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

SEF662Y
EC-868
http://vnx.su
HO2S2
6.
A
EC
PBIB0551E
CAUTION:
Without CONSULT-II
1.
2.
3.

Start engine and keep the engine speed at between 3,500 and 4,000 rpm for at least 1 minute under no
load.
4. Let engine idle for 1 minute.
5. Set voltmeter probes between ECM terminal 16 (HO2S2 signal) and ground.
6. Check the voltage when revving up to 4,000 rpm under no load
at least 10 times.
procedure.
with OD OFF (A/T). 3rd gear position (M/T).
MBIB0020E
procedure.
CAUTION:
EBS0113W

EC-869
http://vnx.su
IGNITION SIGNAL
IGNITION SIGNAL
PFP:22448
EBS0113X
IGNITION COIL & POWER TRANSISTOR

The ignition signal from the ECM is sent to and amplified by the
power transistor. The power transistor turns ON and OFF the ignition
coil primary circuit. This ON/OFF operation induces the proper high
voltage in the coil secondary circuit.
PBIB1969E
EC-870
http://vnx.su
IGNITION SIGNAL
Wiring Diagram
EBS0113Y
EC
TBWA0628E
EC-871
http://vnx.su
IGNITION SIGNAL
CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
[Engine is running]
111
G/W
ECM relay
(Self shut-off)

switch OFF
DATA (DC Voltage)
0 - 1.0V
BATTERY VOLTAGE
(11 - 14V)
119
120
SB
GY
BATTERY VOLTAGE
(11 - 14V)
121
W/L

(Back-up)
BATTERY VOLTAGE
(11 - 14V)
EC-872
http://vnx.su
IGNITION SIGNAL
A
EC
TBWA0629E
EC-873
http://vnx.su
IGNITION SIGNAL
CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
[Engine is running]
60
61
79
80
L/R
B/R
GY/R
PU

Warm-up condition
Idle speed
DATA (DC Voltage)
0 - 0.1V
NOTE:
The pulse cycle changes depending on rpm at
idle
PBIB0521E
0 - 0.2V
[Engine is running]
Warm-up condition
PBIB0522E
EBS0113Z

Turn ignition switch OFF, and restart engine.
Is engine running?
Yes or No
Yes (With CONSULT-II)>>GO TO 2.
Yes (Without CONSULT-II)>>GO TO 3.
No
>> GO TO 4.

With CONSULT-II
CONSULT-II.
speed drop.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 12.
1.
PBIB0133E
EC-874
http://vnx.su
IGNITION SIGNAL
Without CONSULT-II
Let engine idle.
Read the voltage signal between ECM terminals 60, 61, 79, 80
and ground with an oscilloscope.
3. Verify that the oscilloscope screen shows the signal wave as
shown below.
NOTE:
The pulse cycle changes depending on rpm at idle.
1.
2.
EC
E
MBIB0033E
PBIB0521E
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 12.
4. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-I

1.
2.

OK or NG
OK
>> GO TO 5.
NG
>> Go to EC-622, "POWER SUPPLY AND GROUND CIRCUIT" .
K
MBIB0034E
EC-875
http://vnx.su
IGNITION SIGNAL
5. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-II

1.
2.
3.

PBIB1969E
4.
Check voltage between condenser terminal 1 and ground with

OK or NG
OK
>> GO TO 10.
NG
>> GO TO 6.
PBIB0624E
6. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-III

1.
2.
3.

Check harness continuity between ECM relay terminal 7 and
condenser terminal 1.

OK or NG
OK
>> GO TO 7.
NG
PBIB1973E
7. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-IV

Check voltage between ECM relay terminal 6 and ground with CONSULT-II or tester.
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.
PBIB0625E
EC-876
http://vnx.su
IGNITION SIGNAL
20A fuse

9. CHECK ECM RELAY

OK or NG
OK
>> GO TO 17.
NG
10. CHECK CONDENSER GROUND CIRCUIT FOR OPEN AND SHORT

1.
2.
EC

Check harness continuity between condenser terminal 2 and ground.
Refer to Wiring diagram.

OK or NG
OK
>> GO TO 11.
NG
>> Repair open circuit or short to power in harness or connector.
11. CHECK CONDENSER

J

OK or NG
OK
>> GO TO 12.
NG
EC-877
http://vnx.su
IGNITION SIGNAL
12. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-V

1.
2.
3.
4.

PBIB1969E
5.
Check voltage between ignition coil terminal 1 and ground with

OK or NG
OK
>> GO TO 14.
NG
>> GO TO 13.
SEF107S

Check harness for open or short between ignition coil and ECM relay.
>> Repair open circuit or short to ground or short to power in harness or conectors.
14. CHECK IGNITION COIL GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.

Check harness continuity between ignition coil terminal 2 and ground.

OK or NG
OK
>> GO TO 15.
NG
15. CHECK IGNITION COIL OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.

Check harness continuity between ECM terminals 60, 61, 79, 80 and ignition coil terminal 3.

OK or NG
OK
>> GO TO 16.
NG
EC-878
http://vnx.su
IGNITION SIGNAL
16. CHECK IGNITION COIL WITH POWER TRANSISTOR

OK or NG
OK
>> GO TO 17.
NG
>> Replace ignition coil with power transistor.
EC

D
>> INSPECTION END
EBS01140
ECM RELAY
1.
2.

F
Condition
Continuity
Yes
OFF
No
3.

H
PBIB0077E
CONDENSER
1.
2.
3.

Check resistance between condenser terminals 1 and 2.
Resistance: Above 1 M at 25C (77F)

K
MBIB0031E
EC-879
http://vnx.su
IGNITION SIGNAL
1.
2.
3.

Check resistance between ignition coil terminals as follows.
Terminal No.
2 and 3
Except 0 or
1 and 2
1 and 3
Except 0
MBIB0032E
EBS01141

Refer to EM-31, "IGNITION COIL" .
EC-880
http://vnx.su


Description
PFP:14920
A
EBS01142
SYSTEM DESCRIPTION
Sensor
Input Signal to ECM

Engine speed*1
Battery
Battery voltage*1
Throttle position

Wheel sensor*2
Vehicle speed
ECM function
Actuator
EC
EVAP canister
purge flow control

This system controls flow rate of fuel vapor from the EVAP canister. The opening of the vapor by-pass passage in the EVAP canister purge volume control solenoid valve changes to control the flow rate. The EVAP
canister purge volume control solenoid valve repeats ON/OFF operation according to the signal sent from the
ECM. The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is
determined by considering various engine conditions. When the engine is operating, the flow rate of fuel vapor
from the EVAP canister is regulated as the air flow changes.
I
The EVAP canister purge volume control solenoid valve uses a ON/
OFF duty to control the flow rate of fuel vapor from the EVAP canister. The EVAP canister purge volume control solenoid valve is
moved by ON/OFF pulses from the ECM. The longer the ON pulse,
the greater the amount of fuel vapor that will flow through the valve.
L
SEF337U
EBS01143

MONITOR ITEM
CONDITION

(M/T)
No load
PURG VOL C/V
SPECIFICATION
Idle
0%
2,000 rpm
20 - 30%
EC-881
http://vnx.su

Wiring Diagram
EBS01144
TBWA0648E
EC-882
http://vnx.su

A
CAUTION:
EC
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
C
BATTERY VOLTAGE
(11 - 14V)
D
[Engine is running]
Idle speed
E
19
EVAP canister purge

volume control solenoid
valve
PBIB0050E
Approximately 10V
[Engine is running]
Engine speed is about 2,000 rpm

(More than 100 seconds after starting engine)
PBIB0520E
EC-883
http://vnx.su

EBS01145

1.
2.
3.
4.
With CONSULT-II
Disconnect the EVAP purge hose connected to the EVAP canister.
Turn ignition switch ON, and select PURG VOL CONT/V in
ACTIVE TEST mode with CONSULT-II.
PBIB0569E
5.
Change the valve opening percentage with touching Qu or

Qd on CONSULT-II screen, and check for vacuum existence at
the EVAP purge hose under the following conditions.
Conditions
(PURG VOL CONT/V)
0%
Vacuum
Should not exist.
100%
Should exist.
PBIB0676E
1.
2.
3.
4.
Without CONSULT-II
Disconnect the EVAP purge hose connected to the EVAP canister.
Check for vacuum existence at the EVAP purge hose under the
Conditions
At idle
Engine speed is about 2,000 rpm.
Vacuum
Should not exist.
Should exist.
OK or NG
OK
>> GO TO 2.
NG
>> GO TO 3.
PBIB0676E
2. CHECK EVAP CANISTER

OK or NG
OK
>> INSPECTION END
NG
>> Replace EVAP canister.
EC-884
http://vnx.su

3. CHECK EVAP PURGE LINE
Check EVAP purge line (pipe, rubber tube, fuel tank and EVAP canister) for cracks or improper connection.
Refer to EC-959, "EVAPORATIVE EMISSION LINE DRAWING" .
OK or NG
OK
>> GO TO 4.
NG
>> Repair or reconnect the hose.
4. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE POWER SUPPLY CIR-
EC
CUIT
1.
2.
3.

Disconnect EVAP canister purge volume control solenoid valve
harness connector.
G
PBIB1993E
PBIB1968E
4.
Check voltage between EVAP canister purge volume control

solenoid valve terminal 1 and ground with CONSULT-II or tester.
L

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.
PBIB0148E

Harness for open or short between EVAP canister purge volume control solenoid valve and ECM relay
Harness for open or short between EVAP canister purge volume control solenoid valve and ECM
EC-885
http://vnx.su

6. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Check harness continuity between EVAP canister purge volume control solenoid valve terminal 2 and
ECM terminal 19. Refer to Wiring Diagram.

OK or NG
NG
>> Repair open circuit or short to ground and short to power in harness or connectors.
7. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION

With CONSULT-II
2. Start engine.
3. Perform PURG VOL CONT/V in ACTIVE TEST mode with
CONSULT-II. Check that engine speed varies according to the
valve opening.
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.
PBIB0569E
8. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

OK or NG
OK
>> GO TO 9.
NG
>> Replace EVAP canister purge volume control solenoid valve.

>> INSPECTION END
EC-886
http://vnx.su

EBS01146

With CONSULT-II
Condition
(PURG VOL CONT/V)
EC

between A and B
100%
Yes
0%
No
PBIB0149E
Without CONSULT-II
Condition

between A and B
Yes
No supply
No
H
PBIB0150E
EBS01147

EC-887
http://vnx.su
INJECTOR CIRCUIT
INJECTOR CIRCUIT
PFP:16600
EBS0114I
supplies a ground to the injector circuit, the coil in the injector is
energized. The energized coil pulls the ball valve back and allows
fuel to flow through the injector into the intake manifold. The amount
of fuel injected depends upon the injection pulse duration. Pulse
duration is the length of time the injector remains open. The ECM
controls the injection pulse duration based on engine fuel needs.
SEF375Z
EBS0114J

MONITOR ITEM
B/FUEL SCHDL
CONDITION
SPECIFICATION

(M/T)
No load
INJ PULSE-B1
Idle
2.0 - 3.0 msec
2,000 rpm
1.9 - 2.9 msec
EC-888
http://vnx.su
INJECTOR CIRCUIT
Wiring Diagram
EBS0114K
EC
TBWA0630E
EC-889
http://vnx.su
INJECTOR CIRCUIT
CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)

BATTERY VOLTAGE
[Engine is running]
22
23
41
42
G/B
R/B
L/B
Y/B
Injector No. 3
Injector No. 1
Injector No. 4
Injector No. 2
Warm-up condition
Idle speed
(11 - 14V)
NOTE:
idle
PBIB0529E
BATTERY VOLTAGE
(11 - 14V)
[Engine is running]
Warm-up condition
PBIB0530E
EBS0114L
1. INSPECTION START
Turn ignition switch to START.
Is any cylinder ignited?
Yes or No
Yes
>> GO TO 2.
No
>> GO TO 3.
EC-890
http://vnx.su
INJECTOR CIRCUIT
With CONSULT-II
Start engine.
CONSULT-II.
speed drop.
1.
2.
EC
E
PBIB0133E
Without CONSULT-II
1. Start engine.

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 3.
I
PBIB1986E
3. CHECK INJECTOR POWER SUPPLY CIRCUIT

1.
2.
3.

PBIB1970E
4.
Check voltage between injector terminal 1 and ground with

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
PBIB0582E
EC-891
http://vnx.su
INJECTOR CIRCUIT

10A fuse
Harness for open or short between injector and fuse

5. CHECK INJECTOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1.
2.
3.

Check harness continuity between injector terminal 2 and ECM terminals 22, 23, 41, 42.

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.
6. DETECT MALFONCTIONING PART

Harness for open or short between injector and ECM

7. CHECK INJECTOR
OK or NG
OK
>> GO TO 8.
NG
>> Replace injector.

>> INSPECTION END
EC-892
http://vnx.su
INJECTOR CIRCUIT
EBS0114M
INJECTOR
1.
2.

Check resistance between terminals as shown in the figure.
EC
Resistance: 13.5 - 17.5 [at 10 - 60C (50 - 140F)]
PBIB1727E
EBS0114N
INJECTOR
EC-893
http://vnx.su
VIAS
VIAS
Description
PFP:14956
EBS011I0
SYSTEM DESCRIPTION
Sensor
Input Signal to ECM

Engine speed*
Throttle position
Battery
Battery voltage*
ECM function
VIAS control
Actuator
*: The ECM determines the start signal status by the signals of engine speed and battery voltage.
PBIB0843E
When the engine is running at low or medium speed, the power valve is fully closed. Under this condition, the
effective suction port length is equivalent to the total length of the intake manifold collector's suction port
including the intake valve. This long suction port provides increased air intake which results in improved suction efficiency and higher torque generation.
The surge tank and one-way valve are provided. When engine is running at high speed, the ECM sends the
signal to the VIAS control solenoid valve. This signal introduces the intake manifold vacuum into the power
valve actuator and therefore opens the power valve to two suction passages together in the collector.
Under this condition, the effective port length is equivalent to the length of the suction port provided independently for each cylinder. This shortened port length results in enhanced engine output with reduced suction
resistance under high speeds.
Power Valve
The power valve is installed in intake manifold collector and used to
control the suction passage of the variable induction air control system. It is set in the fully closed or fully opened position by the power
valve actuator operated by the vacuum stored in the surge tank. The
vacuum in the surge tank is controlled by the VIAS control solenoid
valve.
PBIB0946E
EC-894
http://vnx.su
VIAS
VIAS Control Solenoid Valve
A
The VIAS control solenoid valve cuts the intake manifold vacuum
signal for power valve control. It responds to ON/OFF signals from
the ECM. When the solenoid is off, the vacuum signal from the
intake manifold is cut. When the ECM sends an ON signal the coil
pulls the plunger downward and feeds the vacuum signal to the
power valve actuator.
EC
PBIB0947E

MONITOR ITEM
VIAS S/V
EBS011I1
CONDITION
SPECIFICATION
Idle
OFF
More than 5,000 rpm
ON
EC-895
http://vnx.su
VIAS
Wiring Diagram
EBS011I3
TBWA0651E
EC-896
http://vnx.su
VIAS
CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
[Engine is running]

valve
Idle speed
[Engine is running]
DATA (DC Voltage)

BATTERY VOLTAGE
(11 - 14V)
0 - 1.0V
EC-897
http://vnx.su
VIAS
EBS011I4

With CONSULT-II
2. Perform VIAS SOL VALVE in ACTIVE TEST mode with CONSULT-II.
PBIB0844E
3.
Turn VIAS control solenoid valve ON and OFF, and make sure
that power valve actuator rod moves.
PBIB0949E
Without CONSULT-II
2. Rev engine quickly up to above 5,000 rpm and make sure that
power valve actuator rod moves.
PBIB0949E
OK or NG
OK
>> INSPECTION END
NG (With CONSULT-II) >>GO TO 2.
NG (Without CONSULT-II) >>GO TO 3.
EC-898
http://vnx.su
VIAS
With CONSULT-II
Perform VIAS SOL VALVE in ACTIVE TEST mode with CONSULT-II.
4. Turn VIAS control solenoid valve ON and OFF, and check vacuum existence under the following conditions.
1.
2.
3.
VIAS SOL VALVE
EC
Vacuum
ON
Should exist
OFF
Should not exist
E
PBIB0844E
OK or NG
OK
NG
>> GO TO 4.

Without CONSULT-II
Apply 12V of direct current between VIAS control solenoid valve
terminals 1 and 2.
5. Check vacuum existence under the following conditions.
1.
2.
3.
4.
Condition
No supply
Vacuum
Should exist
Should not exist
OK or NG
OK
NG
>> GO TO 4.
L
PBIB0845E
4. CHECK VACUUM HOSE
1.
2.
Stop engine.
Check hoses and tubes between intake manifold and power
valve actuator for crack, clogging, improper connection or disconnection. Refer to EC-543, "Vacuum Hose Drawing" .
OK or NG
OK
>> GO TO 5.
NG
>> Repair hoses or tubes.
SEF109L
EC-899
http://vnx.su
VIAS
5. CHECK VACUUM TANK

OK or NG
OK
>> GO TO 6.
NG
>> Replace vacuum tank.
6. CHECK VIAS CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT

1.
2.

PBIB0947E
3.
Check voltage between VIAS control solenoid valve terminal 1

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.
PBIB0173E

Check harness for open or short between VIAS control solenoid valve and ECM relay.
8. CHECK VIAS CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Check harness continuity between VIAS control solenoid valve terminal 2 and ECM terminal 6.

OK or NG
OK
>> GO TO 9.
NG
EC-900
http://vnx.su
VIAS
9. CHECK VIAS CONTROL SOLENOID VALVE

OK or NG
OK
>> GO TO 10.
NG
>> Replace VIAS control solenoid valve.
EC

D
>> INSPECTION END
EBS011I5

With CONSULT-II
1.
2.
3.
4.

Perform VIAS SOL VALVE in ACTIVE TEST mode.
Check air passage continuity and operation delay time under the
Condition
VIAS SOL VALVE

between A and B

between A and C
ON
Yes
No
OFF
No
Yes

PBIB0177E
Without CONSULT-II
Check air passage continuity and operation delay time under the following conditions.
Condition

between A and B

between A and C

Yes
No
No supply
No
Yes

MEC488B
VACUUM TANK
1.
2.
3.
Disconnect vacuum hose connected to vacuum tank.

Connect a vacuum pump to the port A of vacuum pump.
Apply vacuum and make sure that vacuum exists at the port B .
PBIB0846E
EC-901
http://vnx.su
VIAS
EBS011I6

EC-902
http://vnx.su
FUEL PUMP CIRCUIT

FUEL PUMP CIRCUIT

Description
PFP:17042
A
EBS0114O
SYSTEM DESCRIPTION
Sensor
Input Signal to ECM

Engine speed*
Battery
Battery voltage*
ECM Function
Actuator
Fuel pump control
EC
Fuel pump relay
*: ECM determines the start signal status by the signals of engine speed and battery voltage.
The ECM activates the fuel pump for several seconds after the ignition switch is turned ON to improve engine
startability. If the ECM receives a engine speed signal from the crankshaft position sensor (POS) and camshaft position sensor (PHASE), it knows that the engine is rotating, and causes the pump to operate. If the
engine speed signal is not received when the ignition switch is ON, the engine stalls. The ECM stops pump
operation and prevents battery discharging, thereby improving safety. The ECM does not directly drive the fuel
pump. It controls the ON/OFF fuel pump relay, which in turn controls the fuel pump.
Condition
Fuel pump operation
Ignition switch is turned to ON
Operates for 1 second
Engine running and cranking
Operates
When engine is stopped
Stops in 1.5 seconds
Stops
A turbine type design fuel pump is used in the fuel tank.
K
PBIB0513E
EBS0114P

MONITOR ITEM
FUEL PUMP RLY
CONDITION
SPECIFICATION
ON
OFF
EC-903
http://vnx.su
FUEL PUMP CIRCUIT

Wiring Diagram
EBS0114Q
LHD MODELS
TBWA0632E
EC-904
http://vnx.su
FUEL PUMP CIRCUIT

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
114
B/OR
Fuel pump relay
C
0 - 1.0V
[Engine is running]

switch ON
EC
DATA (DC Voltage)
D
BATTERY VOLTAGE
(11 - 14V)
EC-905
http://vnx.su
FUEL PUMP CIRCUIT

RHD MODELS
TBWA0633E
EC-906
http://vnx.su
FUEL PUMP CIRCUIT

CAUTION:
TERMINAL
NO.
EC
WIRE
COLOR
ITEM
CONDITION
DATA (DC Voltage)
114
B/OR
Fuel pump relay
C
0 - 1.0V
[Engine is running]

switch ON
D
BATTERY VOLTAGE
(11 - 14V)
EBS0114R

1.
2.

Pinch fuel feed hose with two fingers.
Fuel pressure pulsation should be felt on the fuel hose
for 1 second after ignition switch is turned ON.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
I
PBIB1983E
2. CHECK FUEL PUMP RELAY POWER SUPPLY CIRCUIT
1.
2.
3.

Disconnect fuel pump relay.
PBIB1974E
4.
Check voltage between fuel pump relay terminals 1, 5 and

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.
MBIB0191E
EC-907
http://vnx.su
FUEL PUMP CIRCUIT


15A fuse
Harness for open or short between fuel pump relay and fuse
4. CHECK CONDENSER CIRCUIT FOR OPEN AND SHORT

1.
2.
3.

Check harness continuity between fuel pump relay terminal 3 and condenser terminal 1, condenser terminal 2 and ground.

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

Harness for open or short between fuel pump relay and condenser
Harness for open or short between condenser and ground
6. CHECK CONDENSER
OK or NG
OK
>> GO TO 7.
NG
7. CHECK FUEL PUMP POWER SUPPLY AND GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
Check harness continuity between fuel pump relay terminal 3
and fuel level sensor unit and fuel pump terminal 5, fuel level
sensor unit and fuel pump terminal 3 and ground.

OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.
EC-908
http://vnx.su
PBIB0506E
FUEL PUMP CIRCUIT

Harness for open or short between fuel pump relay and fuel level sensor unit and fuel pump
Harness for open or short between fuel level sensor unit and fuel pump and ground
9. CHECK FUEL PUMP RELAY OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.

Check harness continuity between fuel pump relay terminal 2 and ECM terminal 114.
EC

OK or NG
OK
>> GO TO 11.
NG
>> GO TO 10.

Harness connectors B1, M17 (LHD models)
Harness connectors B2, M18 (RHD models)
Harness for open or short between fuel pump relay and ECM
11. CHECK FUEL PUMP RELAY

OK or NG
OK
>> GO TO 12.
NG
>> Replace fuel pump relay.
12. CHECK FUEL PUMP

M

OK or NG
OK
>> GO TO 13.
NG
>> Replace fuel pump.

>> INSPECTION END
EC-909
http://vnx.su
FUEL PUMP CIRCUIT

EBS0114S
FUEL PUMP RELAY

Check continuity between terminals 3 and 5 under the following conditions.
Conditions
Continuity

1 and 2
Yes
No current supply
No
PBIB0098E
FUEL PUMP
1.
2.
Check resistance between fuel level sensor unit and fuel pump
terminals 3 and 5.
Resistance: Approximately 0.2 - 5.0 [at 25C (77F)]
PBIB0658E
CONDENSER
1.
2.
3.

Check resistance between condenser terminal 1 and 2.
Resistance: Above 1M [at 25C (77F)]
MBIB0031E
EBS011UV
FUEL PUMP
Refer to FL-4, "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY" .
EC-910
http://vnx.su


PFP:92136
A
EBS0114U
The refrigerant pressure sensor is installed at the condenser of the

air conditioner system. The sensor uses an electrostatic volume
pressure transducer to convert refrigerant pressure to voltage. The
voltage signal is sent to ECM, and ECM controls cooling fan system.
EC
D
PBIB0503E
H
PBIB2657E
EC-911
http://vnx.su

Wiring Diagram
EBS0114V
TBWA0634E
EC-912
http://vnx.su

CAUTION:
TERMINAL
NO.
EC
WIRE
COLOR
ITEM
46
Sensor power supply

57
Sensor ground
CONDITION
DATA (DC Voltage)
Approximately 5V
Approximately 0V
[Engine is running]
Warm-up condition
Idle speed
[Engine is running]
69
Warm-up condition
Both A/C switch and blower switch are ON
E
1.0 - 4.0V
EBS0114W
1. CHECK REFRIGERANT PRESSURE SENSOR OVERALL FUNCTION

1.
2.
3.

Turn A/C switch and blower switch ON.
Voltage: 1.0 - 4.0V

I
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
MBIB0035E
EC-913
http://vnx.su


1.
2.
3.
Turn A/C switch and blower switch OFF.

Stop engine.
PBIB2021E
OK or NG
OK
>> GO TO 3.
NG
EC-914
http://vnx.su

3. CHECK REFRIGERANT PRESSURE SENSOR POWER SUPPLY CIRCUIT

1.
2.
Disconnect refrigerant pressure sensor harness connector.

EC
D
PBIB0503E
3.
Check voltage between refrigerant pressure sensor terminal 3

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
SEF479Y

5. CHECK REFRIGERANT PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.


OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

EC-915
http://vnx.su

7. CHECK REFRIGERANT PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.


OK or NG
OK
>> Replace refrigerant pressure sensor.
NG
EBS0114X

Refer to ATC-141, "REFRIGERANT LINES" .
EC-916
http://vnx.su


PFP:25350
A
EBS01FFG

MONITOR ITEM
LOAD SIGNAL
HEATER FAN SW
CONDITION
Ignition switch: ON
Ignition switch: ON
SPECIFICATION
Rear window defogger switch is ON and/or

lighting switch is in 2nd position (placed in LOW
position for models with Xenon headlamp).
ON
Rear window defogger switch is OFF and lighting switch is OFF.
OFF
Heater fan is operating
ON
OFF
EC
EC-917
http://vnx.su

Wiring Diagram
EBS01FFH
TBWB0468E
EC-918
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
84
L/Y

(Headlamp signal)
Lighting switch: 2nd position
[Engine is running]
96
LG/B
Heater fan switch
[Engine is running]
DATA (DC Voltage)

BATTERY VOLTAGE
(11 - 14V)
Approximately 0V
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
EC-919
http://vnx.su

TBWA0636E
EC-920
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
93
BR

signal)
DATA (DC Voltage)

BATTERY VOLTAGE
(11 - 14V)
Approximately 0V
EC-921
http://vnx.su

TBWB0469E
EC-922
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
84
L/Y

(Headlamp signal)
Lighting switch: 2nd position and placed in

LOW position
[Engine is running]
96
LG/B
Heater fan switch
[Engine is running]
DATA (DC Voltage)
BATTERY VOLTAGE
(11 - 14V)
Approximately 0V
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
EC-923
http://vnx.su

TBWB0470E
EC-924
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
93
BR

signal)
DATA (DC Voltage)

BATTERY VOLTAGE
(11 - 14V)
Approximately 0V
EC-925
http://vnx.su

RHD MODELS
TBWB0471E
EC-926
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
EC
ITEM
CONDITION
84
L/Y

(Headlamp signal)

[Engine is running]
96
LG/B
Heater fan switch
[Engine is running]
DATA (DC Voltage)
BATTERY VOLTAGE
(11 - 14V)
Approximately 0V
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
EC-927
http://vnx.su

TBWB0472E
EC-928
http://vnx.su

CAUTION:
TERMINAL
NO.
EC
WIRE
COLOR
ITEM
CONDITION
93

signal)
BR
DATA (DC Voltage)
BATTERY VOLTAGE
(11 - 14V)
Approximately 0V
D
EBS01FFI
1. INSPECTION START
Yes or No
Yes
>> GO TO 2.
No
>> GO TO 3.

H
With CONSULT-II
Condition
LOAD SIGNAL
ON
OFF
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 8.
PBIB0103E

M
Without CONSULT-II
Condition
Voltage
BATTERY VOLTAGE
0V
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 8.
MBIB0158E
EC-929
http://vnx.su


With CONSULT-II
Condition
LOAD SIGNAL
ON
OFF
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 11.
PBIB0103E

Without CONSULT-II
Condition
Voltage
BATTERY VOLTAGE
0V
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 11.
PBIB1773E

With CONSULT-II
Condition
LOAD SIGNAL
ON
OFF
OK or NG
OK
>> INSPECTION END.
NG
>> GO TO 14.
PBIB1995E

Without CONSULT-II
Condition
Voltage
0V
BATTERY VOLTAGE
OK or NG
OK
>> INSPECTION END.
NG
>> GO TO 14.
PBIB1219E
EC-930
http://vnx.su

A
1. Start engine.
2. Turn the lighting switch ON at 2nd position.
EC
OK or NG
OK
>> GO TO 9.
NG
>> Refer to LT-25, "HEADLAMP - CONVENTIONAL TYPE -" or LT-51, "HEADLAMP (WITH DAY- C
TIME) - CONVENTIONAL TYPE -" .
1.
2.
3.
4.
Stop engine.
conditions.
I
PBIB1994E
Condition
Continuity
Should exist
Should not exist

OK or NG
OK
>> GO TO 16.
NG
>> GO TO 10.

Diode E123
Diode E124
Harness for open and short between lighting switch and ECM
EC-931
http://vnx.su


1.
2.
3.
Start engine.
Yes or No
Yes
>> GO TO 12.
No
1.
2.
3.
4.
Stop engine.

OK or NG
OK
>> GO TO 16.
NG
>> GO TO 13.


1.
2.
3.
Start engine.
Yes or No
Yes
>> GO TO 15.
No
EC-932
http://vnx.su


1.
2.
3.
4.
Stop engine.
EC

OK or NG
OK
>> GO TO 16.
NG

>> INSPECTION END
1. INSPECTION START
H

Yes or No
Yes
>> GO TO 2.
No
>> GO TO 3.

J
With CONSULT-II
Condition
LOAD SIGNAL

ON
OFF
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 8.
PBIB0103E
EC-933
http://vnx.su


Without CONSULT-II
Condition
Voltage

BATTERY VOLTAGE
0V
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 8.
MBIB0158E

With CONSULT-II
Condition
LOAD SIGNAL
ON
OFF
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 11.
PBIB0103E

Without CONSULT-II
Condition
Voltage
BATTERY VOLTAGE
0V
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 11.
PBIB1773E
EC-934
http://vnx.su

With CONSULT-II
Condition
EC
LOAD SIGNAL
ON
OFF
OK or NG
OK
>> INSPECTION END.
NG
>> GO TO 14.
D
PBIB1995E

Without CONSULT-II
Condition
Voltage
0V
BATTERY VOLTAGE
OK or NG
OK
>> INSPECTION END.
NG
>> GO TO 14.
I
PBIB1219E
1. Start engine.
2. Turn the lighting switch ON at 2nd position and placed in LOW position.
OK or NG
OK
>> GO TO 9.
NG
>> Refer to LT-5, "HEADLAMP - XENON TYPE -" or LT-41, "HEADLAMP (WITH DAYTIME) XENON TYPE -" .

1.
2.
3.
4.
Stop engine.
Disconnect daytime light relay LH or HID relay LH.
Check harness continuity between ECM terminal 84 and daytime light relay LH terminal 3 or HID relay LH
terminal 3.
OK or NG
OK
>> GO TO 16.
NG
>> GO TO 10.
EC-935
http://vnx.su


Harness for open and short between ECM and daytime light relay LH or HID relay LH

1.
2.
3.
Start engine.
Yes or No
Yes
>> GO TO 12.
No
1.
2.
3.
4.
Stop engine.

OK or NG
OK
>> GO TO 16.
NG
>> GO TO 13.


1.
2.
3.
Start engine.
Yes or No
Yes
>> GO TO 15.
No
EC-936
http://vnx.su


1.
2.
3.
4.
Stop engine.
EC

OK or NG
OK
>> GO TO 16.
NG

>> INSPECTION END
RHD MODELS
1. INSPECTION START
H

Yes or No
Yes
>> GO TO 2.
No
>> GO TO 3.

J
With CONSULT-II
Condition
LOAD SIGNAL

ON
OFF
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 8.
PBIB0103E
EC-937
http://vnx.su


Without CONSULT-II
Condition
Voltage
BATTERY VOLTAGE
0V
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 8.
MBIB0158E

With CONSULT-II
Condition
LOAD SIGNAL
ON
OFF
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 13.
PBIB0103E

Without CONSULT-II
Condition
Voltage
BATTERY VOLTAGE
0V
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 13.
PBIB1773E
EC-938
http://vnx.su

With CONSULT-II
Condition
EC
LOAD SIGNAL
ON
OFF
OK or NG
OK
>> INSPECTION END.
NG
>> GO TO 16.
D
PBIB1995E

Without CONSULT-II
Condition
Voltage
0V
BATTERY VOLTAGE
OK or NG
OK
>> INSPECTION END.
NG
>> GO TO 16.
I
PBIB1219E
1. Start engine.
2. Turn the lighting switch ON at 2nd position (placed in LOW position for models with Xenon headlamp).
OK or NG
OK (Models without Xenon headlamp)>>GO TO 9.
OK (Models with Xenon headlamp)>>GO TO 11.
NG
>> Refer to LT-5, "HEADLAMP - XENON TYPE -" , LT-25, "HEADLAMP - CONVENTIONAL TYPE -"
, LT-41, "HEADLAMP (WITH DAYTIME) - XENON TYPE -" or LT-51, "HEADLAMP (WITH DAYTIME) - CONVENTIONAL TYPE -" .
EC-939
http://vnx.su


1.
2.
3.
4.
Stop engine.
conditions.
PBIB1994E
Condition
Continuity
Should exist
Should not exist

OK or NG
OK
>> GO TO 18.
NG
>> GO TO 10.

Diode E123
Diode E124
Harness for open and short between ECM and combination switch

1.
2.
3.
4.
Stop engine.
Disconnect HID relay LH.
Check harness continuity between ECM terminal 84 and HID relay LH terminal 3.
OK or NG
OK
>> GO TO 18.
NG
>> GO TO 12.
EC-940
http://vnx.su

Harness for open and short between ECM and HID relay LH
EC

1.
2.
3.
Start engine.
Yes or No
Yes
>> GO TO 14.
No
1.
2.
3.
4.
Stop engine.

OK or NG
OK
>> GO TO 18.
NG
>> GO TO 15.


1.
2.
3.
Start engine.
Yes or No
Yes
>> GO TO 17.
No
EC-941
http://vnx.su


1.
2.
3.
4.
Stop engine.

OK or NG
OK
>> GO TO 18.
NG

>> INSPECTION END
EC-942
http://vnx.su
ASCD BRAKE SWITCH

ASCD BRAKE SWITCH

PFP:25320
A
EBS01FBP

EC
D
SEC009D
EBS01FBQ

MONITOR ITEM
CONDITION
BRAKE SW1
(ASCD brake switch)
BRAKE SW2
(Stop lamp switch)
Ignition switch: ON
Ignition switch: ON
SPECIFICATION

Fully released
ON

Slightly depressed
OFF
OFF
ON
EC-943
http://vnx.su
ASCD BRAKE SWITCH

Wiring Diagram
EBS01FBR
TBWA0763E
EC-944
http://vnx.su
ASCD BRAKE SWITCH

CAUTION:
TERMINAL
NO.
EC
WIRE
COLOR
ITEM
CONDITION
101
Stop lamp switch
DATA (DC Voltage)
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
108
GY/L
ASCD brake switch

Slightly depressed

Fully released
Approximately 0V
E
BATTERY VOLTAGE
(11 - 14V)
F
EBS01FBT
With CONSULT-II
A/T models
I
CONDITION
INDICATION
OFF
ON
M/T models
CONDITION
INDICATION
OFF
ON
SEC011D
1.
2.
Without CONSULT-II
A/T models
CONDITION
VOLTAGE
Approximately 0V
Battery voltage
M/T models
CONDITION
VOLTAGE
Approximately 0V
Battery voltage
OK or NG
OK
>> GO TO 2.
NG
>> GO TO 3.
EC-945
http://vnx.su
MBIB0061E
ASCD BRAKE SWITCH


1.
2.
With CONSULT-II
CONDITION
INDICATION
OFF
ON
SEC013D
Without CONSULT-II
CONDITION
VOLTAGE
Approximately 0V
Battery voltage
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 11.
MBIB0060E

1.
2.
3.

SEC009D
4.

OK or NG
OK
>> GO TO 9.
PBIB0857E
EC-946
http://vnx.su
ASCD BRAKE SWITCH

10A fuse
EC

1.
2.
3.
4.


OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.
H
PBIB0799E
10A fuse
1.
2.


OK or NG
OK
>> GO TO 8.
NG

OK or NG
OK
>> GO TO 15.
NG
EC-947
http://vnx.su
ASCD BRAKE SWITCH

1.
2.
3.


OK or NG
OK
>> GO TO 10.
NG

Refer toEC-950, "Component Inspection" .
OK or NG
OK
>> GO TO 15.
NG

1.
2.

PBIB0498E
3.
PBIB2284E

OK or NG
OK
>> GO TO 13.
NG
>> GO TO 12.
EC-948
http://vnx.su
ASCD BRAKE SWITCH

15A fuse
1.
2.

EC

OK or NG
OK
>> GO TO 14.
NG

H

OK or NG
OK
>> GO TO 15.
NG

>> INSPECTION END
EC-949
http://vnx.su
ASCD BRAKE SWITCH

EBS01FBU
ASCD BRAKE SWITCH

1.
2.
3.

Condition

Continuity
Should exist
Should not exist

SEC023D
ASCD CLUTCH SWITCH

1.
2.
3.

Condition

Continuity
Should exist
Should not exist

SEC024D
STOP LAMP SWITCH

1.
2.
3.

PBIB2285E
Condition
Continuity
Should not exist
Should exist
EC-950
http://vnx.su
ASCD INDICATOR
ASCD INDICATOR
PFP:24814
A
EBS01FBV
ASCD indicator lamp illuminates to indicate ASCD operation status. Lamp has two indicators, CRUISE, SET,
and is integrated in combination meter.
EC
SET indicator illuminates when following conditions are met.
C
ASCD setting.
D
EBS01FBW
Specification data are reference value.

MONITOR ITEM
CRUISE LAMP
SET LAMP
CONDITION
SPECIFICATION
Ignition switch: ON

at the 2nd time
ON OFF
MAIN switch: ON
ASCD: Operating
ON
Vehicle speed is between40 km/h

(25 MPH) and 144 km/h (89
MPH)
ASCD: Not operating
OFF
EC-951
http://vnx.su
ASCD INDICATOR
Wiring Diagram
EBS01FBX
TBWA0764E
EC-952
http://vnx.su
ASCD INDICATOR
EBS01FBY

ASCD INDICATOR
CRUISE LAMP
SET LAMP
CONDITION
SPECIFICATION
Ignition switch: ON

at the 2nd time
ON OFF
MAIN switch: ON
ASCD: Operating
ON
When vehicle speed is between

40 km/h (25 MPH) and 144 km/h
(89 MPH)
ASCD: Not operating
OFF
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
EC
2. CHECK DTC
F
Check that DTC U1000 or U1001 is not displayed.

OK or NG
OK
>> GO TO 3.
NG
>> Perform trouble diagnoses for DTC U1000, U1001. Refer to EC-630, "DTC U1000, U1001 CAN
COMMUNICATION LINE" .
3. CHECK COMBINATION METER FUNCTION

OK or NG
OK
>> GO TO 4.
NG
>> Replace combination meter.

>> INSPECTION END

L
EC-953
http://vnx.su


Wiring Diagram
PFP:24814
EBS01152
LHD MODELS
TBWA0639E
EC-954
http://vnx.su

A
EC
TBWA0640E
EC-955
http://vnx.su

Wiring Diagram
EBS01153
RHD MODELS
TBWA0641E
EC-956
http://vnx.su

A
EC
TBWA0642E
EC-957
http://vnx.su


Description
PFP:14950
EBS01154
SYSTEM DESCRIPTION
PBIB0491E
The evaporative emission system is used to reduce hydrocarbons emitted into the atmosphere from the fuel
system. This reduction of hydrocarbons is accomplished by activated charcoals in the EVAP canister.
The fuel vapor in the sealed fuel tank is led into the EVAP canister which contains activated carbon and the
vapor is stored there when the engine is not operating or when refueling to the fuel tank.
The vapor in the EVAP canister is purged by the air through the purge line to the intake manifold when the
engine is operating. EVAP canister purge volume control solenoid valve is controlled by ECM. When the
engine operates, the flow rate of vapor controlled by EVAP canister purge volume control solenoid valve is
proportionally regulated as the air flow increases.
EVAP canister purge volume control solenoid valve also shuts off the vapor purge line during decelerating and
idling.
EC-958
http://vnx.su

EVAPORATIVE EMISSION LINE DRAWING
EC
PBIB0490E
EC-959
http://vnx.su

PBIB1998E
EC-960
http://vnx.su

EBS01155
EVAP CANISTER
Check EVAP canister as follows:
1. Block port B . Orally blow air through port A .
2. Block port A . Orally blow air through port B .
EC
D
PBIB0663E
FUEL CHECK VALVE

1.
2.
3.
Blow air through connector on fuel tank side.

A considerable resistance should be felt and a portion of air flow
should be directed toward the EVAP canister side.
Blow air through connector on EVAP canister side.
Air flow should be smoothly directed toward fuel tank side.
If fuel check valve is suspected of not properly functioning in
steps 1 and 2 above, replace it.
H
SEF552Y
FUEL TANK VACUUM RELIEF VALVE (BUILT INTO FUEL FILLER CAP)
1.
Wipe clean valve housing.
SEF989X
2.
Check valve opening pressure and vacuum.

Pressure:
Vacuum:
3.
15.3 - 20.0 kPa (0.153 - 0.200 bar,

0.156 - 0.204 kg/cm2 , 2.22 - 2.90 psi)
6.0 to 3.4 kPa (0.060 to 0.034 bar,
0.061 to 0.035 kg/cm2 , 0.87 to 0.49 psi)
If out of specification, replace fuel filler cap as an assembly.
SEF943S
EC-961
http://vnx.su

WATER SEPARATOR
1.
2.
3.
4.
5.
Check visually for insect nests in the water separator air inlet.
Check visually for cracks or flaws in the appearance.
Check visually for cracks or flaws in the hose.
Check that A and C are not clogged by blowing air into B with
A , and then C plugged.
In case of NG in items 2 - 4, replace the parts.
NOTE:
Do not disassemble water separator.
PBIB1032E

EC-962
http://vnx.su


Description
PFP:11810
A
EBS01156
SYSTEM DESCRIPTION
EC
G
PBIB0492E
This system returns blow-by gas to the intake manifold.

The positive crankcase ventilation (PCV) valve is provided to conduct crankcase blow-by gas to the intake
manifold. During partial throttle operation of the engine, the intake manifold sucks the blow-by gas through the
PCV valve. Normally, the capacity of the valve is sufficient to handle any blow-by and a small amount of ventilating air. The ventilating air is then drawn from the air inlet tubes into the crankcase. In this process the air
passes through the hose connecting air inlet tubes to rocker cover. Under full-throttle condition, the manifold
vacuum is insufficient to draw the blow-by flow through the valve. The flow goes through the hose connection
in the reverse direction.
On vehicles with an excessively high blow-by, the valve does not
meet the requirement. This is because some of the flow will go
through the hose connection to the air inlet tubes under all conditions.
PBIB1588E
EBS01157
PCV (POSITIVE CRANKCASE VENTILATION) VALVE

With engine running at idle, remove PCV valve from rocker cover. A
properly working valve makes a hissing noise as air passes through
it. A strong vacuum should be felt immediately when a finger is
placed over valve inlet.
PBIB1589E
EC-963
http://vnx.su

PCV VALVE VENTILATION HOSE
1.
2.

S-ET277
EC-964
http://vnx.su


System Description
PFP:18930
A
EBS01FBZ

Sensor
Input signal to ECM
ASCD brake switch
Stop lamp switch
ASCD clutch switch (M/T models)
Park/Neutral position (PNP)

switch
Gear position
Wheel sensor*
Vehicle speed
ECM function
Actuator
EC
C

actuator
BASIC ASCD SYSTEM

h (25 MPH) and 144 km/h (89 MPH).
ECM controls throttle angle of electric throttle control actuator to regulate engine speed.
NOTE:
Always drive vehicle in safe manner according to traffic conditions and obey all traffic laws.
SET OPERATION
MPH), press SET/COAST switch. (Then SET indicator in combination meter illuminates.)
ACCEL OPERATION
If the RESUME/ACCELERATE switch is pressed during cruise control driving, increase the vehicle speed until
the switch is released or vehicle speed reaches maximum speed controlled by the system.
CANCEL OPERATION
CANCEL switch is pressed
More than 2 switches at ASCD steering switch are pressed at the same time (Set speed will be cleared)
Clutch pedal is depressed or gear position is changed to the neutral position
Vehicle speed decreased to 13 km/h (8 MPH) lower than the set speed
ESP/TCS system is operated

Engine coolant temperature is slightly higher than the normal operating temperature, CRUISE lamp may
blink slowly.
When the engine coolant temperature decreases to the normal operating temperature, CRUISE lamp will
stop blinking and the cruise operation will be able to work by pressing SET/COAST switch or RESUME/
ACCELERATE switch.
EC-965
http://vnx.su

COAST OPERATION
When the SET/COAST switch is pressed during cruise control driving, decrease vehicle set speed until the
RESUME OPERATION
When the RESUME/ACCELERATE switch is pressed after cancel operation other than pressing MAIN switch
is performed, vehicle speed will return to last set speed. To resume vehicle set speed, vehicle condition must
meet following conditions.
Brake pedal is fully released
Clutch pedal is fully released (M/T models)
A/T selector lever is in other than P and N position (A/T models)
EBS01FC0

Refer to EC-777 .
ASCD BRAKE SWITCH

ASCD CLUTCH SWITCH

Refer to EC-787 and EC-943
STOP LAMP SWITCH

Refer to EC-787 , EC-806 and EC-943 .

Refer to EC-720 , EC-723 , EC-734 and EC-742 .
ASCD INDICATOR
Refer to EC-951 .
EC-966
http://vnx.su


Fuel Pressure
PFP:00030
A
EBS01158
Approximately 350 kPa (3.5bar, 3.57kg/cm2 , 51psi)
Fuel pressure at idle
EC
Idle Speed and Ignition Timing

QR20DE
Target idle speed
QR25DE
QR20DE
Air conditioner: ON
QR25DE
QR20DE
Ignition timing
QR25DE
EBS01159
M/T
65050 rpm
A/T
M/T
A/T
M/T
In Neutral position
A/T
In P or N position
M/T
In Neutral position
750 rpm or more
A/T
In P or N position
700 rpm or more
M/T
In Neutral position
A/T
In P or N position
M/T
In Neutral position
A/T
In P or N position
C
70050 rpm
D
725 rpm or more
F
155 BTDC
*: Under the following conditions:
Electric load: OFF (Lights, heater fan & rear window defogger)
Steering wheel: Kept in straight-ahead position
EBS0115B
Supply voltage

0.7 - 1.1*V (QR20DE)
0.8 - 1.2*V (QR25DE)
Output voltage at idle
*: Engine is warmed up to normal operating temperature and running under no-load.
Intake Air Temperature Sensor
EBS0115C
Temperature C (F)
Resistance k
25 (77)
1.800 - 2.200
80 (176)
0.283 - 0.359

Temperature C (F)
EBS0115D
Resistance k
20 (68)
2.1 - 2.9
50 (122)
0.68 - 1.00
90 (194)
0.236 - 0.260
Heated Oxygen Sensor 1 Heater
EBS0115E
3.3 - 4.0
Heated Oxygen sensor 2 Heater
EBS0115F
5.0 - 7.0
Crankshaft Position Sensor (POS)
EBS0115G
EC-967
http://vnx.su

Camshaft Position Sensor (PHASE)
EBS0115H
Throttle Control Motor
EBS0115I
Approximately 1 - 15
Injector
EBS0115J
Resistance [at 10 - 60C (50 - 140F)]
13.5 - 17.5
Fuel Pump
EBS0115K
Approximately 0.2 - 5.0
EC-968
http://vnx.su
INDEX FOR DTC

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

Alphabetical Index
PFP:00024
A
EBS0116O
EC
NOTE:
If DTC U1000 is displayed with other DTC, first perform the trouble diagnosis for DTC U1000. Refer to
EC-1050, "DTC U1000 CAN COMMUNICATION LINE" .
C
X: Applicable : Not applicable
Items
DTC*1
CONSULT-II
GST*2
Trip
MI lighting
up
Reference page
ECM*3
APP SEN 1/CIRCUIT
P0122
0122
EC-1093
APP SEN 1/CIRCUIT
P0123
0123
EC-1093
APP SEN 2/CIRCUIT
P0222
0222
EC-1130
APP SEN 2/CIRCUIT
P0223
0223
EC-1130
APP SENSOR
P2135
2135
EC-1274
BARO SEN/CIRC
P2228
2228
EC-1291
BARO SEN/CIRC
P2229
2229
EC-1291
BATTERY VOLTAGE
P0563
0563
EC-1206
BRAKE SW/CIRCUIT
P0504
0504
EC-1197
EC-1050
CAN COMM CIRCUIT
U1000
1000*
CKP SEN/CIRCUIT
P0335
0335
EC-1148
CKP SENSOR
P0336
0336
EC-1154
CMP SEN/CIRCUIT
P0340
0340
EC-1160
CMP SENSOR
P0341
0341
EC-1166
CMP/CKP RELATION
P0016
0016
EC-1053
CYL1 INJECTOR
P0201
0201
EC-1110
CYL2 INJECTOR
P0202
0202
EC-1110
CYL3 INJECTOR
P0203
0203
EC-1110
CYL4 INJECTOR
P0204
0204
EC-1110
ECM
P0605
0605
EC-1217
ECM
P0606
0606
EC-1219
ECM RELAY
P0686
0686
EC-1235
ECT SEN/CIRC
P0117
0117
EC-1087
ECT SEN/CIRC
P0118
0118
EC-1087
EGR SYSTEM
P0401
0401
EC-1177
EGR VALVE
P0404
0404
EC-1184
ENG OVER TEMP
P0217
0217
EC-1116
FRP RELIEF VALVE
P1272
1272
EC-1253
FRP SEN/CIRC
P0192
0192
EC-1103
FRP SEN/CIRC
P0193
0193
EC-1103
FUEL LEAK
P0093
0093
EC-1065
FUEL PUMP
P0089
0089
EC-1062
FUEL PUMP
P1273
1273
EC-1259
FUEL PUMP
P1274
1274
EC-1264
FUEL PUMP
P1275
1275
EC-1269
EC-969
http://vnx.su
INDEX FOR DTC

DTC*1
Items
CONSULT-II
Trip
MI lighting
up
Reference page
GST*2
ECM*
FUEL PUMP/CIRC
P0628
0628
EC-1221
FUEL PUMP/CIRC
P0629
0629
EC-1221
FUEL TEMP SEN/CIRC
P0182
0182
EC-1099
FUEL TEMP SEN/CIRC
P0183
0183
EC-1099
GLOW RELAY
P0380
0380
EC-1173
HIGH FUEL PRESS
P0088
0088
EC-1060
IAT SEN/CIRCUIT
P0112
0112
EC-1082
IAT SEN/CIRCUIT
P0113
0113
EC-1082
INJ ADJ RES/CIRC1
P1260
1260
EC-1241
INJ ADJ RES/CIRC1
P1261
1261
EC-1241
INJ ADJ RES/CIRC2
P1262
1262
EC-1241
INJ ADJ RES/CIRC2
P1263
1263
EC-1241
INJ ADJ RES/CIRC3
P1264
1264
EC-1241
INJ ADJ RES/CIRC3
P1265
1265
EC-1241
INJ ADJ RES/CIRC4
P1266
1266
EC-1241
INJ ADJ RES/CIRC4
P1267
1267
EC-1241
INJ PWR/CIRC
P2146
2146
EC-1280
INJ PWR/CIRC
P2149
2149
EC-1280
INJECTOR
P0200
0200
EC-1108
INJECTOR/CIRC
P2147
2147
EC-1285
INJECTOR/CIRC
P2148
2148
EC-1285
INJECTOR 1
P1268
1268
EC-1247
INJECTOR 2
P1269
1269
EC-1247
INJECTOR 3
P1270
1270
EC-1247
INJECTOR 4
P1271
1271
EC-1247
MAF SEN/CIRCUIT
P0102
0102
EC-1077
MAF SEN/CIRCUIT
P0103
0103
EC-1077
MAF SENSOR
P0101
0101
EC-1069
P1610 - P1617
1610 - 1617
EC-996
NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.
P0000
0000
SENSOR PWR/CIRC1
P0642
0642
EC-1226
SENSOR PWR/CIRC1
P0643
0643
EC-1226
SENSOR PWR/CIRC2
P0652
0652
EC-1230
SENSOR PWR/CIRC2
P0653
0653
EC-1230
STRG SW/CIRC
P0580
0580
EC-1208
STRG SW/CIRC
P0581
0581
EC-1208
TC BOOST SEN/CIRC
P0237
0237
EC-1142
TC BOOST SEN/CIRC
P0238
0238
EC-1142
TC BOOST SOL/CIRC
P0045
0045
EC-1055
TC SYSTEM
P0234
0234
EC-1136
TCS/CIRC
P1212
1212
EC-1240
NATS MALFUNCTION
EC-970
http://vnx.su
INDEX FOR DTC

DTC*1
Items
CONSULT-II
Trip
MI lighting
up
Reference page
GST*2
ECM*
TCS C/U FUNCTN
P1211
1211
EC-1239
VEHICLE SPEED
P0501
0501
EC-1191
VEHICLE SPEED
P0502
0502
EC-1193
VEHICLE SPEED
P0503
0503
EC-1195
*1: 1st trip DTC No. and 2nd trip DTC No. are the same as DTC No.
*3: In Diagnostic Test Mode II (Self-diagnostic results).
EC
EC-971
http://vnx.su
INDEX FOR DTC

DTC No. Index
EBS0116P
NOTE:
DTC*1
CONSULT-II
Items
(CONSULT-II screen item)
Trip
MI lighting
up
Reference page
CAN COMM CIRCUIT
EC-1050
GST*2
ECM*
U1000
1000*4
P0000
0000
NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.
P0016
0016
CMP/CKP RELATION
EC-1053
P0045
0045
TC BOOST SOL/CIRC
EC-1055
P0088
0088
HIGH FUEL PRESS
EC-1060
P0089
0089
FUEL PUMP
EC-1062
P0093
0093
FUEL LEAK
EC-1065
P0101
0101
MAF SENSOR
EC-1069
P0102
0102
MAF SEN/CIRCUIT
EC-1077
P0103
0103
MAF SEN/CIRCUIT
EC-1077
P0112
0112
IAT SEN/CIRCUIT
EC-1082
P0113
0113
IAT SEN/CIRCUIT
EC-1082
P0117
0117
ECT SEN/CIRC
EC-1087
P0118
0118
ECT SEN/CIRC
EC-1087
P0122
0122
APP SEN 1/CIRCUIT
EC-1093
P0123
0123
APP SEN 1/CIRCUIT
EC-1093
P0182
0182
FUEL TEMP SEN/CIRC
EC-1099
P0183
0183
FUEL TEMP SEN/CIRC
EC-1099
P0192
0192
FRP SEN/CIRC
EC-1103
P0193
0193
FRP SEN/CIRC
EC-1103
P0200
0200
INJECTOR
EC-1108
P0201
0201
CYL1 INJECTOR
EC-1110
P0202
0202
CYL2 INJECTOR
EC-1110
P0203
0203
CYL3 INJECTOR
EC-1110
P0204
0204
CYL4 INJECTOR
EC-1110
P0217
0217
ENG OVER TEMP
EC-1116
P0222
0222
APP SEN 2/CIRCUIT
EC-1130
P0223
0223
APP SEN 2/CIRCUIT
EC-1130
P0234
0234
TC SYSTEM
EC-1136
P0237
0237
TC BOOST SEN/CIRC
EC-1142
P0238
0238
TC BOOST SEN/CIRC
EC-1142
P0335
0335
CKP SEN/CIRCUIT
EC-1148
P0336
0336
CKP SENSOR
EC-1154
P0340
0340
CMP SEN/CIRCUIT
EC-1160
P0341
0341
CMP SENSOR
EC-1166
EC-972
http://vnx.su
INDEX FOR DTC

DTC*1
CONSULT-II
Items
Trip
MI lighting
up
Reference page
GST*2
ECM*
P0380
0380
GLOW RELAY
EC-1173
P0401
0401
EGR SYSTEM
EC-1177
P0404
0404
EGR VALVE
EC-1184
P0501
0501
VEHICLE SPEED
EC-1191
P0502
0502
VEHICLE SPEED
EC-1193
P0503
0503
VEHICLE SPEED
EC-1195
P0504
0504
BRAKE SW/CIRCUIT
EC-1197
P0563
0563
BATTERY VOLTAGE
EC-1206
P0580
0580
STRG SW/CIRC
EC-1208
P0581
0581
STRG SW/CIRC
EC-1208
P0605
0605
ECM
EC-1217
P0606
0606
ECM
EC-1219
P0628
0628
FUEL PUMP/CIRC
EC-1221
P0629
0629
FUEL PUMP/CIRC
EC-1221
P0642
0642
SENSOR PWR/CIRC1
EC-1226
P0643
0643
SENSOR PWR/CIRC1
EC-1226
P0652
0652
SENSOR PWR/CIRC2
EC-1230
P0653
0653
SENSOR PWR/CIRC2
EC-1230
P0686
0686
ECM RELAY
EC-1235
P1211
1211
TCS C/U FUNCTN
EC-1239
P1212
1212
TCS/CIRC
EC-1240
P1260
1260
INJ ADJ RES/CIRC1
EC-1241
P1261
1261
INJ ADJ RES/CIRC1
EC-1241
P1262
1262
INJ ADJ RES/CIRC2
EC-1241
P1263
1263
INJ ADJ RES/CIRC2
EC-1241
P1264
1264
INJ ADJ RES/CIRC3
EC-1241
P1265
1265
INJ ADJ RES/CIRC3
EC-1241
P1266
1266
INJ ADJ RES/CIRC4
EC-1241
P1267
1267
INJ ADJ RES/CIRC4
EC-1241
P1268
1268
INJECTOR 1
EC-1247
P1269
1269
INJECTOR 2
EC-1247
P1270
1270
INJECTOR 3
EC-1247
P1271
1271
INJECTOR 4
EC-1247
P1272
1272
FRP RELIEF VALVE
EC-1253
P1273
1273
FUEL PUMP
EC-1259
P1274
1274
FUEL PUMP
EC-1264
P1275
1275
FUEL PUMP
EC-1269
P1610 - P1617
1610 - 1617
NATS MALFUNTION
EC-996
P2135
2135
APP SENSOR
EC-1274
P2146
2146
INJ PWR/CIRC
EC-1280
P2147
2147
INJECTOR/CIRC
EC-1285
P2148
2148
INJECTOR/CIRC
EC-1285
EC-973
http://vnx.su
EC
INDEX FOR DTC

DTC*1
CONSULT-II
Items
Trip
MI lighting
up
Reference page
GST*2
ECM*
P2149
2149
INJ PWR/CIRC
EC-1280
P2228
2228
BARO SEN/CIRC
EC-1291
P2229
2229
BARO SEN/CIRC
EC-1291
EC-974
http://vnx.su
PRECAUTIONS
PRECAUTIONS
PFP:00001
BELT PRE-TENSIONER
EBS0116Q
C
WARNING:
E
harness connectors.
F
EBS011T4
CAUTION:
may cause the MI to light up due to the malfunction of the fuel system, etc.
Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM
before returning the vehicle to the customer.
Precautions
EBS0116R

running.
SEF289H
EC-975
http://vnx.su
PRECAUTIONS
MBIB0625E

figure.
PBIB1512E

break).
damage to IC's.
Keep engine control system harness at least 10cm (4 in)
operation of IC's, etc.
Before replacing ECM, perform ECM Terminals and Reference Value inspection and make sure ECM functions properly. Refer to EC-1022, "ECM Terminals And Reference
Value" .
Do not shock or jar the camshaft position sensor, crankshaft position sensor.
EC-976
http://vnx.su
SEF291H
MEF040D
PRECAUTIONS

EC
C
SAT652J

the ground.
Do not disassemble fuel pump.
If NG, take proper action.
If NG, replace fuel injector.
SEF348N
Do not depress accelerator pedal when staring.

Immediately after staring, do not rev up engine unnecessarily.
SEF709Y

control units.
Adjust the antenna and feeder line so that the standingwave
radio can be kept smaller.
EC-977
http://vnx.su
SEF708Y
PRECAUTIONS

When you read Wiring diagrams, refer to the following:
GI-14, "How to Read Wiring Diagrams".

GI-10, "HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES".
GI-23, "How to Perform Efficient Diagnosis for an Electrical Incident".
EC-978
http://vnx.su
EBS0116S
PREPARATION
PREPARATION
PFP:00002
A
EBS011T9
Tool number
Tool name
Description
EG17650301
Radiator cap tester
adapter
EC

a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
S-NT564
KV109E0010
Break-out box
Measuring the ECM signals with a circuit tester
F
S-NT825
KV109E0080
Y-cable adapter
H
S-NT826
EBS011TA
Tool name
Description
Socket wrench

temperature sensor
S-NT705
EC-979
http://vnx.su


System Diagram
PFP:23710
EBS0116T
PBIB2884E
EC-980
http://vnx.su

Vacuum Hose Drawing
EBS0116U
EC
PBIB2019E
Refer to EC-980, "System Diagram" for Vacuum Control System.
EC-981
http://vnx.su

System Chart
EBS0116V
Input (Sensor)
ECM Function
Output (Actuator)
Fuel injector and Fuel pump
Fuel rail pressure sensor
Fuel injection timing control
Fuel pump temperature sensor
Fuel cut control
Glow control system
Glow relay and glow indicator lamp*2
Malfunction indicator (MI)*2
EGR volume control
Cooling fan control
Cooling fan relay
Turbocharger boost sensor

Vehicle speed sensor*1
Turbocharger boost control

valve
ESP/TCS/ABS control unit*1
Fuel transport pump control
Fuel transport pump relay
Ignition switch
Stop lamp switch
Air conditioner switch*1
Battery voltage
Fuel level switch
Power steering pressure switch
*1: The input signal is sent to the ECM through CAN communication line.
*2: The output signal is sent from the ECM through CAN communication line.
Fuel Injection Control System
EBS0116W
SYSTEM DESCRIPTION
Three types of fuel injection control are provided to accommodate engine operating conditions; normal control,
idle control and start control. The ECM determines the appropriate fuel injection control. Under each control,
the amount of fuel injected is adjusted to improve engine performance.
Pulse signals are sent to fuel injectors according to the input signals to adjust the amount of fuel injected to
preset value.
START CONTROL
Input/Output Signal Chart
Sensor
Input Signal to ECM
Engine speed
Piston position
Ignition switch
Start signal
Fuel rail pressure
ECM Function
Fuel injection
control (start
control)
Actuator
Fuel injector
Fuel pump
When the ECM receives a start signal from the ignition switch, the
ECM adapts the fuel injection system for the start control. The
amount of fuel injected at engine starting is a preset program value
in the ECM. The program is determined by the engine speed, engine
coolant temperature and fuel rail pressure.
For better startability under cool engine conditions, the lower the
coolant temperature becomes, the greater the amount of fuel
injected. The ECM ends the start control when the engine speed
reaches the specific value, and shifts the control to the normal or idle
control.
SEF648S
EC-982
http://vnx.su

IDLE CONTROL
Sensor
A
Input Signal to ECM
Engine speed
Battery
Battery voltage
Fuel rail pressure
Vehicle speed sensor*
Vehicle speed
Air conditioner switch*
Air conditioner signal
ECM Function
Actuator
EC
Fuel injection
control (Idle
control)
Fuel injector
Fuel pump
*: The input signal is sent to the ECM through CAN communication line.
When the ECM determines that the engine speed is at idle, the fuel injection system is adapted for the idle
control. The ECM regulates the amount of fuel injected corresponding to changes in load applied to the engine
to keep engine speed constant. The ECM also provides the system with a fast idle control in response to the
engine coolant temperature signal.
NORMAL CONTROL
Sensor
Input Signal to ECM
Engine speed
Accelerator position
Fuel rail pressure
ECM Function
Fuel injection
control (Normal control)
Actuator
Fuel injector
Fuel pump
The amount of fuel injected under normal driving conditions is determined according to sensor signals. The crankshaft position sensor
detects engine speed, the accelerator pedal position sensor detects
accelerator pedal position and fuel rail pressure sensor detects fuel
rail pressure. These sensors send signals to the ECM.
The fuel injection data, predetermined by correlation between various engine speeds, accelerator pedal positions and fuel rail pressure are stored in the ECM memory, forming a map. The ECM
determines the optimal amount of fuel to be injected using the sensor signals in comparison with the map.
SEF649S
MAXIMUM AMOUNT CONTROL

Sensor
Input Signal to ECM
Engine speed
ECM Function
Fuel injection
control (Maximum amount
control)
Actuator
Fuel Injector
The maximum injection amount is controlled to an optimum by the engine speed, intake air amount, engine
coolant temperature, and accelerator opening in accordance with the driving conditions.
This prevents the oversupply of the injection amount caused by decreased air density at a high altitude or during a system failure.
EC-983
http://vnx.su

DECELERATION CONTROL
Sensor
Input Signal to ECM
Engine speed
ECM Function
Fuel injection
control (Deceleration control)
Actuator
Fuel injector
Fuel pump
The ECM sends a fuel cut signal to the fuel injectors and fuel pump during deceleration for better fuel efficiency. The ECM determines the time of deceleration according to signals from the accelerator pedal position
sensor and crankshaft position sensor.
Fuel Injection Timing Control System
EBS0116X
DESCRIPTION
The target fuel injection timing in accordance with the engine speed and the fuel injection amount are recorded
as a map in the ECM beforehand. The ECM determines the optimum injection timing using sensor signals
accordance with the map.
EBS0116Y
INPUT / OUTPUT SIGNAL CHART

Sensor
Input Signal to ECM
ECM Function
Actuator
Accelerator pedal opening angle
Vehicle speed
Air conditioner
cut control
SYSTEM DESCRIPTION
This system improves acceleration when the air conditioner is used.
When the accelerator pedal is fully depressed, the air conditioner is turned off for a few seconds.
When engine coolant temperature becomes excessively high, the air conditioner is turned off. This continues
until the engine coolant temperature returns to normal.
Fuel Cut Control (At No Load & High Engine Speed)
EBS0116Z

Sensor
Input Signal to ECM
Vehicle speed
Engine speed
ECM Function
Fuel cut control
Actuator
Fuel injector
based on engine speed. Fuel cut will be operated until the engine speed reaches 1,500 rpm, then fuel cut will
be cancelled.
NOTE:
This function is different from deceleration control listed under EC-982, "Fuel Injection Control System" .
EC-984
http://vnx.su

Crankcase Ventilation System
EBS01170
DESCRIPTION
In this system, blow-by gas is sucked into the air duct after oil separation by oil separator in the rocker cover.
EC
G
PBIB0590E
INSPECTION
Ventilation Hose
1.
2.

K
SEC692
CAN Communication
EBS01171
SYSTEM DESCRIPTION
CAN COMMUNICATION UNIT

Go to CAN system, when selecting your CAN system type from the following table.
Body type
Wagon
Axle
4WD
Engine
YD22DDTi
Transmission
M/T
Brake control
ECM
ABS
ESP
EC-985
http://vnx.su

Body type
Wagon
Axle
4WD
Engine
YD22DDTi
Transmission
M/T
Brake control
ABS
ESP
Steering angle sensor
4WD control unit
: Applicable
Models Without ESP

SYSTEM DIAGRAM
PKIA6458E

Signals
ABS actuator and

electric unit
(control unit)
4WD control unit
Combination meter
ECM
Engine speed signal
MI signal
R
R
R
R
R
R

EC-986
http://vnx.su

Signals
ABS actuator and

electric unit
(control unit)
ECM
4WD control unit
Combination meter
Glow indicator lamp signal
A/C switch signal
EC
Models With ESP

SYSTEM DIAGRAM
PKIA9634E
Signals
ECM
ESP/TCS/ABS
control unit
Steering angle
sensor

A/C switch signal
Combination
meter

4WD control
unit
Engine speed signal
R
R
R
R
MI signal

R
T
T
T
EC-987
http://vnx.su

4WD control
unit
Combination
meter
Signals
A/C switch signal
ECM
Steering angle
sensor

ESP/TCS/ABS
control unit
T
T
Engine speed signal
R
R
R
R
MI signal

R
T
T

R
R
EC-988
http://vnx.su


Fuel Filter
PFP:00018
A
EBS01172
DESCRIPTION
A water draining cock is on the lower side and a priming pump for bleeding air is on the upper side.
EC
AIR BLEEDING
Pump the priming pump to bleed air.
When air is bled completely, the pumping of the priming pump

suddenly becomes heavy. Stop the operation at that time.
If it is difficult to bleed air by the pumping of the priming pump

(the pumping of the priming pump does not become heavy), disconnect the fuel supply hose between the fuel filter and the fuel
gallery. Then, perform the operation described above, and make
sure that fuel comes out. (Use a pan, etc. so as not to spill fuel.
Do not let fuel get on engine and other parts.) After that, connect
the hose, then bleed air again.
Start engine and let it idle for at least 1 minute after performing
air bleeding.
E
PBIB1932E
WATER DRAINING
1.
a.
b.
2.
3.
4.
Remove the fuel filter, filter bracket, protector assembly from the dash panel as follows.
Remove the air cleaner case (upper), air duct assembly, and vacuum hose for brake booster (between the
vacuum pump and vacuum pipe).
CAUTION:
After the duct is removed, cover the opening with gum tape, etc. to prevent foreign object from
getting into the engine during the operation.
Remove the mounting nuts on the dash panel, then remove the fuel filter, filter bracket, and protector
assembly from the dash panel.
It is not necessary to disconnect the fuel hose.
Using a tool such as a pliers, loosen the water draining cock at
the bottom of the fuel filter.
Loosening drain cock four to five turns causes water to
start draining.
Do not remove drain cock by loosening it excessively.
If water dose not drain properly, move the priming up and down.
CAUTION:
When the water is drained, the fuel is also drained. Use a
pan, etc. to avoid fuel adherence to the rubber parts such as
the engine mount insulator.
Do not over-tighten the water draining cock. This will damSMA825B
age the cock thread, resulting in water or fuel leak.
Bleed air of the fuel filter. Refer to EC-989, "AIR BLEEDING" .
Start the engine.
Fuel Pump Learning Value Clearing
EBS01173
DESCRIPTION
In order to always keep optimum fuel pressure in fuel rail, the ECM controls fuel pump in high precision with
monitoring the signal of fuel rail pressure sensor.
Accordingly, the ECM always learns characteristic value of fuel pump. Fuel Pump Learning Value Clearing is
an operating to clear the value of the fuel pump learning.
It must be performed after the fuel pump is changed. When the ECM is replaced with brand new one, the Fuel
Pump Learning Value Clearing is not necessary to be performed. If the ECM to be replaced has the possibility
of learning the characteristic value of fuel pump, the Fuel Pump Learning Value Clearing is necessary to be
performed after the ECM has been replaced.
OPERATION PROCEDURE
NOTE:
When removing fuel pump, perform Fuel Pump Learning Value Clearing before starting engine.
EC-989
http://vnx.su

1.
2.

Select PUMP LEARNT CLEAR in ACTIVE TEST mode with
CONSULT-II.
MBIB0896E
3.
Touch CLEAR and wait a few seconds.
MBIB0893E
4.
Make sure that CMPLT is displayed on CONSULT-II screen.
MBIB0894E
EC-990
http://vnx.su


Introduction
PFP:00028
A
EBS011UJ
EC
ISO Standard
Freeze Frame data
1st/2nd Trip Diagnostic Trouble Code (1st/2nd Trip DTC)
Calibration ID
: Applicable
: Not applicable
DTC
1st trip DTC
2nd trip DTC
Freeze Frame data
CONSULT-II
GST
ECM
*: When DTC and 1st/2nd trip DTC simultaneously appear on the display, they cannot be clearly distinguished from each other.
The malfunction indicator (MI) on the instrument panel lights up when the same malfunction is detected in
three consecutive trips (Three trip detection logic).
Three Trip Detection Logic and One Trip Detection Logic
EBS011UK
On board diagnosis (OBD) system of this vehicle has Three Trip Detection Logic and One Trip Detection
Logic. For which logic each self-diagnosis corresponds with, refer to EC-969, "INDEX FOR DTC" .
Trip of Three Trip Detection Logic means a driving mode in which the self-diagnosis is performed while
driving.
THREE TRIP DETECTION LOGIC

When a malfunction is detected for the first time, 1st trip DTC is stored in the ECM memory. MI does not illuminate at this stage. <1st trip>
When the same malfunction is detected again during the next driving, 2nd trip DTC is stored in the ECM memory and 1st trip DTC is cleared from the ECM memory. MI does not illuminate at this stage. <2nd trip>
When the same malfunction is detected again at the third driving, DTC and Freeze Frame Data are stored in
the ECM memory and 2nd trip DTC is cleared from the ECM memory. MI illuminates at the same time when
DTC is stored. <3rd trip>
In other words, DTC and Freeze Frame Data are stored and MI illuminates when the same malfunction occurs
in 3 consecutive trips.
This is called Three Trip Detection Logic.
ONE TRIP DETECTION LOGIC

When a malfunction is detected for the first time, DTC and Freeze Frame Data are stored in the ECM memory
and MI lights up. This is called One Trip Detection Logic. Some self-diagnoses will not illuminate MI when
DTC is stored. (Refer to EC-991, "Emission-related Diagnostic Information" .) 1st/2nd trip DTC is not stored for
one trip detection logic.
EBS011UL
EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS

Items
DTC*1
CONSULT-II
GST*2
1st/2nd trip
DTC
MI lighting
up
Reference page
ECM*3
CAN COMM CIRCUIT
U1000
1000
EC-1050
NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.
P0000
0000
CMP/CKP RELATION
P0016
0016
EC-1053
EC-991
http://vnx.su

DTC*1
Items
CONSULT-II
1st/2nd trip
DTC
MI lighting
up
Reference page
GST*2
ECM*
TC BOOST SOL/CIRC
P0045
0045
EC-1055
HIGH FUEL PRESS
P0088
0088
EC-1060
FUEL PUMP
P0089
0089
EC-1062
FUEL LEAK
P0093
0093
EC-1065
MAF SENSOR
P0101
0101
EC-1069
MAF SEN/CIRCUIT
P0102
0102
EC-1077
MAF SEN/CIRCUIT
P0103
0103
EC-1077
IAT SEN/CIRCUIT
P0112
0112
EC-1082
IAT SEN/CIRCUIT
P0113
0113
EC-1082
ECT SEN/CIRC
P0117
0117
EC-1087
ECT SEN/CIRC
P0118
0118
EC-1087
APP SEN 1/CIRCUIT
P0122
0122
EC-1093
APP SEN 1/CIRCUIT
P0123
0123
EC-1093
FUEL TEMP SEN/CIRC
P0182
0182
EC-1099
FUEL TEMP SEN/CIRC
P0183
0183
EC-1099
FRP SEN/CIRC
P0192
0192
EC-1103
FRP SEN/CIRC
P0193
0193
EC-1103
INJECTOR
P0200
0200
EC-1108
CYL1 INJECTOR
P0201
0201
EC-1110
CYL2 INJECTOR
P0202
0202
EC-1110
CYL3 INJECTOR
P0203
0203
EC-1110
CYL4 INJECTOR
P0204
0204
EC-1110
ENG OVER TEMP
P0217
0217
EC-1116
APP SEN 2/CIRCUIT
P0222
0222
EC-1130
APP SEN 2/CIRCUIT
P0223
0223
EC-1130
TC SYSTEM
P0234
0234
EC-1136
TC BOOST SEN/CIRC
P0237
0237
EC-1142
TC BOOST SEN/CIRC
P0238
0238
EC-1142
CKP SEN/CIRCUIT
P0335
0335
EC-1148
CKP SENSOR
P0336
0336
EC-1154
CMP SEN/CIRCUIT
P0340
0340
EC-1160
CMP SENSOR
P0341
0341
EC-1166
GLOW RELAY
P0380
0380
EC-1173
EGR SYSTEM
P0401
0401
EC-1177
EGR VALVE
P0404
0404
EC-1184
VEHICLE SPEED
P0501
0501
EC-1191
VEHICLE SPEED
P0502
0502
EC-1193
VEHICLE SPEED
P0503
0503
EC-1195
BRAKE SW/CIRCUIT
P0504
0504
EC-1197
BATTERY VOLTAGE
P0563
0563
EC-1206
STRG SW/CIRC
P0580
0580
EC-1208
STRG SW/CIRC
P0581
0581
EC-1208
EC-992
http://vnx.su

DTC*1
Items
CONSULT-II
1st/2nd trip
DTC
MI lighting
up
Reference page
EC
GST*2
ECM*
ECM
P0605
0605
EC-1217
ECM
P0606
0606
EC-1219
FUEL PUMP/CIRC
P0628
0628
EC-1221
FUEL PUMP/CIRC
P0629
0629
EC-1221
SENSOR PWR/CIRC1
P0642
0642
EC-1226
SENSOR PWR/CIRC1
P0643
0643
EC-1226
SENSOR PWR/CIRC2
P0652
0652
EC-1230
SENSOR PWR/CIRC2
P0653
0653
EC-1230
ECM RELAY
P0686
0686
EC-1235
TCS C/U FUNCTN
P1211
1211
EC-1239
TCS/CIRC
P1212
1212
EC-1240
INJ ADJ RES/CIRC1
P1260
1260
EC-1241
INJ ADJ RES/CIRC1
P1261
1261
EC-1241
INJ ADJ RES/CIRC2
P1262
1262
EC-1241
INJ ADJ RES/CIRC2
P1263
1263
EC-1241
INJ ADJ RES/CIRC3
P1264
1264
EC-1241
INJ ADJ RES/CIRC3
P1265
1265
EC-1241
INJ ADJ RES/CIRC4
P1266
1266
EC-1241
INJ ADJ RES/CIRC4
P1267
1267
EC-1241
INJECTOR 1
P1268
1268
EC-1247
INJECTOR 2
P1269
1269
EC-1247
INJECTOR 3
P1270
1270
EC-1247
INJECTOR 4
P1271
1271
EC-1247
FRP RELIEF VALVE
P1272
1272
EC-1253
FUEL PUMP
P1273
1273
EC-1259
FUEL PUMP
P1274
1274
EC-1264
FUEL PUMP
P1275
1275
EC-1269
P1610 - P1617
1610 - 1617
EC-996
APP SENSOR
P2135
2135
EC-1274
INJ PWR/CIRC
P2146
2146
EC-1280
INJECTOR/CIRC
P2147
2147
EC-1285
INJECTOR/CIRC
P2148
2148
EC-1285
INJ PWR/CIRC
P2149
2149
EC-1280
BARO SEN/CIRC
P2228
2228
EC-1291
BARO SEN/CIRC
P2229
2229
EC-1291
NATS MALFUNTION
*3: In Diagnostic Test Mode II (Self diagnostic results), this number is controlled by NISSAN.
DTC AND 1ST/2ND TRIP DTC

The number of 1st/2nd trip DTC is the same as the number of DTC.
When a malfunction is detected during 1st trip, 1st trip DTC is stored in the ECM memory. MI does not illuminate at this time. When the same malfunction is detected in the next trip (2nd trip), 2nd trip DTC is stored in the
ECM memory and 1st trip DTC is cleared from the ECM memory. MI does not illuminate at this time. In addi-
EC-993
http://vnx.su

tion, DTC is stored in the ECM memory and MI lights up when the same malfunction is detected during the following consecutive trip (3rd trip).
The procedure for erasing DTC, 1st trip DTC, and 2nd trip DTC from the ECM memory is described in EC-994,
"HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" .
For malfunctions in which 1st/2nd trip DTC are displayed, Refer to EC-991, "Emission-related Diagnostic Information" .
1st/2nd trip DTC is specified in Service $07 of ISO15031-5. 1st/2nd trip DTC detection occurs without lighting
up MI and therefore does not warn the driver of a malfunction.
When 1st/2nd trip DTC is detected, check, print out or write down, and erase 1st/2nd trip DTC as specified
with step II of Work Flow, refer to EC-1003, "WORK FLOW" . Then perform DTC Confirmation Procedure or
Overall Function Check to try to duplicate the malfunction. If the malfunction is duplicated, it is necessary to
investigate the cause again.
How to Read DTC and 1st/2nd Trip DTC

DTC and 1st/2nd trip DTC can be read by the following procedures.
With CONSULT-II
With GST
CONSULT-II or GST (Generic Scan Tool): Examples: P0117, P0335, P1260, etc.
These numbers are prescribed by ISO 15031-6.
(CONSULT-II also displays the malfunctioning parts and systems.)
A sample of CONSULT-II display for DTC and 1st/2nd trip DTC is
shown in the figure. DTC and 1st/2nd trip DTC are displayed in the
SELF-DIAG RESULTS mode of CONSULT-II.
TIME data shows how many times the vehicle was driven after the
last detection of DTC or 1st/2nd trip DTC. When DTC or 1st/2nd trip
DTC has been detected currently, TIME becomes 0.
CONSULT-II displays for DTC and 1st/2nd trip DTC become the
same.
The output of a DTC indicates a malfunction. However, GST

does not indicate whether the malfunction is still occurring or
has occurred in the past and has returned to normal. CONSULTII can identify the malfunction status. Therefore the use of CONSULT-II (If available) is recommended.
PBIB2022E
FREEZE FRAME DATA

ECM records driving conditions such as calculated load value, engine coolant temperature, engine speed,
vehicle speed, and intake manifold pressure at the moment a malfunction is detected.
The data stored together with DTC is called Freeze Frame Data, and is displayed on CONSULT-II or GST.
When 1st/2nd trip DTC is detected, Freeze Frame Data is not recorded.
Only a set of Freeze Frame Data can be stored in the ECM memory. When ECM records Freeze Frame Data,
and another Freeze Frame Data is generated after that, the first (original) Freeze Frame Data is not updated in
ECM and it remains.
When the DTC is erased from ECM memory, Freeze Frame Data is erased with DTC. The procedure for erasing DTC is described in EC-994, "How to Erase DTC" .

How to Erase DTC
With CONSULT-II
1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least 5
seconds and then turn it ON (engine stopped) again.
2. Touch ENGINE.
EC-994
http://vnx.su

4.

A
EC
F
PBIB2452E
With GST
The emission related diagnostic information in the ECM can be erased by selecting Service $04 with GST.
1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least 5
2. Select Service $04 with GST (Generic Scan Tool).
hours.
2nd trip diagnostic trouble codes
Freeze frame data

No Tools
1.
2.
3.
hours.
Freeze frame data
Fuel pump learning value
Others
EC-995
http://vnx.su

EBS01177

the ON position or "NATS MALFUNCTION" is displayed on
"SELF-DIAG RESULTS" screen, perform self-diagnostic
Refer to NATS (Nissan Anti-Theft System) in BL section.
before touching "ERASE" in "SELF-DAIG RESULTS" mode
with CONSULT-II.
SEF543X
Regarding the procedure of NATS initialization and NATS ignition key ID registration, refer to CONSULT-II operation manual, NATS.
EBS01F87
DESCRIPTION
If the MI does not light up, refer to EC-1682, "MI & DATA LINK
CONNECTORS" .
SAT652J

The on board diagnostic system has the following three functions.
Diagnostic Test
Mode
KEY and ENG.

Status
Function
Mode I
Ignition switch in
ON position
BULB CHECK

circuit, etc.).
If the MI does not come on, check MI circuit. (See EC1682, "MI & DATA LINK CONNECTORS" .)
Engine running
MALFUNCTION
WARNING
This is a usual driving condition. When ECM detects a malfunction, the MI will light up to inform the driver that a malfunction has been detected.
Ignition switch in
ON position
SELF-DIAGNOSTIC
RESULTS
This function allows DTCs to be read.
Engine stopped
Mode II
Engine stopped
EC-996
http://vnx.su

A
NOTE:
EC
has a malfunction.

1.
2.
a.
b.
3.
4.
blinking.
PBIB0092E
EC-997
http://vnx.su

1.
2.
3.

In this mode, the MI on the instrument panel should stay ON. If it remains OFF, check the bulb. Refer to EC1336, "MI & DATA LINK CONNECTORS" .

MI
Condition
ON
OFF
No malfunction.

In this mode, the DTC is indicated by the number of blinks of the MI as shown below. A DTC will be used as an
example for how to read a code.
PBIA3905E

The DTC can be erased from the back up memory in the ECM by depressing accelerator pedal. Refer to EC998, "How to Erase Diagnostic Test Mode II (Self-diagnostic Results)" .
EC-998
http://vnx.su

OBD System Operation Chart
EBS011UM
RELATIONSHIP BETWEEN MI, 1ST/2ND TRIP DTC, DTC, AND DETECTABLE ITEMS
When the malfunction is detected for the first time, 1st trip DTC is stored in the ECM memory.
When the same malfunction is detected during 2nd consecutive trip, 2nd trip DTC is stored and 1st trip
EC
DTC is cleared.
When the same malfunction is detected during 3rd consecutive trip, DTC and Freeze Frame Data are
stored and MI illuminates. Refer to EC-991, "Three Trip Detection Logic and One Trip Detection Logic" for
details.1st/2nd trip DTC are cleared from the ECM memory.
C
MI will go off after the vehicle is driven 3 consecutive times with no malfunction (driving pattern A).
1st/2nd trip DTC, DTC, and Freeze Frame Data will be stored until the vehicle is driven 41 times (driving
pattern B) without the same malfunction recurring. TIME data displayed in the SELF-DIAG RESULTS D
mode of CONSULT-II shows the number of times the vehicle is driven without the same malfunction recurring.
E
SUMMARY CHART
Items
Trip
Counter
Driving Pattern
MI (goes off)
DTC, Freeze Frame Data (clear)
41
40
1st/2nd Trip DTC (clear)
41
40
Refer to EC-1001 for details of pattern A and B.
EC-999
http://vnx.su

RELATIONSHIP BETWEEN MI, DTC, 1ST/ 2NDTRIP DTC AND DRIVING PATTERNS
PBIB2048E
*1: CONSULT-II displays for DTC and

1st/2nd trip DTC become the same.
*2: 1st/2nd trip DTC becomes the same

display in mode7 of GST.

times (pattern A) without any malfunctions.
*5: When the malfunction is detected for *6: When the same malfunction is
the first time, 1st trip DTC is stored in
detected during 2nd consecutive trip,
the ECM memory.
2nd trip DTC is stored and 1st trip
DTC is cleared.

detected during 3rd consecutive trip,
DTC and Freeze Frame Data are
stored.
*8: The DTC and the freeze frame data

vehicle is driven 41 times (pattern B)
EC-1000
http://vnx.su

detected in three consecutive trips,
MI will light up.

<Driving Pattern A>
Driving pattern A means the vehicle operation as follows:
Engine speed should go over 500 rpm at least 5 seconds and the DTC Confirmation Procedure is performed.
The A counter will be cleared when the same malfunction is detected.
The A counter will be counted up when the same malfunction is not detected.
The MI will go off when the A counter reaches 3.
<Driving Pattern B>
EC

Driving pattern A and (1)-(3) are satisfied.
D
PBIB2049E
The B counter will be cleared when the same malfunction is detected.

The B counter will be counted up when the same malfunction is not detected.
The DTC will not be displayed after the B counter reaches 40.
EC-1001
http://vnx.su
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS
PFP:00004
EBS01179
INTRODUCTION
The engine has an ECM to control major systems such as fuel injection control, fuel injection timing control, glow control system, etc.
The ECM accepts input signals from sensors and instantly actuators.
It is essential that both input and output signals are proper and stable. At the same time, it is important that there are no malfunctions
such as vacuum leaks, or other malfunctions with the engine.
MEF036D
It is much more difficult to diagnose a malfunction that occurs intermittently rather than continuously. Most intermittent malfunctions are
SEF233G
be performed. Follow the EC-1003, "WORK FLOW" .
on next page should be used.
Start your diagnosis by looking for conventional incidents first. This
will help troubleshoot driveability incidents on an electronically controlled engine vehicle.
EC-1002
http://vnx.su
SEF234G
TROUBLE DIAGNOSIS
WORK FLOW
A
EC
PBIB2047E
*1

RESULTS is other than 0, perform EC-1040, "TROUBLE DIAGNOSIS FOR INTERMITTENT
INCIDENT" .
*4

*2

INCIDENT" .
EC-1003
http://vnx.su

Refer to EC-1041, "POWER SUPPLY AND GROUND CIRCUIT" .
TROUBLE DIAGNOSIS
STEP
DESCRIPTION
STEP I
Get detailed information about the conditions and the environment when the incident/symptom occurred using the
EC-1004, "DIAGNOSTIC WORK SHEET" .
STEP II
Before confirming the concern, check and write down (print out using CONSULT-II or GST) the (1st/2nd trip) DTC and
the freeze frame data (When 1st/2nd trip DTC is detected, Freeze Frame Data is not recorded.), then erase the DTC
and the data. (Refer to EC-994 .) The (1st/2nd trip) DTC and the freeze frame data can be used when duplicating the
incident at STEP III & IV.
Study the relationship between the cause, specified by (1st/2nd trip) DTC, and the symptom described by the customer. (The Symptom Matrix Chart will be useful. See EC-1011 .)
STEP III
STEP IV
Try to detect the (1st/2nd trip) DTC by driving in (or performing) the DTC Confirmation Procedure. Check and read
the (1st/2nd trip) DTC and freeze frame data by using CONSULT-II or GST.
During the (1st/2nd trip) DTC verification, be sure to connect CONSULT-II to the vehicle in DATA MONITOR (AUTO
In case the DTC Confirmation Procedure is not available, perform the Overall Function Check instead. The (1st/2nd
trip) DTC cannot be displayed by this check, however, this simplified check is an effective alternative.
The NG result of the Overall Function Check is the same as the (1st/2nd trip) DTC detection.
STEP V
If the normal code is indicated, proceed to the BASIC INSPECTION. (Refer to EC-1007 .)Then perform inspections
according to the Symptom Matrix Chart. (Refer to EC-1011 .)
STEP VI
(AUTO TRIG) mode.
Refer to EC-1022 , EC-1037 .
STEP VII
Before returning the vehicle to the customer, be sure to erase the unnecessary (already fixed) (1st/2nd trip) DTC in
ECM. (Refer to EC-994, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" .)
DIAGNOSTIC WORK SHEET

In general, each customer feels differently about an incident. It is
Utilize a diagnostic worksheet like the one shown below in order to
organize all the information for troubleshooting.
SEF907L
EC-1004
http://vnx.su
TROUBLE DIAGNOSIS
Worksheet Sample
A
EC
MTBL0533
EBS012AS
chart.
NOTE:
EC-1005
http://vnx.su
TROUBLE DIAGNOSIS
Priority
1
U1000 CAN communication line
P0016 Crankshaft position - camshaft position correlation
P0101 P0102 P0103 Mass air flow sensor
P0182 P0183 Fuel pump temperature sensor
P0192 P0193 Fuel rail pressure sensor
P0237 P0238 Turbocharger boost sensor
P0335 P0336 Crankshaft position sensor
P0340 P0341 Camshaft position sensor
P0563 Battery voltage
P0605 P0606 ECM
P0642 P0643 P0652 P0653 Sensor power supply
P1260 - P1267 Fuel injector adjustment resistor
P1610 - P1617 NATS
P2228 P2229 Barometric pressure sensor
P0045 Turbocharger boost control solenoid valve
P0089 P0628 P0629 P1272 - P1275 Fuel pump
P0200 - P0204 P1268 - P1271 P2146 - P2149 Fuel injector
P0380 Glow relay
P0404 EGR volume control valve
P0686 ECM relay
P0088 P0093 Fuel system
P0234 Turbocharger system
P0401 EGR function
P0501 P0502 P0503 ASCD vehicle speed sensor
P0504 ASCD brake switch
P0580 P0581 ASCD steering switch
EC-1006
http://vnx.su
TROUBLE DIAGNOSIS
Basic Inspection
EBS0117A
A
Precaution:
Perform Basic Inspection without electrical or mechanical loads applied;

EC
only small lamps.

C
Rear defogger switch is OFF.

D
1. INSPECTION START
1.
2.
3.
4.
Check service records for any recent repairs that may indicate a related malfunction.
Check the current need for scheduled maintenance, especially for fuel filter and air cleaner filter. Refer to
MA-7, "PERIODIC MAINTENANCE" .
Vacuum hoses for splits, kinks, or improper connections
Wiring for improper connections, pinches, or cuts
>> GO TO 2.
I
J
SEF142I
2. PREPARATION FOR CHECKING IDLE SPEED

K
With CONSULT-II
Connect CONSULT-II to the data link connector.
Without CONSULT-II
Install diesel tacho tester to the vehicle.
>> GO TO 3.
EC-1007
http://vnx.su
TROUBLE DIAGNOSIS
3. CHECK IDLE SPEED

With CONSULT-II
1. Select CKPSRPM (TDC) in DATA MONITOR mode with CONSULT-II.
2. Read idle speed.
72525 rpm
SEF817Y
Without CONSULT-II
Read idle speed.
72525 rpm
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 4.

OK or NG
OK
>> GO TO 5.
NG
5. BLEED AIR FROM FUEL SYSTEM

1.
2.
Stop engine.
Use priming pump to bleed air from fuel system. Refer to EC-989, "AIR BLEEDING" .
>> GO TO 6.
EC-1008
http://vnx.su
TROUBLE DIAGNOSIS
6. CHECK IDLE SPEED AGAIN
With CONSULT-II
3. Read idle speed.
EC
72525 rpm
E
SEF817Y
Without CONSULT-II
Read idle speed.
72525 rpm
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 7.
7. DRAIN WATER FROM FUEL FILTER

I
Drain water from fuel filter. Refer to EC-989, "WATER DRAINING" .

>> GO TO 8.

K
With CONSULT-II
3. Read idle speed.
72525 rpm
M
SEF817Y
Without CONSULT-II
Read idle speed.
72525 rpm
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 9.
EC-1009
http://vnx.su
TROUBLE DIAGNOSIS
9. CHECK AIR CLEANER FILTER

Check air cleaner filter for clogging or breaks.
OK or NG
OK
>> GO TO 10.
NG
>> Replace air cleaner filter.
10. CHECK BATTERY VOLTAGE

Check battery voltage.
Voltage: More than 12.13V
OK or NG
OK
>> GO TO 12.
NG
>> GO TO 11.
11. CHECK BATTERY

Refer to SC-3, "BATTERY" .
OK or NG
OK
>> Check charging system. Refer to SC-12, "CHARGING SYSTEM" .
NG

OK or NG
OK
>> GO TO 13.
NG
>> Follow the instruction of CHECKING COMPRESSION PRESSURE.

With CONSULT-II
3. Read idle speed.
72525 rpm
SEF817Y
Without CONSULT-II
Read idle speed.
72525 rpm
OK or NG
OK
>> INSPECTION END
NG
>> 1. Replace fuel injector.
2. GO TO 3.
EC-1010
http://vnx.su
TROUBLE DIAGNOSIS
EBS0117B
A
LOW IDLE
HI IDLE
POOR ACCELERATION
LACK OF POWER
KNOCK/DETONATION
AA
AB
AC
Fuel pump
Fuel injector
Glow control system
Engine body
Fuel transport pump
AD
AE
AF
EC-1110
1
3
EM-219
EC-1319
EC-1177
Air cleaner and duct
EM-139
EC-1065
Fuel pump circuit
EC-1221
Fuel injector circuit
EC-1110
ENGINE CONTROL
Fuel rail pressure relief valve
1
1
Fuel rail pressure sensor circuit
EC-1077
1

EC-1087
LAN-4
EC-1093
EC-1103
EC-1011
http://vnx.su
EC-1293
EGR system
Engine coolant temperature circuit
EC
WHEN DECELERATING
DURING DRIVING
AT IDLE
HARD TO START WHEN ENGINE IS HOT
HARD TO START WHEN ENGINE IS COLD
NO START (without first firing)
NO START (with first firing)
ENGINE STALL
SYSTEM Basic engine control system
Reference page
SYMPTOM
TROUBLE DIAGNOSIS
LOW IDLE
HI IDLE
POOR ACCELERATION
AD
LACK OF POWER
Camshaft position sensor circuit
AB
1
KNOCK/DETONATION
Crankshaft position sensor circuit
AC
WHEN DECELERATING
AA
DURING DRIVING
AT IDLE
ENGINE STALL
Reference page
SYMPTOM
AE
1
AF
1
EC-1148
EC-1160
ENGINE CONTROL
Turbocharger boost sensor circuit
EC-1142

valve circuit
EC-1055
EC-1333
Start signal circuit
Ignition switch circuit
EC-1041
Power supply for ECM circuit
EC-1041
Cooling fan relay circuit
EC-1116
EGR volume control valve circuit

Glow relay circuit
1
1
ECM relay (Self-shutoff) circuit

ECM, connector circuit
EC-1184
EC-1173
1
2
EC-1235
2
EC-1217,
EC-1291
EC-996

EC-1012
http://vnx.su
TROUBLE DIAGNOSIS
Can be detected by CONSULT-II?
Fuel pump
Fuel injector
AM
AP
Glow control system

3
Malfunction indicator illuminates.
AJ
DEAD BATTERY (UNDER CHARGE)
AH
HA
EC-1110
EC-1293
EM-219
EC-1177
EM-139
ENGINE CONTROL
EC-1065
Fuel pump circuit
EC-1259
EC-1110
EC-1077
EC-1087
1
1

EC-1319
EGR system
EC
Fuel transport pump
AG
Engine body
WHITE SMOKE
BLACK SMOKE
AL
ABNORMAL SMOKE COLOR
AK
OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE
IDLING VIBRATION
ROUGH IDLE/HUNTING
Reference page
SYMPTOM
LAN-4
EC-1093
EC-1103
EC-1013
http://vnx.su
TROUBLE DIAGNOSIS
AL
AM
EC-1160
EC-1142
Turbocharger boost control solenoid valve circuit
AP
AK
WHITE SMOKE
AJ
BLACK SMOKE
AH
ENGINE CONTROL
EC-1148
IDLING VIBRATION
ROUGH IDLE/HUNTING
AG
Reference page
SYMPTOM
HA
EC-1055
EC-1333
EC-1041
2
1
Glow relay circuit
EC-1184
1
EC-1173

2

EC-1014
http://vnx.su
EC-1041
EC-1116
EC-1235
EC1217,EC1291
EC-996
TROUBLE DIAGNOSIS
EBS0117C
EC
PBIB1888E
EC-1015
http://vnx.su
TROUBLE DIAGNOSIS
PBIB1938E
EC-1016
http://vnx.su
TROUBLE DIAGNOSIS
A
EC
PBIB1939E
EC-1017
http://vnx.su
TROUBLE DIAGNOSIS
PBIB1940E
EC-1018
http://vnx.su
TROUBLE DIAGNOSIS
A
EC
PBIB2881E
1.
2.
3.
CANSEL switch
4.
SET/COAST switch
5.
MAIN switch
6.
Stop lamp switch harness connector
7.
ASCD brake switch harness connector
8.
ASCD clutch switch harness connector
EC-1019
http://vnx.su
TROUBLE DIAGNOSIS
Circuit Diagram
EBS0117D
TBWB0473E
EC-1020
http://vnx.su
TROUBLE DIAGNOSIS
A
EC
TBWB0474E
EC-1021
http://vnx.su
TROUBLE DIAGNOSIS
EBS0117E
MBIB0045E
ECM Terminals And Reference Value
EBS0117F
PREPARATION
1.
2.

remove glove box.
PBIB1899E
3.
4.

levers as far as they will go as shown in the figure.
PBIB1512E

Remarks: Specification data are reference values and are measured between each terminal and ground.
CAUTION:
TERMINAL
NO.
1
2
3
WIRE
COLOR
B
B
B
ITEM
ECM ground
CONDITION
[Engine is running]
Idle speed
EC-1022
http://vnx.su
DATA
(DC Voltage and Pulse Signal)
Approximately 0V
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
[Engine is running]
W/B
G/B
Fuel injector power supply

(For cylinder No. 1 and 4)
Warm-up condition
Idle speed
DATA
5 - 10V
EC
NOTE:
idle.
C
MBIB0883E
5 - 10V
[Engine is running]
Warm-up condition
F
MBIB0884E
[Ignition switch ON]
Warm-up condition
Idle speed
0 - 12.5V
NOTE:
idle.
6
H
MBIB0889E

solenoid valve
0 - 12.5V
Warm-up condition
MBIB0890E
[Engine is running]
Warm-up condition
Idle speed
0 - 12.5V
NOTE:
idle.
M
MBIB0885E
10
Y/L
Fuel pump power supply

0 - 12.5V
[Engine is running]
Warm-up condition
MBIB0886E
14
W/PU
Fuel level switch
Some fuel is in the fuel tank
No fuel is in the fuel tank
EC-1023
http://vnx.su
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
[Engine is running]
19
Air conditioner switch is OFF
Both air conditioner switch and blower fan

switch are ON (Compressor is operating)
[Engine is running]
G/R
GY/L
G/R
GY/L
Fuel injector No. 2

Fuel injector No. 2
Fuel injector No. 3
Fuel injector No. 3
BATTERY VOLTAGE
(11 - 14V)
[Engine is running]
21
22
23
24
DATA
Warm-up condition
Idle speed
Approximately 0.1V
0 - 9V
NOTE:
idle.
MBIB0881E
0 - 9V
[Engine is running]
Warm-up condition
MBIB0882E
25
26
27
28
GY
W/L
OR/B
GY/B
[Engine is running]
Warm-up condition
Idle speed
[Engine is running]
Warm-up condition
Idle speed
0.1 - 14V
(Voltage signals of each ECM terminals differ according to the control position of EGR volume
control valve.)
0.5 - 1.0V
NOTE:
idle.
MBIB0887E
29
Fuel pump
0.5 - 1.0V
[Engine is running]
Warm-up condition
MBIB0888E
[Engine is running]
34
LG/B
Cooling fan is operating at low speed
[Engine is running]
Cooling fan is operating at high speed
BATTERY VOLTAGE
(11 - 14V)
Approximately 0.1V
[Engine is running]
36
LG
[Engine is running]
EC-1024
http://vnx.su
BATTERY VOLTAGE
(11 - 14V)
Approximately 0.1V
TROUBLE DIAGNOSIS
TERMINAL
NO.
37
WIRE
COLOR
W/R
ITEM
Glow relay
B/OR
[Engine is running]
[Engine is running]
40
41
42
43
G/R
GY/L
G/R
GY/L
Fuel injector No. 4

Fuel injector No. 4
Fuel injector No. 1
Fuel injector No. 1
Refer to EC-1293, "GLOW CONTROL SYSTEM" .

[Engine is running]
39
DATA
CONDITION
Warm-up condition
Idle speed
EC
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
0 - 9V
NOTE:
idle.
E
MBIB0881E
0 - 9V
[Engine is running]
Warm-up condition
MBIB0882E
44
L/W
Crankshaft position sensor power supply
Approximately 5.3V
45
G/OR

power supply
Approximately 5.3V
[Engine is running]
Warm-up condition
Idle speed
0 - 6V
NOTE:
idle.
MBIB0879E
46
0 - 6V
[Engine is running]
Warm-up condition
MBIB0880E
EC-1025
http://vnx.su
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
[Engine is running]
Warm-up condition
Idle speed
DATA
0 - 6V
NOTE:
idle.
MBIB0877E
47
G/R

0 - 6V
[Engine is running]
Warm-up condition
MBIB0878E
[Engine is running]
48
49
50
51
Y/R
R
PU
L/OR
Warm-up condition
Idle speed
1.7 - 2.0V
[Engine is running]
Fuel pump temperature

sensor
Warm-up condition
[Engine is running]
Warm-up condition
[Engine is running]
Warm-up condition
2.0 - 2.3V
Approximately 0.3 - 5.3V

Output voltage varies with fuel
pump temperature
coolant temperature
[Engine is running]
52
Warm-up condition
Idle speed
2.3 - 2.6V
[Engine is running]
Warm-up condition
2.5 - 2.8V
[Engine is running]
54
55
59
W/B
60
Y/B
61
G/B
62
R/B

Fuel injector adjustment
resistor No. 1
resistor No. 3
resistor No. 4
resistor No. 2
Warm-up condition
Idle speed
1.8 - 2.3V
[Engine is running]
Warm-up condition
[Engine is running]
Warm-up condition
EC-1026
http://vnx.su
2.5 - 3.0V

air temperature
0.5 - 5.1V
(There are individual differences
between fuel injector adjustment
resistors.)
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA

power supply
Approximately 5.3V
64

power supply
Approximately 5.3V
65
L/R
Crankshaft position sensor ground
Approximately 0.3V
66
G/Y

ground
Approximately 0.3V
67
Sensor ground
(Sensors shield circuit)
Approximately 0.3V
68

ground
Approximately 0.3V
69

sensor ground
Approximately 0.3V
70
Engine coolant temperature sensor ground
Approximately 0.3V
71

ground
Approximately 0.3V
73

ground
Approximately 0.3V
74
Intake air temperature sensor ground
Approximately 0.3V
78

resistor ground
Approximately 0.3V
82

sensor 1 power supply
Approximately 5.3V
63

sensor 1
Engine stopped
Engine stopped
4.2 - 5.2V
Sensor ground
(Accelerator pedal position sensor shield circuit)
Approximately 0.3V
87
GY/R

Output voltage varies with the
communication status.
89
LG
Data link connector
Approximately 0.3V
CONSULT-II or GST is disconnected.
Approximately 0V - Battery voltage (11 - 14V)

Approximately 5.3V

sensor 2
0.5 - 1.0V
85
91

84

sensor 1 ground
90
EC
83
Engine stopped
0.4 - 0.7V
Engine stopped
EC-1027
http://vnx.su
2.2 - 2.7V
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA
92

sensor 2 ground
Approximately 0.3V
95
G/R

Approximately 0.3V
99
B/Y
Start signal
[Ignition switch START]
BATTERY VOLTAGE
(11 - 14V)
[Ignition switch OFF]
100
Stop lamp switch
101
GY/L
ASCD brake switch
Brake pedal and clutch pedal: Fully released
Brake pedal and/or clutch pedal: Slightly

depressed
PU*1
W/R*2
103
B/OR

ground

105
ECM relay (self-shutoff)

switch OFF
107
108
W/R
W/R
Ignition switch
Park/Neutral position
switch

110
G/OR
Gear position is Neutral
Except the above gear position
[Engine is running]
111
P/B

switch
BATTERY VOLTAGE
(11 - 14V)
BATTERY VOLTAGE
(11 - 14V)
102
Approximately 0V
[Engine is running]
EC-1028
http://vnx.su
Approximately 0V
Approximately 4.3V
Approximately 0.3V
Approximately 1.3V
Approximately 3.3V
Approximately 2.3V
Approximately 0.3V
Approximately 1.2V
BATTERY VOLTAGE
(11 - 14V)
BATTERY VOLTAGE
(11 - 14V)
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
113

switch OFF
114
ECM ground
[Engine is running]
DATA
EC
Approximately 1.2V
BATTERY VOLTAGE
(11 - 14V)
Approximately 0V
Idle speed
119
120
Y
R
BATTERY VOLTAGE
(11 - 14V)
121
W/L

(Back-up)
BATTERY VOLTAGE
(11 - 14V)
*1: LHD models
*2: RHD models
EBS0117G
FUNCTION
Function
Self-diagnostic results such as 1st/2nd trip DTC, DTC and freeze frame data can be read and erased
quickly.*
Data monitor

monitor
Active test
Function test
ECM part number
1st/2nd trip diagnostic trouble codes
Freeze frame data
EC-1029
http://vnx.su
TROUBLE DIAGNOSIS
SELF-DIAG RESULTS
Item
INPUT
OUTPUT
DATA MONITOR
DTC*
FREEZE
FRAME
DATA
Accelerator pedal position sensor 1
Battery voltage
ACTIVE
TEST
Stop lamp switch
Barometric pressure sensor (built-into ECM)
Fuel injector adjustment resistor
ASCD brake switch
ASCD clutch switch
Fuel pump
Fuel injector
Glow relay
Cooling fan relay
X: Applicable
*: This item includes 1st/2nd trip DTCs.
1.
2.
3.

Connect CONSULT-II to data link connector, which is located
under the driver side dash panel.
PBIB0376E
EC-1030
http://vnx.su
TROUBLE DIAGNOSIS
4.
Touch START (NISSAN BASED VHCL).

A
EC
C
BCIA0029E
5.
Touch ENGINE.
G
BCIA0030E
6.

procedure.
BCIA0031E
SELF-DIAGNOSTIC MODE
Regarding items of DTC and 1st/2nd trip DTC, refer to EC-969, "INDEX FOR DTC" .
Freeze Frame Data

Freeze frame data item
Description
DIAG TROUBLE CODE

[PXXXX]
The engine control component part/control system has a trouble code, it is displayed as PXXXX.
(Refer to EC-969, "INDEX FOR DTC" .)
CAL/LD VALUE [%]
COOLANT TEMP [C] or [F]
ENGINE SPEED [rpm]
VEHICL SPEED [km/h] or

[mph]
INT MANI PRES [kPa]
The intake manifold pressure at the moment a malfunction is detected is displayed.
INT/A TEMP SE [C] or [F]
FUEL/R PRESS [kPa]
The fuel rail pressure at the moment a malfunction is detected is displayed.
MASS AIRFLOW [g/s]
The mass air flow at the moment a malfunction is detected is displayed.
EC-1031
http://vnx.su
TROUBLE DIAGNOSIS
DATA MONITOR MODE
MONITOR ITEM
CKPSRPM (TDC) [rpm]
ECM
INPUT
SIGNAL
MAIN
SIGNALS
CONDITION
The engine speed computed from the

crankshaft position sensor signal is displayed.
The engine coolant temperature (determined by the signal voltage of the engine
coolant temperature sensor) is displayed.
The vehicle speed computed form the

vehicle speed sensor signal is displayed.
The fuel temperature (determined by the

signal voltage of the fuel pump temperature sensor) is displayed.
COOLAN TEMP/S
[C] or [F]
VHCL SPEED SE
[km/h] or [mph]
FUEL TEMP SEN

[C] or [F]
ACCEL POS SEN [V]
The accelerator pedal position sensor 1

signal voltage is displayed.
ACCEL SEN 2 [V]

ACT CR PRESS [MPa]
The Fuel rail pressure (determined by

the signal voltage of the fuel rail pressure
sensor) is displayed.
BATTERY VOLT [V]
P/N POSI SW [ON/OFF]
Indicates [ON/OFF] condition from the

park/neutral position switch signal.
START SIGNAL [ON/OFF]
indicates [ON/OFF] condition from the

starter signal.
PW/ST SIGNAL [ON/OFF]

power steering pressure switch signal.
BRAKE SW [ON/OFF]

stop lamp switch signal.
BRAKE SW2 [ON/OFF]

ASCD brake switch and ASCD clutch
switch signal.
IGN SW [ON/OFF]
Indicates [ON/OFF] condition from ignition switch signal.
MAS AIR/FL SE [V]

sensor is displayed.
Indicates the actual fuel injection pulse

width compensated by ECM according to
the input signals.
Indicates the fuel pump power supply

current from the ECM.
The glow relay control condition (determined by ECM according to the input signal) is displayed.
Indicates the control condition of the

cooling fans (determined by ECM
according to the input signal).
LOW ... Operates at low speed.
HI ... Operates at high speed.
OFF ... Stopped
MAIN INJ WID [msec]
PUMP CURRENT [mA]
GLOW RLY [ON/OFF]
COOLING FAN
[LOW/HI/OFF]
EC-1032
http://vnx.su
SPECIFICATION
When the engine coolant temperature circuit is open or short, ECM

enters fail-safe mode. The engine
coolant temperature determined
by the ECM is displayed.
TROUBLE DIAGNOSIS
MONITOR ITEM
ECM
INPUT
SIGNAL
MAIN
SIGNALS
CONDITION
EGR VOL CON/V [step]
INT/A VOLUME [mg/]
BARO SEN [kPa]
Indicates the EGR volume control value

computed by the ECM according to the
input signals.
The opening becomes larger as the

value increases.
The intake air volume computed from the

mass air flow sensor signal is displayed.
The barometric pressure (determined by

the signal voltage from the absolute
pressure sensor built into the ECM) is
displayed.
Turbocharger boost (determined by the

signal voltage from the turbocharger
boost sensor) is displayed.
The cylinder being injected is displayed.

1 ... Cylinder No.1 is injected.
INT/M PRES SE [kPa]
CYL COUNT [1/2/3/4]

RESUME/ACC SW
[ON/OFF]
Indicates [ON/OFF] condition from

RESUME/ACCELERATE switch signal.
CANCEL SW
[ON/OFF]
Indicates [ON/OFF] condition from CANCEL switch signal.
MAIN SW
[ON/OFF]

switch signal.
SET SW
[ON/OFF]
SPECIFICATION
EC
Voltage [V]

ones.
They are the same figures as an
actual piece of data which was
just previously measured. [Hz] or
[%]
Frequency [msec], [Hz] or

[%]
Voltage, frequency, duty cycle or pulse
width measured by the probe.
DUTY-HI
DUTY-LOW
PLS WIDTH-HI
PLS WIDTH-LOW
NOTE:
ACTIVE TEST MODE

TEST ITEM
POWER BALANCE
COOLING FAN *
CONDITION
Engine: After warming up, idle the

engine.
A/C switch: OFF
Shift lever: Neutral position

a time using CONSULT-II
Ignition switch: ON
Operate the cooling fan at LOW,

HI speed and turn OFF using
CONSULT-II.
JUDGEMENT
Cooling fan moves at LOW, HI

speed and stops.
EC-1033
http://vnx.su
CHECK ITEM (REMEDY)
Compression
Fuel injector
Harness and connector
Cooling fan motor
Cooling fan relay
TROUBLE DIAGNOSIS
TEST ITEM
ENG COOLANT
TEMP
GLOW RLY
EGR VOL CONT/

V
PRES REGULATOR
PUMP LEANT
CLEAR
CONDITION

trouble condition

stopped)
Turn the glow relay ON and OFF

using CONSULT-II and listen to
operating sound.
Ignition switch: ON
Change EGR volume control

valve opening step using CONSULT-II.
JUDGEMENT
CHECK ITEM (REMEDY)
Fuel injector
Glow relay makes the operating

sound.
Glow relay
EGR volume control valve makes

an operating sound.
Fuel line
Fuel pressure relief valve

CHECK ITEM.
Ignition switch: ON
Change fuel rail pressure using

CONSULT-II
This mode is used for performing Fuel Pump Learning Value Clearing. Refer to EC-989, "Fuel Pump Learning
Value Clearing" .
Fuel leaks.
REAL TIME DIAGNOSIS IN DATA MONITOR MODE

mode.
The malfunction will be identified on the CONSULT-II screen in

real time.
In other words, DTC/1st trip DTC/2nd trip DTC will be displayed
if the malfunction is detected by ECM.
At the moment a malfunction is detected by ECM, MONITOR
in DATA MONITOR screen is changed to Recording Data ...
xx% as shown in the figure, and the data after the malfunction
detection is recorded. Then when the percentage reached
100%, REAL-TIME DIAG screen is displayed. If STOP is
touched on the screen during Recording Data ... xx%, REALPBIB0480E
TIME DIAG screen is also displayed.
The recording time after the malfunction detection and the recording speed can be changed by TRIGGER POINT and Recording Speed. Refer to CONSULT-II OPERATION MANUAL.
DTC/1st trip DTC/2nd trip DTC will not be displayed automatically on CONSULT-II screen even though a malfunction is
detected by ECM.
DATA MONITOR can be performed continuously even though a
malfunction is detected.
Use these triggers as follows:
1. AUTO TRIG
While trying to detect the DTC/1st trip DTC/2nd trip DTC by performing the DTC Confirmation Procedure, be sure to select to
SEF707X
DATA MONITOR (AUTO TRIG) mode. You can confirm the
malfunction at the moment it is detected.
When you are inspecting the circuit by gently shaking (or twisting) the suspicious connectors, components
and harness in the DTC Confirmation Procedure, the moment a malfunction is found the DTC/1st trip
DTC/2nd trip DTC will be displayed. Refer to GI-23, "How to Perform Efficient Diagnosis for an Electrical
Incident" , INCIDENT SIMULATION TESTS.
EC-1034
http://vnx.su
TROUBLE DIAGNOSIS
2.
MANU TRIG
TRIG. By selecting MANU TRIG you can monitor and store the data. The data can be utilized for further
diagnosis, such as a comparison with the value for the normal operating condition.
EC
SEF720X
FUNCTION TEST
This mode is used to inform customers of their vehicle condition of periodic maintenance.
Generic Scan Tool (GST) Function
K
EBS011UO
DESCRIPTION
Generic Scan Tool (OBDII scan tool) complying with ISO 15031-4
has 8 different functions explained below.
ISO9141 is used as the protocol.
The name GST or Generic Scan Tool is used in this service manual.
SEF139P
FUNCTION
Function
Service $01
READINESS TESTS
This diagnostic service gains access to current emission-related data values, including
analog inputs and outputs, digital inputs and outputs, and system status information.
Service $02
(FREEZE DATA)
This diagnostic service gains access to emission-related data value which were stored by
ECM during the freeze frame. For details, refer to EC-994, "FREEZE FRAME DATA" .
Service $03
DTCs
This diagnostic service gains access to emission-related power train trouble codes which
were stored by ECM.
EC-1035
http://vnx.su
TROUBLE DIAGNOSIS
Function
This diagnostic service can clear all emission-related diagnostic information. This
includes:
Service $04
CLEAR DIAG INFO
Clear number of diagnostic trouble codes (Service $01)
Clear diagnostic trouble codes (Service $03)
Clear trouble code for freeze frame data (Service $01)
Clear freeze frame data (Service $02)
Reset status of system monitoring test (Service $01)
Clear on board monitoring test results (Service $07)
Service $06
(ON BOARD TESTS)
This diagnostic service is not applicable on this vehicle.
Service $07
(ON BOARD TESTS)
This diagnostic service enables the off board test drive to obtain test results for emissionrelated powertrain components/systems that are continuously monitored during normal
driving conditions.
Service $09
(CALIBRATION ID)
This diagnostic service enables the off-board test device to request specific vehicle information such as Vehicle Identification Number (VIN) and Calibration IDs.
1.
2.
3.

Connect GST to data link connector, which is located under
drivers side dash panel near the fuse box cover.
PBIB0376E
4.
Enter the program according to instruction on the screen or in

the operation manual.
(*: Regarding GST screens in this section, sample screens are
shown.)
SEF398S
5.
Perform each diagnostic mode according to each service procedure.

For further information, see the GST Operation Manual of the
tool maker.
SEF416S
EC-1036
http://vnx.su
TROUBLE DIAGNOSIS
EBS0117H
Remarks:
MONITOR ITEM
CONDITION
SPECIFICATION
Run engine and compare CONSULT-II value with the tachometer

indication.

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

Ignition switch: ON
(Engine stopped)
0.2 - 0.7V
3.9 - 4.9V
Ignition switch: ON
(Engine stopped)
0.1 - 0.4V
1.9 - 2.4V
Idle
1.5 - 2.0V
2,000 rpm
2.2 - 2.7V
No-load
BATTERY VOLT
P/N POSI SW
Ignition switch: ON
CKPS-RPM (TDC)
COOLAN TEMP/S
VHCL SPEED SE
FUEL TEMP SEN
ACCEL POS SEN*
ACCEL SEN 2*
MAS AIR/FL SE*
START SIGNAL
PW/ST SIGNAL
BRAKE SW
BRAKE SW2
IGN SW
GLOW RLY
Ignition switch: ON
Ignition switch: ON OFF
ON
Except above
OFF
No-load
Steering wheel is in neutral position. (Forward direction)
OFF ON OFF
I
OFF
ON
OFF
ON
Brake pedal and clutch pedal:

Fully released
OFF
Brake pedal and/or clutch pedal:

Slightly depressed
ON
ON OFF
Idle
20 - 30 MPa
2,000 rpm
45 - 55 MPa
No-load
0.68 - 0.78 msec
Idle speed
Blower fan switch: ON

0.78 - 0.88 msec
No-load
When cooling fan is stopped.
OFF
When cooling fans operate at low speed.
LOW
When cooling fans operate at high speed.
HI
PUMP CURRENT
COOLING FAN
Ignition switch: ON
ACT CR PRESS
MAIN INJ WID

the engine
11 - 14V
EC
Idle
1,700 - 1,900 mA
2,000 rpm
1,600 - 1,800 mA
EC-1037
http://vnx.su
TROUBLE DIAGNOSIS
MONITOR ITEM
CONDITION
No-load
Engine: After warming up, idle the engine
150 - 450 mg/st
Idle
Approx. 100 kPa
2,800 rpm
Approx. 126 kPa
No-load
4,000 rpm
Approx. 106 kPa
EGR VOL CON/V
INT/A VOLUME
SPECIFICATION
INT/M PRES SE [kPa]
After 1 minute at idle
More than 10 steps

rpm
0 step
Altitude
Approx. 0m: Approx. 100.62 kPa
(1.0062 bar, 1.026 kg/cm2 , 14.59
psi)
Approx. 1,000 m: Approx. 88.95
BARO SEN
kPa (0.8895 bar, 0.907 kg/cm2 ,

12.90 psi)
Ignition switch: ON
kPa (0.8316 bar, 0.848 kg/cm2 ,

12.06 psi)
kPa (0.7836 bar, 0.799 kg/cm2 ,
11.36 psi)
CYL COUNT
Engine is running
SET SW
Ignition switch: ON
RESUME/ACC SW
CANCEL SW
MAIN SW
Ignition switch: ON
Ignition switch: ON
Ignition switch: ON
1342
OFF
ON
Released
OFF
Pressed
ON
OFF
ON
OFF
ON
NOTE:
*: These signals are converted by ECM internally. Thus, these differ from ECM terminals voltage.
EBS0117I
ACCEL POS SEN, CKPSRPM (TDC), MAS AIR/FL SE

Below is the data for ACCEL POS SEN, CKPSRPM (TDC) and MAS AIR/FL SE when revving engine
quickly up to 3,000 rpm under no load after warming up engine to the normal operating temperature.
EC-1038
http://vnx.su
TROUBLE DIAGNOSIS
A
EC
SEF321Y
EC-1039
http://vnx.su


Description
PFP:00006
EBS0117J
Intermittent incidents may occur. In many cases, the incident resolves itself (the part or circuit function returns
to normal without intervention). It is important to realize that the symptoms described in the customer's complaint often do not recur on (1st/2nd trip) DTC visits. Realize also that the most frequent cause of intermittent
incidents occurrences is poor electrical connections. Because of this, the conditions under which the incident
COMMON INTERMITTENT INCIDENTS REPORT SITUATIONS

STEP in Work Flow
Situation
II
The CONSULT-II is used. The SELF-DIAG RESULTS screen shows time data other than 0.
III
IV
(1st/2nd trip) DTC does not appear during the DTC Confirmation Procedure.
VI
The Diagnostic Procedure for XXXX does not indicate the malfunctioning area.
EBS0117K
1. INSPECTION START
Erase (1st/2nd trip) DTCs. Refer to EC-994, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" .
>> GO TO 2.

OK or NG
OK
>> GO TO 3.
NG

Perform GI-23, "How to Perform Efficient Diagnosis for an Electrical Incident" , INCIDENT SIMULATION
TESTS.
OK or NG
OK
>> INSPECTION END
NG
EC-1040
http://vnx.su


Wiring Diagram
PFP:24110
A
EBS0117M
EC
TBWA0563E
EC-1041
http://vnx.su

CAUTION:
TERMINAL
NO.
1
2
3
WIRE
COLOR
B
B
B
ITEM
ECM ground
CONDITION
[Engine is running]
Idle speed

105

switch OFF
107
108
W/R
W/R
Ignition switch

113

switch OFF
114
ECM ground
[Engine is running]
Idle speed
DATA
Approximately 0V
Approximately 1.2V
BATTERY VOLTAGE
(11 - 14V)
BATTERY VOLTAGE
(11 - 14V)
Approximately 1.2V
BATTERY VOLTAGE
(11 - 14V)
Approximately 0V
119
120
Y
R
BATTERY VOLTAGE
(11 - 14V)
121
W/L

(Back-up)
BATTERY VOLTAGE
(11 - 14V)
EBS0117N
1. INSPECTION START
Start engine.
Is engine running?
Yes or No
Yes
>> GO TO 6.
No
>> GO TO 2.

1.
2.

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.
MBIB0610E
EC-1042
http://vnx.su

10A fuse
EC

1.
2.

Loosen and retighten engine ground screws. Refer to EC-1049, "Ground Inspection" .
E
PBIB2020E
OK or NG
OK
>> GO TO 5.
NG
5. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT

1.
2.
3.

Check harness continuity between ECM terminals 1, 2, 3, 114 and ground. Refer to Wiring Diagram.

OK or NG
OK
>> GO TO 6.
NG
EC-1043
http://vnx.su


1.
2.
3.
Reconnect ECM harness connector.

Voltage:

drop to approximately 0V.
MBIB0611E
OK or NG
OK
>> GO TO 13.
NG (Battery voltage does not exist)>>GO TO 7.
NG (Battery voltage exists for more then a few seconds)>>GO TO 9.

1.
PBIB1899E
2.
Check voltage between relay terminals 1, 3, 6 and ground with

OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.
PBIB1886E

20A fuse

EC-1044
http://vnx.su


1.
2.
A
Check harness continuity between ECM terminals 105, 113 and ECM relay terminal 2. Refer to Wiring
EC
Diagram.

OK or NG
OK
>> GO TO 11.
NG
>> GO TO 10.

Harness for open or short between ECM and ECM relay.

1.
Check harness continuity between ECM terminal 119 and ECM relay terminal 5, ECM terminal 120 and
ECM relay terminal 7. Refer to Wiring Diagram.

OK or NG
OK
>> GO TO 13.
NG
>> GO TO 12.

13. CHECK ECM RELAY

OK or NG
OK
>> GO TO 14.
NG
EC-1045
http://vnx.su


OK or NG
OK
>> GO TO 16.
NG
>> GO TO 15.
MBIB0026E

20A fuse

EC-1046
http://vnx.su


1.
2.

EC
PBIB2020E
OK or NG
OK
>> GO TO 17.
NG

1.
Check harness continuity between ECM terminals 1, 2, 3, 114 and ground. Refer to Wiring Diagram.

OK or NG
OK
>> GO TO 18.
NG

>> INSPECTION END
EC-1047
http://vnx.su

EBS0117O
ECM RELAY
1.
2.

Condition
Continuity
Yes
OFF
No
3.

PBIB0077E
EC-1048
http://vnx.su

Ground Inspection
EBS011T6
A
Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drasti- EC
cally affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit. Even
C

D
If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the E
F
PBIB1870E
EC-1049
http://vnx.su
DTC U1000 CAN COMMUNICATION LINE


Description
PFP:23710
EBS0117P
EBS0117Q

DTC No.
Trouble diagnosis
name
U1000
1000
CAN communication
line
ECM can not communicate to other control

unit.
ECM can not communicate for more than the
specified time.

1.
2.
3.
Possible cause
shorted)
EBS0117R

EC-1050
http://vnx.su

Wiring Diagram
EBS0117S
EC
TBWA0564E
EC-1051
http://vnx.su

EBS016ZI
EC-1052
http://vnx.su
DTC P0016 CKP - CMP CORRELATION


DTC No.
P0016
0016
Trouble diagnosis
name
Crankshaft position camshaft position correlation
The correlation between crankshaft position sensor signal and camshaft position sensor signal is
out of the normal range.
PFP:10328
A
EBS0117U
Possible cause
Timing chain
Signal plate
EC
EBS0117V
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

I
SEF817Y
WITH GST
J
EBS0117W
1. CHECK CAMSHAFT POSITION SENSOR

OK or NG
OK
>> GO TO 2.
NG
>> Replace camshaft position sensor.
2. CHECK SPROCKET

OK or NG
OK
>> GO TO 3.
NG
>> Remove debris and clean the signal plate or replace sprocket.
3. CHECK CRANKSHAFT POSITION SENSOR

OK or NG
OK
>> GO TO 4.
NG
>> Replace crankshaft position sensor.
EC-1053
http://vnx.su

4. CHECK GEAR TOOTH

OK or NG
OK
>> GO TO 5.
NG
5. CHECK TIMING CHAIN

Refer to EM-190, "SECONDARY TIMING CHAIN" , EM-195, "PRIMARY TIMING CHAIN" and EM-160, "VACUUM PUMP" .
OK or NG
OK
>> GO TO 6.
NG
>> Replace timing chain.

>> INSPECTION END
EC-1054
http://vnx.su
DTC P0045 TC BOOST CONTROL SOLENOID VALVE


Description
PFP:14956
A
EBS011O7
The turbocharger boost control solenoid valve controls vacuum signal to the turbocharger boost control actuator. By changing the variable nozzle vane opening through the rods, the intake air volume is
adjusted.
EC
D
MBIB0626E
The turbocharger boost control solenoid valve is moved by ON/OFF

pulse from the ECM. The longer the ON pulse, the charge air pressure rises.
H
PBIB1897E

DTC No.
EBS011TP
Possible cause
P0045
0045
Turbocharger boost control solenoid valve circuit / open
An improper voltage is sent to ECM

through turbocharger boost control
solenoid valve.
(The solenoid valve circuit is
open or shorted.)
solenoid valve
EBS011TQ
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITH GST
EC-1055
http://vnx.su

Wiring Diagram
EBS011O9
TBWA0588E
EC-1056
http://vnx.su

Specification data are reference valves, and are measured between each terminal and ground.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may damage the
ECM's transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA
C
Warm-up condition
Idle speed
0 - 12.5V
NOTE:
idle.
6
E
MBIB0889E

solenoid valve
0 - 12.5V
F
Warm-up condition
G
MBIB0890E
H
EBS011OA
1. CHECK TURBOCHARGER BOOST CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT

1.
2.
Disconnect turbocharger boost control solenoid valve harness

connector.
L
PBIB1897E
3.
Check voltage between turbocharger boost control solenoid

valve terminals 1 and ground with CONSULT-II or tester.
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
PBIB1945E
EC-1057
http://vnx.su


Harness for open and short between turbocharger boost control solenoid valve and ECM relay
Harness for open and short between turbocharger boost control solenoid valve and ECM
3. CHECK TURBOCHARGER BOOST CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR
OPEN AND SHORT
1.
2.
3.

Check harness continuity between ECM terminal 6 and turbocharger boost control solenoid valve terminal

OK or NG
OK
>> GO TO 4.
NG
4. CHECK TURBOCHARGER BOOST CONTROL SOLENOID VALVE

OK or NG
OK
>> GO TO 5.
NG
>> Replace turbocharger boost control solenoid valve.

>> INSPECTION END
EBS011OB
TURBOCHARGER BOOST CONTROL SOLENOID VALVE

1.
2.

connector.
Apply 12V direct current between turbocharger boost control
solenoid valve terminals.
PBIB1897E
EC-1058
http://vnx.su

3.
Check air passage continuity of turbocharger boost control solenoid valve under the following conditions.
CONDITIONS

between A and B

between A and C

Yes
No
No supply
No
Yes
EC
If NG, replace turbocharger boost control solenoid valve.
MBIB0996E
EC-1059
http://vnx.su
DTC P0088 FUEL SYSTEM


DTC No.
P0088
0088
PFP:17520
EBS0117X
Fuel rail pressure too high

Fuel pressure is too much higher than the specified value.
Possible cause
Fuel pump
Fuel injector

EBS0117Y
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

Keep engine speed more than 2,000 rpm for at least 20 seconds.
SEF817Y
WITH GST
EBS0117Z
1. CHECK FUEL RAIL PRESSURE SENSOR

OK or NG
OK
>> GO TO 2.
NG
>> Replace fuel rail.
2. CHECK FUEL INJECTOR

OK or NG
OK
>> GO TO 3.
NG
>> Replace fuel injector.
3. CHECK FUEL PUMP

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
EC-1060
http://vnx.su

4. REPLACE FUEL PUMP

1.
2.
Replace fuel pump.

Perform Fuel Pump Learning Value Clearing. Refer to EC-989, "Fuel Pump Learning Value Clearing" .
EC
>> INSPECTION END

D
>> INSPECTION END
EBS01180
FUEL INJECTOR
Refer to EM-164, "INJECTION TUBE AND FUEL INJECTOR" .
FUEL PUMP
Refer to EM-168, "FUEL PUMP" .

G
EC-1061
http://vnx.su
DTC P0089 FUEL PUMP

DTC P0089 FUEL PUMP

DTC No.
P0089
0089
Fuel pump performance
PFP:16700
EBS01181
Fuel pressure is too much higher than the target

value.
Possible cause
Fuel pump
Air mixed with fuel
Lack of fuel
Fuel transport pump operation
EBS01182
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

Let engine idle for at least 30 seconds.
SEF817Y
WITH GST
EBS01183
1. CHECK FUEL TRANSPORT PUMP OPERATION

Perform Diagnostic Procedure for fuel transport pump. Refer to EC-1322 .
OK or NG
OK
>> GO TO 2.
NG
>> Follow the instruction of Diagnostic Procedure for fuel transport pump.
EC-1062
http://vnx.su
DTC P0089 FUEL PUMP

2. PERFORM FUEL PUMP LEARNING VALUE CLEARING
A
NOTE:
If the DTC is detected because of air mixed with fuel (i.e.: caused by lack of fuel), it may become normal by
performing following procedure.
EC
With CONSULT-II
2. Perform Fuel Pump Learning value clearing. Refer to EC-989, "Fuel Pump Learning Value Clearing" .
C
4. Select SELF-DIAG RESULT mode with CONSULT-II.
D
5. Touch ERASE.
6. Perform EC-1062, "DTC Confirmation Procedure" , again.
7. Is 1st trip DTC detected again?
E
With GST
F
G
5. Touch ERASE.
H
Yes or No
Yes
>> GO TO 3.
No
>> INSPECTION END
I
CHECK FUEL RAIL PRESSURE SENSOR
3.

OK or NG
OK
>> GO TO 4.
NG
4. CHECK FUEL PUMP

Perform EC-1221, "DTC Confirmation Procedure" .
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

1.
2.
Replace Fuel pump.

>> INSPECTION END

>> INSPECTION END
EC-1063
http://vnx.su
DTC P0089 FUEL PUMP

EBS01184
FUEL PUMP
EC-1064
http://vnx.su


DTC No.
P0093
0093
Fuel system leak
PFP:17520
A
EBS01185
ECM detects a fuel system leak.

(The relation between the output voltage to the
fuel pump and input voltage from the fuel rail
pressure sensor is out of the normal range.)
Possible cause
EC
Fuel pump
Fuel rail
Fuel pipe
Air mixed with fuel
Lack of fuel
D
EBS01186
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

Start engine and keep engine speed more than 4,000 rpm for at
least 5 seconds.
SEF817Y
WITH GST
K
EBS01187

OK or NG
OK
>> GO TO 2.
NG
EC-1065
http://vnx.su


NOTE:
With CONSULT-II
5. Touch ERASE.
With GST
5. Touch ERASE.
Yes or No
Yes
>> GO TO 3.
No
>> INSPECTION END
3. CHECK FUEL LINE FOR LEAK

1.
2.
Start engine.
Visually check the following for fuel leak.
Fuel tube from fuel pump to fuel rail
Fuel rail
Fuel tube from fuel rail to fuel injector

3. Also check for improper connection or pinches.
OK or NG
OK
>> GO TO 4.
NG
>> Repair malfunctioning part.
4. CHECK FUEL RAIL PRESSURE RELIEF VALVE

OK or NG
OK
>> GO TO 5.
NG

OK or NG
OK
>> GO TO 6.
NG
EC-1066
http://vnx.su


1.
2.
Replace fuel pump.

EC
>> INSPECTION END
EBS011V0
FUEL RAIL PRESSURE RELIEF VALVE

With CONSULT-II
WARNING:
Prepare pans or saucers under the disconnected fuel line because the fuel may spill out.
2. Remove fuel hose from fuel rail pressure relief valve.
3. Attach a blind cap or plug to removed hose.
H
PBIB1941E
5.
6.
7.
8.
Select PRES REGULATOR in ACTIVE TEST MODE with

CONSULT-II.
Start engine and keep engine speed 2,000 rpm.
Raise fuel pressure to 160 MPa with touching UP or Qu on
the CONSULT-II screen.
Confirm that the fuel does not come out from the fuel rail pressure relief valve.
WARNING:
compartment. Especially, ensure to keep engine mount
insulator clear of fuel.
If the fuel comes out, stop the engine immediately.
PBIB0587E
Without CONSULT-II
WARNING:
4. Start engine and keep engine speed more than 4,000 rpm for at
least 5 seconds.
5. Confirm that the fuel does not come out from the fuel rail pressure relief valve.
WARNING:
EC-1067
http://vnx.su
PBIB1941E

EBS01188
FUEL RAIL
FUEL PUMP
EC-1068
http://vnx.su
DTC P0101 MAF SENSOR


PFP:22680
A
EBS011OD
the heat loss.
EC
D
PBIB1604E
EBS011OE

MONITOR ITEM
CONDITION
No-load
MAS AIR/FL SE*
SPECIFICATION
Idle
1.5 - 2.0V
2,000 rpm
2.2 - 2.7V
*: This signal is converted by ECM internally. Thus this differs from ECM terminal voltage.

DTC No.
P0101
0101
Mass air flow sensor circuit range/performance

problem
EBS011OG
Improper voltage from the sensor is sent to

ECM compared with the driving condition.
Possible cause
shorted.)
Intake air leaks
Air cleaner
EC-1069
http://vnx.su

EBS011OH
CAUTION:
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

Drive vehicle under the following condition.
CKPSRPM
Approx. 2800 rpm
VHCL SPEED SE
70 - 100 km/h
Shift lever
4th position
5.
6.
Release accelerator pedal for at least 10 seconds.

Do not depress brake pedal during this procedure.
WITH GST
EC-1070
http://vnx.su
MBIB1085E

Wiring Diagram
EBS011OI
EC
TBWA0565E
EC-1071
http://vnx.su

Specification data are reference values, and are measured between each terminal and ground.
CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
DATA
(DC Voltage)
CONDITION
[Engine is running]
54
Warm-up condition
Idle speed
1.8 - 2.3V
[Engine is running]
Warm-up condition
2.5 - 3.0V
67
Sensor ground
Approximately 0.3V
73

ground
Approximately 0.3V
EBS011OJ

1.
2.
Check air cleaner for clogging.

Check the following for connection and cracks.
Air duct
Vacuum hoses
Intake air passage between air duct and intake manifold

OK or NG
OK
>> GO TO 2.
NG
>> Reconnect or repair the parts.
EC-1072
http://vnx.su


1.
2.

Loosen and retighten body ground screws. Refer to EC-1049, "Ground Inspection" .
EC
PBIB2020E
OK or NG
OK
>> GO TO 3.
NG
EC-1073
http://vnx.su

3. CHECK MAFS POWER SUPPLY CIRCUIT

1.
2.

PBIB1891E
3.
Check voltage between mass air flow sensor terminals 2 and

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
PBIB1168E

Harness for open or short between ECM relay and mass air flow sensor
5. CHECK MAFS GROUND CIRCUIT FOR OPEN AND SHORT

1.
2.
3.


OK or NG
OK
>> GO TO 6.
NG
EC-1074
http://vnx.su

6. CHECK MAFS INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1.
Check harness continuity between mass air flow sensor terminal 4 and ECM terminal 54. Refer to Wiring
Diagram.
EC

OK or NG
OK
>> GO TO 7.
NG
7. CHECK EGR VOLUME CONTROL VALVE FUNCTION
1.
2.
3.
4.
With CONSULT-II
Remove EGR volume control valve from cylinder head.
Perform EGR VOL CONT/V in ACTIVE TEST mode with CONSULT-II. Check that EGR volume control
valve shaft moves smoothly forward and backward according to the valve opening.
SEF819Y
NOTE:
When installing the EGR volume control valve, make sure that the shaft is in the same position before
checking.
Without CONSULT-II
2. Remove EGR volume control valve from cylinder head.
3. Turn ignition switch ON and OFF.
4. Check that EGR volume control valve shaft moves smoothly forward and backward according to the ignition switch position.
NOTE:
When installing the EGR volume control valve, make sure that
the shaft is in the same position before checking.
OK or NG
OK
>> GO TO 8.
NG
>> Check EGR volume control valve and its circuit. Refer to
EC-1187, "Diagnostic Procedure" .

OK or NG
OK
>> GO TO 9.
NG
>> Replace mass sir flow sensor (with intake air temperature sensor).
EC-1075
http://vnx.su
SEF560W

9. CHECK TURBOCHARGER BOOST SENSOR

OK or NG
OK
>> GO TO 10.
NG
>> Replace turbocharger boost sensor.

OK or NG
OK
>> GO TO 11.
NG

>> INSPECTION END
EBS011OK

1.
2.
3.

signal) and ground.
Condition
Voltage V
Approx. 0.7
Idle (Engine is warmed up to normal

operating temperature.)
1.8 - 2.3
2,000 rpm (Engine is warmed up to normal operating temperature.)
2.5 - 3.0
4.
If the voltage is out of specification, disconnect MAF sensor harness connector and connect it again.
Then repeat above check.
SEF865T
EBS011OL

EC-1076
http://vnx.su


PFP:22680
A
EBS01189
the heat loss.
EC
D
PBIB1604E
EBS0118A

MONITOR ITEM
CONDITION
No-load
MAS AIR/FL SE*
SPECIFICATION
Idle
1.5 - 2.0V
2,000 rpm
2.2 - 2.7V
*: This signal is converted by ECM internally. Thus this differs from ECM terminal voltage.

DTC No.
EBS0118C
P0102
0102

low input

sent to ECM.
P0103
0103

high input

sent to ECM.
Possible cause
shorted.)
J
EBS0118D
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITH GST
EC-1077
http://vnx.su

Wiring Diagram
EBS0118E
TBWA0565E
EC-1078
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
EC
DATA
(DC Voltage)
CONDITION
[Engine is running]
54
Warm-up condition
Idle speed
C
1.8 - 2.3V
[Engine is running]
Warm-up condition
2.5 - 3.0V
67
Sensor ground
Approximately 0.3V
73

ground
Approximately 0.3V
F
EBS0118F
1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1079
http://vnx.su


1.
2.

PBIB1891E
3.

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.
PBIB1168E


1.
2.
3.


OK or NG
OK
>> GO TO 5.
NG
EC-1080
http://vnx.su


1.
Diagram.
EC

OK or NG
OK
>> GO TO 6.
NG

OK or NG
OK
>> GO TO 7.
NG

>> INSPECTION END
EBS0118G

1.
2.
3.

signal) and ground.
J
Condition
Voltage V
Approx. 0.7

1.8 - 2.3
2.5 - 3.0
4.
L
SEF865T
M
EBS0118H

EC-1081
http://vnx.su


PFP:22630
EBS0118I
the ECM.
PBIB1604E
<Reference data>
Intake air
temperature C (F)
Voltage*
Resistance
25 (77)
2.4
1.800 - 2.200
80 (176)
0.8
0.283 - 0.359
CAUTION:
SEF012P

DTC No.
EBS0118J
P0112
0112
Intake air temperature sensor circuit low input

sent to ECM.
P0113
0113
Intake air temperature sensor circuit high input

sent to ECM.
Possible cause
shorted.)

EBS0118K
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITH GST
EC-1082
http://vnx.su

Wiring Diagram
EBS0118L
EC
TBWA0587E
EC-1083
http://vnx.su

EBS0118M

1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1084
http://vnx.su


1.
2.

EC
D
PBIB1891E
3.

Voltage: Approximately 5.3V

F
OK or NG
OK
>> GO TO 3.
NG
PBIB1169E
1.
2.
3.

Check harness continuity between MAF sensor terminal 6 and ECM terminal 74. Refer to Wiring Diagram.

OK or NG
OK
>> GO TO 4.
NG

OK or NG
OK
>> GO TO 5.
NG

>> INSPECTION END
EC-1085
http://vnx.su

EBS0118N

1.
2.

Resistance k
25 (77)
1.800 - 2.200
sensor).
PBIB1604E
SEF012P
EBS0118O

EC-1086
http://vnx.su


Description
PFP:22630
A
EBS0118P

EC
D
SEF594K
<Reference data>
Engine coolant temperature C (F)
Voltage* (V)
Resistance (k)
10 (14)
4.7
7.0 - 11.4
20 (68)
3.8
2.1 - 2.9
50 (122)
2.6
0.68 - 1.00
90 (194)
1.3
0.236 - 0.260
*: These data are reference values and measured between ECM terminal 51 (Engine
SEF012P
CAUTION:

DTC No.
EBS0118Q
Possible cause
P0117
0117
Engine coolant temperature sensor circuit low

input

sent to ECM.
P0118
0118
Engine coolant temperature sensor circuit high

input
shorted.)

sent to ECM.
EBS0118R
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
EC-1087
http://vnx.su

WITH GST
EC-1088
http://vnx.su

Wiring Diagram
EBS0118S
EC
TBWA0566E
EC-1089
http://vnx.su

EBS0118T

1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1090
http://vnx.su


1.
2.
Disconnect engine coolant temperature sensor harness connector.

EC
D
PBIB1892E
3.


F
OK or NG
OK
>> GO TO 3.
NG
PBIB0152E

1.
2.
3.

Check harness continuity between ECT sensor terminal 2 and ECM terminal 70. Refer to Wiring Diagram.

OK or NG
OK
>> GO TO 4.
NG

OK or NG
OK
>> GO TO 5.
NG

>> INSPECTION END
EC-1091
http://vnx.su

EBS0118U

1.

PBIB2005E
<Reference data>
2.
Resistance k
20 (68)
2.1 - 2.9
50 (122)
0.68 - 1.00
90 (194)
0.236 - 0.260
SEF012P
EBS0118V

Refer to EM-206, "CYLINDER HEAD" .
EC-1092
http://vnx.su


Description
PFP:18002
A
EBS0118W

of the accelerator pedal assembly. The ECM uses the signal to
determine the amount of fuel to be injected.
EC
D
PBIB1741E
EBS0118X

MONITOR ITEM
ACCEL POS SEN*
ACCEL SEN 2*
CONDITION
SPECIFICATION
Ignition switch: ON
(Engine stopped)
0.2 - 0.7V
3.9 - 4.9V
Ignition switch: ON
(Engine stopped)
0.1 - 0.4V
1.9 - 2.4V
EBS0118Z

MI will not light up for these self-diagnoses.
DTC No.
P0122
0122

An excessively low voltage from the APP sensor

1 is sent to ECM.
P0123
0123

An excessively high voltage from the APP sensor

1 is sent to ECM.
I
Possible cause
shorted.)

EBS01190
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITH GST
EC-1093
http://vnx.su

Wiring Diagram
EBS01191
TBWA0567E
EC-1094
http://vnx.su

CAUTION:
TERMINAL
NO.
82
WIRE
COLOR
B
ITEM
CONDITION
DATA
EC
Approximately 5.3V
0.5 - 1.0V
4.2 - 5.2V
83

sensor 1
Engine stopped
Engine stopped
84

sensor 1 ground
Approximately 0.3V
85
Sensor ground
Approximately 0.3V

90
G
Approximately 5.3V
91
92

sensor 2

sensor 2 ground
Engine stopped
0.4 - 0.7V
Engine stopped
2.2 - 2.7V
J
Approximately 0.3V
EC-1095
http://vnx.su

EBS01192

1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1096
http://vnx.su


1.
2.

connector.
EC
D
PBIB1893E
3.


F
OK or NG
OK
>> GO TO 3.
NG
PBIB0914E

1.
2.
3.


OK or NG
OK
>> GO TO 4.
NG
1.
Check harness continuity between ECM terminal 83 and APP sensor terminal 5.

OK or NG
OK
>> GO TO 5.
NG
5. CHECK APP SENSOR

OK or NG
OK
>> GO TO 6.
NG
>> Replace accelerator pedal assembly.
EC-1097
http://vnx.su


>> INSPECTION END
EBS01193

1.
2.
3.

conditions.
Terminal
Accelerator pedal
Voltage
83
sensor 1)
Fully released
0.5 - 1.0V
Fully depressed
4.2 - 5.2V
Fully released
0.4 - 0.7V
Fully depressed
2.2 - 2.7V
91
sensor 2)
4.
MBIB0615E
If NG, replace accelerator pedal assembly.
EBS01194
ACCELERATOR PEDAL
EC-1098
http://vnx.su
DTC P0182, P0183 FUEL PUMP TEMPERATURE SENSOR


Description
PFP:16700
A
EBS01195
Fuel pump temperature sensor is built in the fuel pump. The sensor detects the fuel temperature in the fuel
pump and calibrates the fuel injection amount change by fuel temperature.
EC
EBS01196

MONITOR ITEM
FUEL TEMP SEN
C
CONDITION
SPECIFICATION

DTC No.
EBS01198
P0182
0182


sent to ECM.
P0183
0183


sent to ECM.
Possible cause
shorted.)
F
EBS01199
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITH GST

M
EC-1099
http://vnx.su

Wiring Diagram
EBS0119A
TBWA0572E
EC-1100
http://vnx.su

CAUTION:
TERMINAL
NO.
50
69
WIRE
COLOR
PU
ITEM

sensor
sensor ground
CONDITION
[Engine is running]
Warm-up condition
DATA
EC

pump temperature
Approximately 0.3V
EBS0119B
1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1101
http://vnx.su

2. CHECK FUEL PUMP TEMPERATURE SENSOR POWER SUPPLY CIRCUIT

1.
2.
Disconnect fuel pump temperature sensor harness connector.

PBIB1942E
3.
Check voltage between fuel pump temperature sensor terminal

OK or NG
OK
>> GO TO 3.
NG
PBIB0420E
3. CHECK FUEL PUMP TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Check harness continuity between fuel pump temperature sensor terminal 2 and ECM terminal 69.

OK or NG
OK
>> GO TO 4.
NG

OK or NG
OK
>> GO TO 5.
NG

1.
2.
Replace fuel pump.

>> INSPECTION END
EBS0119C
FUEL PUMP
EC-1102
http://vnx.su
DTC P0192, P0193 FRP SENSOR


Description
PFP:16638
A
EBS0119D
The fuel rail pressure (FRP) sensor is placed to the fuel rail. It measures the fuel pressure in the fuel rail. The
sensor sends voltage signal to the ECM. As the pressure increases, the voltage rises.
EC
The ECM controls the fuel pressure in the fuel rail by the inlet throttling device. The ECM uses the signal from
fuel rail pressure sensor as a feedback signal.
EBS0119E

MONITOR
CONDITION
No-load
ACT CR PRESS
SPECIFICATOIN
Idle
20 - 30 MPa
2,000 rpm
45 - 55 MPa

DTC No.
EBS0119G
P0192
0192

circuit low input

sent to ECM.
P0193
0193
Fuel rail temperature sensor circuit high input

sent to ECM.
Possible cause
shorted.)
Fuel rail temperature sensor
EBS0119H
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

M
SEF817Y
WITH GST
EC-1103
http://vnx.su

Wiring Diagram
EBS0119I
TBWA0568E
EC-1104
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA
[Engine is running]
48
49
Y/R
R
Warm-up condition
Idle speed
Warm-up condition
EC
C
1.7 - 2.0V
[Engine is running]
2.0 - 2.3V
63

power supply
Approximately 5.3V
67
Sensor ground
Approximately 0.3V
68

ground
Approximately 0.3V
EBS0119J
1. CHECK GROUND CONNECTION

1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1105
http://vnx.su

2. CHECK FUEL RAIL PRESSURE SENSOR POWER SUPPLY CIRCUIT

1.
2.
Disconnect fuel rail pressure sensor harness connector.

PBIB1894E
3.
Check voltage between fuel rail pressure sensor terminal 1 and

OK or NG
OK
>> GO TO 3.
NG
PBIB0405E
3. CHECK FUEL RAIL PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Check harness continuity between fuel rail pressure sensor terminal 3 and ECM terminal 68.

OK or NG
OK
>> GO TO 4.
NG
4. CHECK FUEL RAIL PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
Check harness continuity between ECM terminals 48, 49 and fuel rail pressure sensor terminal 2.

OK or NG
OK
>> GO TO 4.
NG

OK or NG
OK
>> GO TO 6.
NG
EC-1106
http://vnx.su


EC
>> INSPECTION END
EBS0119K
FUEL RAIL PRESSURE SENSOR

1.
2.
3.
Condition
1.7 - 2.0
2,000 rpm
2.0 - 2.3
5.
Voltage V
Idle
4.
Reconnect harness connector disconnected.

Check voltage between ECM terminals 48, 49 (Fuel rail pressure sensor signal) and ground under the following conditions.
If the voltage is out of specification, disconnect fuel rail pressure

sensor harness connector and connect it again. Then repeat
above check.
If NG, replace fuel rail.
MBIB0613E
EBS0119L
FUEL RAIL
EC-1107
http://vnx.su
DTC P0200 FUEL INJECTOR


DTC No.
P0200
0200

circuit
PFP:16600
EBS0119M

ECM detects a voltage of power source for the
fuel injector is excessively high or low.
Possible cause
ECM
EBS0119N
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITH GST
EBS0119O
1. INSPECTION START
1.
2.
3.
4.
5.
With CONSULT-II
Touch ERASE.
Perform EC-1108, "DTC Confirmation Procedure" , again.
Is 1st trip DTC P0200 displayed again?
With GST
3. Touch ERASE.
5. Is 1st trip DTC P0200 displayed again?
Yes or No
Yes
>> GO TO 2.
No
>> INSPECTION END
EC-1108
http://vnx.su

2. REPLACE ECM
1.
2.
3.
A
Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to EC-996,
EC
"NATS (Nissan Anti-theft System)" .
C
>> INSPECTION END
EC-1109
http://vnx.su
DTC P0201 - P0204 FUEL INJECTOR


PFP:16600
EBS0119P
supplies a ground to the fuel injector circuit, the coil in the fuel injector is energized. The energized coil pulls the needle valve back and
allows fuel to flow through the fuel injector into the cylinder. The
amount of fuel injected depends upon the injection pulse duration.
Pulse duration is the length of time the fuel injector remains open.
The ECM controls the injection pulse duration based on engine fuel
needs.
PBIB0465E
EBS0119Q

MONITOR ITEM
MAIN INJ WID
CONDITION
SPECIFICATION
No-load
0.68 - 0.78 msec
Idle speed

0.78 - 0.88 msec

DTC No.
EBS0119S
Possible cause
P0201
0201
No. 1 cylinder fuel injector

circuit open
An improper voltage signal is sent to ECM

through No. 1 cylinder fuel injector.
P0202
0202

circuit open

(The fuel injector circuit is open.)
P0203
0203

circuit open

Fuel injector
P0204
0204

circuit open

EC-1110
http://vnx.su

EBS0119T
A
NOTE:
EC
TESTING CONDITION
Before performing the following procedure, confirm the ambient temperature is more than -20C (-4F).
WITH CONSULT-II
1.
2.
3.
4.

F
SEF817Y
WITH GST

H
EC-1111
http://vnx.su

Wiring Diagram
EBS0119U
TBWA0569E
EC-1112
http://vnx.su

A
CAUTION:
EC
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA
C
[Engine is running]
W/B
G/B

Warm-up condition
Idle speed
5 - 10V
NOTE:
idle.
E
MBIB0883E
5 - 10V
F
[Engine is running]
Warm-up condition
G
MBIB0884E
H
[Engine is running]
21
22
23
24
G/R
GY/L
G/R
GY/L
Fuel injector No. 2

Fuel injector No. 2
Fuel injector No. 3
Fuel injector No. 3
Warm-up condition
Idle speed
0 - 9V
NOTE:
idle.
J
MBIB0881E
0 - 9V
K
[Engine is running]
Warm-up condition
L
MBIB0882E
[Engine is running]
40
41
42
43
G/R
GY/L
G/R
GY/L
Fuel injector No. 4

Fuel injector No. 4
Fuel injector No. 1
Fuel injector No. 1
Warm-up condition
Idle speed
0 - 9V
NOTE:
idle.
MBIB0881E
0 - 9V
[Engine is running]
Warm-up condition
MBIB0882E
EC-1113
http://vnx.su

EBS0119V
1. CHECK FUEL INJECTOR POWER SUPPLY FOR OPEN AND SHORT CIRCUIT
1.
2.
3.
4.

Disconnect fuel injector harness connector.
Check harness continuity between the following terminals corresponding to the malfunctioning cylinder. Refer to Wiring Diagram.
Terminal
DTC
Cylinder
ECM
Fuel injector
P0201
No.1
P0202
No.2
P0203
No.3
P0204
No.4
PBIB1896E

OK or NG
OK
>> GO TO 2.
NG
2. CHECK FUEL INJECOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
Check harness continuity between the following terminals corresponding to the malfunctioning cylinder.
Terminal
DTC
Cylinder
ECM
Fuel injector
P0201
42, 43
No.1
P0202
21, 22
No.2
P0203
23, 24
No.3
P0204
40, 41
No.4

OK or NG
OK
>> GO TO 3.
NG
3. CHECK FUEL INJECTOR-I

OK or NG
OK
>> GO TO 4.
NG
EC-1114
http://vnx.su

4. CHECK FUEL INJECTOR-II

1.
2.
3.
4.
5.
6.
7.
8.
With CONSULT-II
Remove two fuel injectors of malfunctioning cylinder and another cylinder.
Install fuel injectors to different cylinder.
Reconnect ECM harness connector and fuel injector harness connector.
Touch ERASE.
Is another DTC displayed?
EC
With GST
1. Remove two fuel injectors of malfunctioning cylinder and another cylinder.
2. Install fuel injectors to different cylinder.
3. Reconnect ECM harness connector and fuel injector harness connector.
6. Touch ERASE.
7. Perform EC-1111, "DTC Confirmation Procedure" .
8. Is another DTC displayed?
Yes or No
Yes
>> Replace fuel injector of malfunctioning cylinder.
No
>> GO TO 5.

>> INSPECTION END
EBS0119W
FUEL INJECTOR
1.
2.
Disconnect fuel injector.

Check continuity between terminals as shown in the figure.

3.
PBIB0406E
EBS0119X
FUEL INJECTOR
EC-1115
http://vnx.su


System Description
PFP:21481
EBS0119Y
COOLING FAN CONTROL

Sensor
Input signal to ECM
Vehicle speed
ECM function
Cooling fan
control
Actuator
Cooling fan relay
*: These signals are sent to the ECM through CAN communication line.
The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, air conditioner ON signal. The control system has 3-step control [HIGH/LOW/OFF].
OPERATION
SEF421Z
EBS0119Z

MONITOR ITEM
COOLING FAN
CONDITION
SPECIFICATION
OFF
LOW
HI
EC-1116
http://vnx.su

EBS011A0

DTC No.
P0217
0217
Engine over temperature

(Overheat)
Possible cause
shorted.)
Cooling fan
Cooling fan system does not operate properly

(Overheat).
Radiator hose
Radiator

Radiator cap
Water pump
Thermostat

range.

EC
EBS011A1
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could be caused by high
pressure fluid escaping from the radiator.
Wrap a thick cloth around cap. Carefully remove the cap by turning it a quarter turn to allow builtup pressure to escape. Then turn the cap all the way off.
WITH CONSULT-II
1.
2.
3.

SEF621W
4.
5.

SEF111X
EC-1117
http://vnx.su

WITHOUT CONSULT-II
1.

3. Start engine.
4. Set temperature control lever to full cold position.
harness connector.
SEF621W
SEC163BA
MEC475B
EC-1118
http://vnx.su

Wiring Diagram
EBS011A2
EC
TBWA0573E
EC-1119
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA
[Engine is running]
34
LG/B
[Engine is running]
BATTERY VOLTAGE
(11 - 14V)
Approximately 0.1V
[Engine is running]
36
LG
[Engine is running]
BATTERY VOLTAGE
(11 - 14V)
Approximately 0.1V
EBS011A3
1. INSPECTION START
Yes or No
Yes
>> GO TO 2.
No
>> GO TO 4.

With CONSULT-II
PBIB1935E
2.
Perform COOLING FAN in ACTIVE TEST mode with CONSULT-II and touch LOW on the CONSULT-II screen.
3. Make sure that cooling fans-1 and -2 operate at low speed.
OK or NG
OK
>> GO TO 3.
NG
SEF784Z
EC-1120
http://vnx.su

With CONSULT-II
1. Touch HIGHon the CONSULT-II screen.
2. Make sure that cooling fans-1 and -2 operate at higher speed
than low speed.
OK or NG
OK
>> GO TO 6.
NG
EC
SEF785Z

1.
2.
3.
4.
5.
Without CONSULT-II
Disconnect cooling fan relays-2 and -3.
Set temperature lever at full cold position.
I
PBIB1935E

OK or NG
OK
>> GO TO 5.
NG
SEC163BA
EC-1121
http://vnx.su

5. CHECK COOLING FAN HIGH SPEED OPERATION-I

Without CONSULT-II
Reconnect cooling fan relays-2 and -3.
Turn air conditioner switch and blower fan switch OFF.
harness connector.
1.
2.
3.
4.
PBIB1892E
6.
Restart engine and make sure that cooling fans-1 and -2 operate at higher speed than low speed.
OK or NG
OK
>> GO TO 6.
NG
MEC475B

CAUTION:
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.
SLC754A

Hose
Radiator

EC-1122
http://vnx.su

pressure.
EC
Radiator cap relief pressure:

59 - 98 kPa (0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2 , 9 - 14 psi)
OK or NG
OK
>> GO TO 9.
NG
D
SLC755A
9. CHECK THERMOSTAT
1.
2.
3.
Remove thermostat.
Valve opening temperature:

80 - 84 C (176 - 183 F)
Valve lift:
More than 10 mm/95 C (0.39 in/203 F)
Check if valve is closed at 5C (9F) below valve opening temperature. For details, refer to CO-45, "THERMOSTAT AND
WATER PIPING" .
OK or NG
OK
>> GO TO 10.
NG
4.

OK or NG
OK
>> GO TO 11.
NG
I
SLC343

>> INSPECTION END
EC-1123
http://vnx.su

PROCEDURE A

1.
2.
3.

PBIB1935E
4.

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
PBIB0422E

10A fuse
40A fusible links
EC-1124
http://vnx.su

3. CHECK COOLING FAN GROUND CIRCUIT FOR OPEN AND SHORT

1.
2.
3.

Check harness continuity between the following.
Cooling fan relay-1 terminal 3 and cooling fan motor-1 terminal 1
Cooling fan motor-1 terminal 4 and ground
EC
D
PBIB1895E

OK or NG
OK
>> GO TO 4.
NG
1.
2.


OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.


OK or NG
OK
>> GO TO 7.
NG

OK or NG
OK
>> GO TO 8.
NG
EC-1125
http://vnx.su


>> INSPECTION END
PROCEDURE B
1. CHECK COOLING FAN RELAYS-2 AND -3 POWER SUPPLY CIRCUIT

1.
2.
3.

Disconnect cooling fan relay-2 and -3.
PBIB1935E
4.
Check voltage between cooling fan relays-2, -3 terminals 1, 3

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
PBIB0251E

10A fuse
40A fusible links
Harness for open or short between cooling fan relays-2, -3 and fuse
Harness for open or short between cooling fan relays-2, -3 and battery
EC-1126
http://vnx.su

3. CHECK COOLING FAN RELAY GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Cooling fan relay-2 terminal 7 and ground.
EC

4.
5.

Cooling fan relay-3 terminal 7 and ground
PBIB1895E

OK or NG
OK
>> GO TO 4.
NG
1.
2.

Check harness continuity between cooling fan relay-2 terminal 2 and ECM terminal 34, cooling fan relay-3
terminal 2 and ECM terminal 34.

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

M
6. CHECK COOLING FAN RELAYS-2 AND -3

OK or NG
OK
>> GO TO 7.
NG
>> Replace cooling fan relays.
EC-1127
http://vnx.su


OK or NG
OK
>> GO TO 7.
NG

>> INSPECTION END

Engine
Step
OFF
Inspection item
Blocked radiator
Blocked condenser
Blocked bumper
EBS011A4
Equipment
Standard
Reference page
Visual
No blocking
Coolant mixture
Coolant tester
See MA-19, "Engine

Coolant Mixture Ratio" .
Coolant level
Visual

See CO-32, "LEVEL

CHECK" .
Radiator cap
Pressure tester
59 - 98 kPa
(0.59 - 0.98 bar, 0.6 - 1.0
See MA-33, "CHECKING

RADIATOR CAP" .

ON*2
Coolant leaks
Visual
No leaks
See CO-32, "CHECKING

RADIATOR SYSTEM
FOR LEAKS" .
ON*2
Thermostat
Touch the upper and

See CO-45, "THERMOSTAT AND WATER PIPING" , and CO-35,

"RADIATOR" .
ON*1
Cooling fan
CONSULT-II
Operating

DTC P0217 (EC-1116 ).
OFF
Combustion gas leak

Negative
ON*3
Coolant temperature
gauge
Visual
Gauge less than 3/4

when driving
Coolant overflow to
reservoir tank
Visual

and idling
See MA-30, "Changing

Engine Coolant" .
OFF*4
10
Coolant return from

Visual

reservoir tank
See CO-32, "LEVEL

CHECK" .
OFF
11
Cylinder head

gauge
SeeEM-206, "CYLINDER HEAD" .
12
Visual
walls or piston
See EM-223, "CYLINDER BLOCK" .

EC-1128
http://vnx.su

EBS011A5
COOLING FAN RELAY-1, -2 AND -3

Conditions
Continuity
Yes
No current supply
No
EC
If NG, replace relay.
D
SEF745U
COOLING FAN MOTORS-1 AND -2

1.
2.
Disconnect cooling fan motor harness connectors.

check operation.
Terminals
Speed
Cooling fan motor
(+)
(-)
Low
High
1, 2
3, 4
Cooling fan motor should operate.

If NG, replace cooling fan motor.
SEF734W
EC-1129
http://vnx.su


Description
PFP:18002
EBS011A6

of the accelerator pedal assembly. The sensors detect the accelerator pedal position and sends a signal to the ECM. The ECM uses the
signal to determine the amount of fuel to be injected.
PBIB1741E
EBS011A7

MONITOR ITEM
ACCEL POS SEN*
ACCEL SEN 2*
CONDITION
SPECIFICATION
Ignition switch: ON
(Engine stopped)
0.2 - 0.7V
3.9 - 4.9V
Ignition switch: ON
(Engine stopped)
0.1 - 0.4V
1.9 - 2.4V
EBS011A9

MI will not light up for these self-diagnoses.
DTC No.
P0222
0222


2 is sent to ECM.
P0223
0223

An excessively high voltage from the APP sensor 2 is sent to ECM.
Possible cause
shorted.)

EBS011AA
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITH GST
EC-1130
http://vnx.su

Wiring Diagram
EBS011AB
EC
TBWA0729E
EC-1131
http://vnx.su

CAUTION:
TERMINAL
NO.
82
WIRE
COLOR
B
ITEM
CONDITION
DATA
Approximately 5.3V
83

sensor 1
Engine stopped
0.5 - 1.0V
Engine stopped
4.2 - 5.2V
84

sensor 1 ground
Approximately 0.3V
85
Sensor ground
Approximately 0.3V
90

Approximately 5.3V
91
92

sensor 2

sensor 2 ground
Engine stopped
0.4 - 0.7V
Engine stopped
EC-1132
http://vnx.su
2.2 - 2.7V
Approximately 0.3V

EBS011AC
1. CHCEK GROUND CONNECTIONS

1.
2.

EC
J
PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1133
http://vnx.su


1.
2.

connector.
PBIB1893E
3.

OK or NG
OK
>> GO TO 3.
NG
PBIB0915E

1.
2.
3.


OK or NG
OK
>> GO TO 4.
NG
1.

OK or NG
OK
>> GO TO 5.
NG
5. CHECK APP SENSOR

OK or NG
OK
>> GO TO 6.
NG
EC-1134
http://vnx.su


EC
>> INSPECTION END
EBS011AD

1.
2.
3.
Terminal
Accelerator pedal
Voltage
83
sensor 1)
Fully released
0.5 - 1.0V
Fully depressed
4.2 - 5.3V
Fully released
0.4 - 0.7V
Fully depressed
2.2 - 2.7V
91
sensor 2)
4.

conditions.
MBIB0615E
EBS011AE
ACCELERATOR PEDAL

I
EC-1135
http://vnx.su
DTC P0234 TC SYSTEM

DTC P0234 TC SYSTEM

Description
PFP:14411
EBS011AF
The load from the turbocharger boost control solenoid valve controls
the actuator. By changing the variable nozzle vane opening through
the rods, the intake air volume is adjusted.
MBIB0626E

PBIB1897E
EBS011AI

DTC No.
P0234
0234
Turbocharger overboost
condition
ECM detects turbocharger boost pressure

is excessively high.
Possible cause
Turbocharger
Vacuum pump
Turbocharger boost control solenoid valve

EBS011AJ
Use this procedure to check the overall function of the turbocharger. During this check, a DTC might not be
confirmed.
2. Make sure that turbocharger control actuator rod moves slightly
when engine is started.
PBIB1936E
EC-1136
http://vnx.su
DTC P0234 TC SYSTEM

Wiring Diagram
EBS011AH
EC
TBWA0588E
EC-1137
http://vnx.su
DTC P0234 TC SYSTEM

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
Warm-up condition
Idle speed
DATA
0 - 12.5V
NOTE:
idle.
6
MBIB0889E

solenoid valve
0 - 12.5V
Warm-up condition
MBIB0890E
EBS011AK
1. CHECK VACUUM SOURCE

1.
2.
3.
4.

Disconnect vacuum hose connected to turbocharger control actuator.
Check vacuum hose for vacuum existence.
Vacuum should exist.
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 2.
PBIB1937E
EC-1138
http://vnx.su
DTC P0234 TC SYSTEM

2. CHECK VACUUM HOSES AND VACUUM GALLERY
1.
2.

Check vacuum hoses and vacuum gallery for clogging, cracks or improper connection.
Refer to EC-981, "Vacuum Hose Drawing" .
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace vacuum hoses and vacuum gallery.
EC
SEF109L

1.
2.

connector.
I
PBIB1897E
3.


K
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
PBIB1945E

Harness for open or short between turbocharger boost control solenoid valve and ECM relay
Harness for open or short between turbocharger boost control solenoid valve and ECM
EC-1139
http://vnx.su
DTC P0234 TC SYSTEM

OPEN AND SHORT
1.
2.
3.

Check harness continuity between ECM terminals 6 and turbocharger boost control solenoid valve terminals 2.

OK or NG
OK
>> GO TO 6.
NG
6. CHECK TURBOCHARGE BOOST CONTROL SOLENOID VALVE

OK or NG
OK
>> GO TO 7.
NG
7. CHECK VACUUM PUMP

Refer to EM-160, "VACUUM PUMP" .
OK or NG
OK
>> GO TO 8.
NG
>> Replace vacuum pump assembly.
8. CHECK TURBOCHARGER BOOST CONTROL ACTUATOR

1.
2.
3.

Install a vacuum pump to turbocharger boost control actuator.
Make sure that the turbocharger boost control actuator rod
moves smoothly when applying vacuum of -53.3kPa (-533mbar,
-400mmHg, -15.75inHg) and releasing it.
OK or NG
OK
>> GO TO 9.
NG
>> Replace turbocharger assembly.
MBIB1022E

OK or NG
OK
>> GO TO 10.
NG

>> INSPECTION END
EC-1140
http://vnx.su
DTC P0234 TC SYSTEM

EBS011AL

1.
2.

connector.
EC
D
PBIB1897E
3.
CONDITIONS

between A and B

between A and C

Yes
No
No supply
No
Yes
MBIB0996E
EC-1141
http://vnx.su
DTC P0237, P0238 TC BOOST SENSOR


PFP:22365
EBS011AM
The turbocharger boost sensor detects pressure in the exit side of

the charge air cooler. The sensor output voltage to the ECM
increases as pressure increases.
MBIB0614E
MBIB0899E
EBS011WE

MONITOR ITEM
CONDITION
SPECIFICATION
Idle
Approx. 100 kPa
2,800 rpm
Approx. 126 kPa
No-load
4,000 rpm
Approx. 106 kPa
INT/M PRES SE [kPa]
EC-1142
http://vnx.su

EBS011AO
A
DTC No.
P0237
0237

circuit low input

sent to ECM.
P0238
0238

circuit high input

sent to ECM.
Possible cause
shorted.)
EC

EBS011AP
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

H
SEF817Y
WITH GST
EC-1143
http://vnx.su

Wiring Diagram
EBS011AQ
TBWA0589E
EC-1144
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
EC
DATA
(DC Voltage)
CONDITION
[Engine is running]
52
Warm-up condition
Idle speed
C
2.3 - 2.6V
[Engine is running]
Warm-up condition
2.5 - 2.8V
64

power supply
Approximately 5.3V
71

ground
Approximately 0.3V
F
EBS011AR
1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1145
http://vnx.su

2. CHECK TURBOCHARGER BOOST SENSOR POWER SUPPLY CIRCUIT

1.
2.
Disconnect turbocharge boost sensor harness connector.

PBIB1898E
3.
Check voltage between turbocharge boost sensor terminal 1

OK or NG
OK
>> GO TO 3.
NG
MBIB0072E
3. CHECK TURBOCHAGER BOOST SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Check harness continuity between turbocharger boost sensor terminal 3 and ECM terminal 71.

OK or NG
OK
>> GO TO 4.
NG
4. CHECK TURBOCHAGER BOOST SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
Check harness continuity between ECM terminals 52 and turbocharger boost sensor terminal 2. Refer to
Wiring Diagram.

OK or NG
OK
>> GO TO 5.
NG

OK or NG
OK
>> GO TO 6.
NG
EC-1146
http://vnx.su


EC
>> INSPECTION END
EBS011AS
CHECK TURBOCHARGER BOOST SENSOR

1.
2.
3.
4.
Remove turbocharger boost sensor with its harness connected.

Use pump to apply pressure sensor as shown in the figure.
CAUTION:
Always calibrate the pressure pump gauge when using it.
Inspection should be done at room temperature [10-30C (50-86F)].
Check the output voltage between turbocharger boost sensor terminal 2 and ground.
Pressure (Relative to atmospheric pressure)
Voltage V
0 kPa (0 mbar, 0 mmHg, 0 inHg)
Approximately 2.3V
+40 kPa (400 mbar, 300mmHg, 11.81 inHg)
Approximately 2.9V
H
MBIB0925E
EBS011AT
TURBOCHARGER BOOST SENSOR

Refer to EM-141, "CHARGE AIR COOLER" .
EC-1147
http://vnx.su
DTC P0335 CKP SENSOR


Description
PFP:23731
EBS011AU
The crankshaft position sensor monitors engine speed by means of

signals from the sensing plate (with 56 protrusions) installed to the
fly wheel. The datum signal output is detected 6 signal and sent to
the ECM. The sensor signal is used for fuel injection control and fuel
injection timing control.
MBIB0619E
EBS011AV

MONITOR ITEM
CKPS-RPM (TDC)
CONDITION
SPECIFICATION

indication.


DTC No.
P0335
0335

EBS011AX
Possible cause
shorted.)
Crankshaft position sensor signal is not detect

by the ECM when engine is running.
EBS011AY
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

If engine could not start, keep ignition switch at START position
for 5 seconds.
SEF817Y
WITH GST
EC-1148
http://vnx.su

Wiring Diagram
EBS011AZ
EC
TBWA0570E
EC-1149
http://vnx.su

CAUTION:
TERMINAL
NO.
44
WIRE
COLOR
L/W
ITEM
CONDITION
[Engine is running]
Warm-up condition
Idle speed
DATA
Approximately 5.3V
0 - 6V
NOTE:
idle.
MBIB0879E
46

0 - 6V
[Engine is running]
Warm-up condition
MBIB0880E
65
L/R
67
Sensor ground
Approximately 0.3V
Approximately 0.3V
EC-1150
http://vnx.su

EBS011B0

1.
2.

EC
J
PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1151
http://vnx.su

2. CHECK CKP SENSOR POWER SUPPLY CIRCUIT

1.
2.
Disconnect crankshaft position (CKP) sensor harness connector.

PBIB1889E
3.
Check voltage between CKP sensor terminal 1 and ground with

OK or NG
OK
>> GO TO 3.
NG
PBIB0405E
3. CHECK CKP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1.
2.
3.

Check harness continuity between ECM terminal 65 and CKP sensor terminal 2.
4. Also check harness for and short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
4. CHECK CKP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

OK or NG
OK
>> GO TO 5.
NG

OK or NG
OK
>> GO TO 6.
NG
EC-1152
http://vnx.su


EC
>> INSPECTION END
EBS011B1
CRANKSHAFT POSITION SENSOR

1.
2.
3.
4.

Disconnect crankshaft position sensor harness connector.
Remove the sensor.
G
MBIB0864E
5.
6.
1 (+) - 2 (-)
Except 0
1 (+) - 3 (-)
Except 0 or
2 (+) - 3 (-)
Except 0
If NG, replace crankshaft position sensor.
MBIB1009E
EBS011B2

Refer to EM-154, "OIL PAN AND OIL STRAINER" .
EC-1153
http://vnx.su


Description
PFP:23731
EBS011B3

MBIB0619E
EBS011B4

MONITOR ITEM
CONDITION
CKPSRPM (TDC)
SPECIFICATION
Tachometer: Connect

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

DTC No.
P0336
0336
Crankshaft position sensor circuit range/performance
EBS011B6
Crankshaft position sensor signal is not in the

normal pattern when engine is running.
Possible cause
shorted.)
Signal plate
EBS011B7
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

for 5 seconds.
SEF817Y
WITH GST
EC-1154
http://vnx.su

Wiring Diagram
EBS011B8
EC
TBWA0570E
EC-1155
http://vnx.su

CAUTION:
TERMINAL
NO.
44
WIRE
COLOR
L/W
ITEM
CONDITION
[Engine is running]
Warm-up condition
Idle speed
DATA
Approximately 5.3V
0 - 6V
NOTE:
idle.
MBIB0879E
46

0 - 6V
[Engine is running]
Warm-up condition
MBIB0880E
65
L/R
67
Sensor ground
Approximately 0.3V
Approximately 0.3V
EC-1156
http://vnx.su

EBS011B9

1.
2.

EC
J
PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1157
http://vnx.su


1.
2.

PBIB1889E
3.


OK or NG
OK
>> GO TO 3.
NG
PBIB0405E

1.
2.
3.

OK or NG
OK
>> GO TO 4.
NG
1.

OK or NG
OK
>> GO TO 5.
NG

OK or NG
OK
>> GO TO 6.
NG
EC-1158
http://vnx.su

6. CHECK GEAR TOOTH

OK or NG
OK
>> GO TO 7.
NG
EC

D
>> INSPECTION END
EBS011BA
1.
2.
3.
4.

Remove the sensor.
I
MBIB0864E
5.
6.

1 (+) - 2 (-)
Except 0
1 (+) - 3 (-)
Except 0 or
2 (+) - 3 (-)
Except 0
MBIB1009E
EBS011BB

EC-1159
http://vnx.su
DTC P0340 CMP SENSOR


Description
PFP:23731
EBS011BC
The camshaft position sensor identifies a particular cylinder by

means of signals from the sensing plate (with five protrusions)
installed to the camshaft. The datum signal output is detected 90
signal and sent to the ECM.
MBIB0618E

DTC No.
P0340
0340

circuit
EBS011BE
Possible cause
shorted.)
Camshaft position sensor signal is not detect by

the ECM when engine is running.
EBS011BF
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

for 5 seconds.
SEF817Y
WITH GST
EC-1160
http://vnx.su

Wiring Diagram
EBS011BG
EC
TBWA0571E
EC-1161
http://vnx.su

CAUTION:
TERMINAL
NO.
45
WIRE
COLOR
G/OR
ITEM
power supply
CONDITION
[Engine is running]
Warm-up condition
Idle speed
DATA
Approximately 5.3V
0 - 6V
NOTE:
idle.
MBIB0877E
47
G/R

0 - 6V
[Engine is running]
Warm-up condition
MBIB0878E
66
G/Y

ground
67
Sensor ground
Approximately 0.3V
Approximately 0.3V
EBS011BH

Yes or No
Yes
>> GO TO 2.
No
EC-1162
http://vnx.su


1.
2.

EC
PBIB2020E
OK or NG
OK
>> GO TO 3.
NG
EC-1163
http://vnx.su

3. CHECK CMP SENSOR POWER SUPPLY CIRCUIT

1.
2.
Disconnect camshaft position (CMP) sensor harness connector.

PBIB1890E
3.
Check voltage between CMP sensor terminal 3 and ground with

OK or NG
OK
>> GO TO 4.
NG
MBIB1010E
4. CHECK CMP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1.
2.
3.

Check harness continuity between ECM terminal 66 and CMP sensor terminal 2.

OK or NG
OK
>> GO TO 5.
NG
5. CHECK CMP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2. Also check harness for short to ground or short to power.

OK or NG
OK
>> GO TO 6.
NG

OK or NG
OK
>> GO TO 7.
NG
EC-1164
http://vnx.su


EC
>> INSPECTION END
EBS011BI
CAMSHAFT POSITION SENSOR

1.
2.
3.
4.

Disconnect camshaft position sensor harness connector.
Remove the sensor.
G
MBIB0647E
5.

1 (+) - 2 (-)
Except 0
1 (+) - 3 (-)
2 (+) - 3 (-)
6.
Except 0 or
If NG, replace camshaft position sensor.
MBIB1009E
EBS011BJ
EC-1165
http://vnx.su


Description
PFP:23731
EBS011BK

MBIB0618E

DTC No.
P0341
0341

EBS011BM
Camshaft position sensor signal is not in the normal pattern when engine is running.
Possible cause
Harness connectors
(The sensor circuit is opener
shorted.)
Signal plate
EBS011BN
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

for 5 seconds.
SEF817Y
WITH GST
EC-1166
http://vnx.su

Wiring Diagram
EBS011BO
EC
TBWA0571E
EC-1167
http://vnx.su

CAUTION:
TERMINAL
NO.
45
WIRE
COLOR
G/OR
ITEM
power supply
CONDITION
[Engine is running]
Warm-up condition
Idle speed
DATA
Approximately 5.3V
0 - 6V
NOTE:
idle.
MBIB0877E
47
G/R

0 - 6V
[Engine is running]
Warm-up condition
MBIB0878E
66
G/Y

ground
67
Sensor ground
Approximately 0.3V
Approximately 0.3V
EBS011BP

Yes or No
Yes
>> GO TO 2.
No
EC-1168
http://vnx.su


1.
2.

EC
PBIB2020E
OK or NG
OK
>> GO TO 3.
NG
EC-1169
http://vnx.su


1.
2.

PBIB1890E
3.

OK or NG
OK
>> GO TO 4.
NG
MBIB1010E

1.
2.
3.


OK or NG
OK
>> GO TO 5.
NG
1.

OK or NG
OK
>> GO TO 6.
NG

OK or NG
OK
>> GO TO 7.
NG
EC-1170
http://vnx.su

7. CHECK CAMSHAFT (EXHAUST)

OK or NG
OK
>> GO TO 8.
NG
EC
D
MBIB0990E

F
>> INSPECTION END
EC-1171
http://vnx.su

EBS011BQ

1.
2.
3.
4.

Remove the sensor.
MBIB0647E
5.

1 (+) - 2 (-)
Except 0
1 (+) - 3 (-)
2 (+) - 3 (-)
6.
Except 0 or
MBIB1009E
EBS011BR

EC-1172
http://vnx.su
DTC P0380 GLOW RELAY


DTC No.
PFP:25230
A
EBS011ON
Possible cause
(The glow relay circuit is open
or shorted.)
Glow relay
(The glow relay circuit is
shorted.)
Glow relay
An excessively low voltage is sent to ECM

through glow relay.
P0380
0380
Glow relay circuit

An excessively high voltage is sent to ECM
through glow relay.
EC
EBS011OO
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITH GST
EC-1173
http://vnx.su

Wiring Diagram
EBS011OP
TBWA0734E
EC-1174
http://vnx.su

EBS011OQ
1. CHECK GLOW RELAY POWER SUPPLY CIRCUIT

1.
2.

Disconnect glow relay.
EC
PBIB1934E
3.


OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
H
PBIB1413E

60A fusible link
Harness for open and short between glow relay and battery
3. CHECK GLOW RELAY OUTPUT SIGNAL CIRCUIT FOR SHORT TO GROUND

1.
2.

Check harness continuity between ECM terminal 37 and glow relay terminal 2.

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

Harness for open and short between glow relay and ECM
EC-1175
http://vnx.su

5. CHECK GLOW RELAY

OK or NG
OK
>> GO TO 6.
NG
>> Replace glow relay.

>> INSPECTION END
EBS011OR
GLOW RELAY
Check continuity between glow relay terminals 3 and 5 under the following conditions.
Conditions
Continuity
Yes
No current supply
No
PBIB0428E
EC-1176
http://vnx.su
DTC P0401 EGR FUNCTION


Description
PFP:14710
A
EBS011OS
SYSTEM DESCRIPTION
Sensor
Input Signal to ECM
Engine speed
Vehicle speed
Ignition switch
Start signal
ECM Function
Actuator
EC
C
EGR volume control
EGR volume control

valve
This system controls flow rate of EGR led from exhaust manifold to intake manifold. The opening of the EGR
by-pass passage in the EGR volume control valve changes to control the flow rate. A built-in step motor
moves the valve in steps corresponding to the ECM output pulses. The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is determined by considering various engine conditions.
The EGR volume control valve remains close under the following conditions.
Engine stopped
Engine starting
Low engine coolant temperature
High engine speed
Accelerator pedal fully depressed
L
SEF908Y
EGR Volume Control Valve
The EGR volume control valve uses a step motor to control the flow
rate of EGR from exhaust manifold. This motor has four winding
phases. It operates according to the output pulse signal of the ECM.
Two windings are turned ON and OFF in sequence. Each time an
ON pulse is issued, the valve opens or closes, changing the flow
rate. When no change in the flow rate is needed, the ECM does not
issue the pulse signal. A certain voltage signal is issued so that the
valve remains at that particular opening.
SEF411Y
EC-1177
http://vnx.su

EBS011OT

MONITOR ITEM
CONDITION
No-load
EGR VOL CON/V
SPECIFICATION
More than 10 steps

rpm
0 step

DTC No.
P0401
0401
EBS011TY
Exhaust gas recirculation flow

insufficient detected
The exhaust gas recirculation flow is

insufficient.
Possible cause
(The EGR volume control valve
EGR volume control valve stuck

closed
EGR passage clogged

EBS011TZ
NOTE:
WITH CONSULT-II
1.
2.
3.

CONSULT-II.
Start engine.
PBIB2156E
COOLAN TEMP/S
50 - 89 C (122 - 192 F)
Voltage between ECM terminal 55 (Intake air temperature sensor) and ground
1.7 - 2.6V
4.
PBIB2017E
WITH GST
EC-1178
http://vnx.su

Wiring Diagram
EBS011OV
EC
TBWA0579E
EC-1179
http://vnx.su

CAUTION:
TERMINAL
NO.
25
26
27
28
WIRE
COLOR
GY
W/L
OR/B
GY/B
ITEM
CONDITION
[Engine is running]
Warm-up condition
Idle speed
DATA
0.1 - 14V
control valve.)
EBS011OW
1. CHECK EGR VOLUME CONTROL VALVE POWER SUPPLY CIRCUIT

1.
2.
3.

Disconnect EGR volume control valve harness connector.
PBIB1901E
4.
Check voltage between EGR volume control valve terminals 2, 5

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
PBIB2013E

Harness for open or short between EGR volume control valve and ECM
Harness for open or short between EGR volume control valve and ECM relay
EC-1180
http://vnx.su

3. CHECK EGR VOLUME CONTROL VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Check harness continuity between ECM terminals and EGR volume control valve terminals as follows.
ECM terminal
EGR volume control valve terminal
25
26
27
28
EC

OK or NG
OK
>> GO TO 4.
NG
4. CHECK EGR VOLUME CONTROL VALVE

OK or NG
OK
>> GO TO 5.
NG
>> Replace EGR volume control valve.
5. CHECK EGR PASSAGE

Check the following for clogging and cracks.
EGR tube
EGR hose
EGR cooler
OK or NG
OK
>> GO TO 6.
NG
>> Repair or replace EGR passage.

M

>> INSPECTION END
EBS011V3
EGR VOLUME CONTROL VALVE

With CONSULT-II
1.
EC-1181
http://vnx.su

2.
3.
4.
5.
Check resistance between the following terminals.

terminal 2 and terminals 1, 3
Temperature C (F)
Resistance
20 (68)
13 - 17
If NG, replace EGR volume control valve.

Reconnect EGR volume control valve harness connector.
PBIB2014E
6.
SEF819Y
If NG, replace the EGR volume control valve.

NOTE:
checking.
Without CONSULT-II
1.
EC-1182
http://vnx.su

2.

3.
4.
5.
Temperature C (F)
Resistance
20 (68)
13 - 17
EC

Turn ignition switch ON and OFF.
G
PBIB2014E
6.
Check that EGR volume control valve shaft moves smoothly forward and backward according to the ignition switch position.
NOTE:
SEF560W
EBS011V4

L
EC-1183
http://vnx.su
DTC P0404 EGR VOLUME CONTROL VALVE


Description
PFP:14710
EBS011P6
SYSTEM DESCRIPTION
Sensor
Input Signal to ECM
Engine speed
Vehicle speed
Ignition switch
Start signal
ECM Function
EGR volume control
Actuator
EGR volume control

valve
Engine stopped
Engine starting
High engine speed
SEF908Y
SEF411Y
EC-1184
http://vnx.su

EBS011P7

MONITOR ITEM
CONDITION
No-load
EGR VOL CON/V
SPECIFICATION
More than 10 steps

rpm
0 step

DTC No.
EBS011U2
Exhaust gas recirculation control circuit range/performance
An improper voltage signal is sent to

ECM through EGR volume control
valve.
P0404
0404
EC
Possible cause
(The EGR volume control valve
EGR volume control valve stuck

closed
EBS011U3
NOTE:
WITH CONSULT-II
1.
2.
3.

CONSULT-II.
Start engine.
PBIB2156E
COOLAN TEMP/S
22 - 87 C (72 - 189 F)
Voltage between ECM terminal 55 (Intake air temperature sensor) and ground
0.9 - 4.0V
4.
PBIB2017E
WITH GST
EC-1185
http://vnx.su

Wiring Diagram
EBS011P9
TBWA0579E
EC-1186
http://vnx.su

CAUTION:
TERMINAL
NO.
25
26
27
28
WIRE
COLOR
GY
W/L
OR/B
GY/B
ITEM
CONDITION
[Engine is running]
Warm-up condition
Idle speed
DATA
0.1 - 14V
control valve.)
EC
EBS011PA
1. CHECK EGR VOLUME CONTROL VALVE POWER SUPPLY CIRCUIT

1.
2.
3.

PBIB1901E
4.


OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
L
PBIB2013E

EC-1187
http://vnx.su

1.
2.
3.

ECM terminal
25
26
27
28

OK or NG
OK
>> GO TO 4.
NG

OK or NG
OK
>> GO TO 5.
NG

>> INSPECTION END
EBS011PB

With CONSULT-II
1.
EC-1188
http://vnx.su

2.

3.
4.
5.
Temperature C (F)
Resistance
20 (68)
13 - 17
EC

G
PBIB2014E
6.
K
SEF819Y

NOTE:
checking.
Without CONSULT-II
1.
EC-1189
http://vnx.su

2.
3.
4.
5.

Temperature C (F)
Resistance
20 (68)
13 - 17

PBIB2014E
6.
NOTE:
SEF560W
EBS011PC

EC-1190
http://vnx.su


PFP:24810
A
EBS01FAZ
The ECM receives vehicle speed sensor signal via CAN communication line. It is sent from combination
meter. The ECM uses this signal for ASCD control. Refer to EC-1327, "AUTOMATIC SPEED CONTROL EC
DEVICE (ASCD)" for ASCD functions.
EBS01FB0

NOTE:
If DTC P0501 is displayed with DTC U1000 first perform the trouble diagnosis for DTC U1000. Refer
to EC-1050, "DTC U1000 CAN COMMUNICATION LINE" .
DTC No.
Trouble Diagnosis
Name
P0501
0501
Vehicle speed sensor range/performance
A change of vehicle speed signal is excessively large during specified time.
Possible Cause
shorted.)
Combination meter

Wheel sensor
ECM
H
EBS01FB1
CAUTION:
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.

Drive the vehicle at more than 10 km/h (6 MPH) for at least 5
seconds.
MBIB1085E
SEF058Y
WITH GST
EC-1191
http://vnx.su

EBS01FB2
1. CHECK DTC WITH ESP/TCS/ABS CONTROL UNIT (MODELS WITH ESP) OR ABS ACTUATOR AND
Refer to BRC-58, "TROUBLE DIAGNOSIS" (models with ESP) or BRC-11, "TROUBLE DIAGNOSIS" (models without ESP).
OK or NG
OK
>> GO TO 2.
NG

>> INSPECTION END
EC-1192
http://vnx.su


PFP:24810
A
EBS01FC1
EBS01FC2

MI will not light up for this self-diagnosis.
NOTE:
DTC No.
Trouble Diagnosis
Name
P0502
0502
Vehicle speed sensor circuit low input
Vehicle speed signal is excessively low compared with the driving condition.
shorted.)
Combination meter

Wheel sensor
ECM
Possible Cause
H
EBS01FC3
CAUTION:
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
Start engine and warm it up to normal operating temperature (ESP switch OFF).
Maintain the following condition for at least 5 seconds.
M
CKPSRPM (TDC)
More than 2,800 rpm
COOLAN TEMP/S
More than 60C (140 F)
Clutch pedal
Released
Shift lever
1st position
4.

MBIB1084E
WITH GST
EC-1193
http://vnx.su

EBS01FC4
Refer to BRC-58, "TROUBLE DIAGNOSIS" (models with ESP) or BRC-11, "TROUBLE DIAGNOSIS" (models
without ESP).
OK or NG
OK
>> GO TO 2.
NG

>> INSPECTION END
EC-1194
http://vnx.su


PFP:24810
A
EBS01FC5
EBS01FC6

NOTE:
DTC No.
Trouble Diagnosis
Name
P0503
0503
Vehicle speed sensor circuit high input
Vehicle speed signal is excessively high compared with the driving condition.
Possible Cause
shorted.)
Combination meter

Wheel sensor
ECM
H
EBS01FC7
CAUTION:
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.

seconds.
MBIB1085E
SEF058Y
WITH GST
EC-1195
http://vnx.su

EBS01FC8
Refer to BRC-58, "TROUBLE DIAGNOSIS" (models with ESP system) or BRC-11, "TROUBLE DIAGNOSIS"
(models without ESP system).
OK or NG
OK
>> GO TO 2.
NG

>> INSPECTION END
EC-1196
http://vnx.su


PFP:25320
A
EBS01FC9
When the brake pedal is depressed, ASCD brake switch (1) and
stop lamp switch (2) are turned ON. ECM detects the state of the
brake pedal by this input of two kinds (ON/OFF signal).
EC
D
PBIB2882E
EBS01FCA

MONITOR ITEM
BRAKE SW
CONDITION
BRAKE SW2
Ignition switch: ON
Ignition switch: ON
SPECIFICATION
OFF
Brake pedal: Slightly

depressed
ON

Fully released
OFF
Brake pedal and/or clutch

ON
EBS01FCC

MI will not light up for this diagnosis.
DTC No.
Trouble Diagnosis
Name
Possible Cause
P0504
0504
ASCD brake switch
When the vehicle speed is above 5 km/h (3

MPH), ON signal from the stop lamp switch
and OFF signal from the ASCD brake
switch are sent to the ECM at the same
time.
EC-1197
http://vnx.su
(The stop lamp switch circuit is open or
shorted.)
(The ASCD brake switch circuit is open or
shorted.)
(The ASCD clutch switch circuit is open or
shorted.)
Stop lamp switch
ASCD brake switch
ASCD clutch switch
ECM

DTC confirmation Procedure
EBS01FCD
CAUTION:
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.

VHCL SPEED SE
Selector lever
Suitable position
4.

If DTC is not detected, go to the following step.
VHCL SPEED SE
Selector lever
Suitable position
Driving location

the above-mentioned condition.
5.
WITH GST
EC-1198
http://vnx.su
MBIB1085E

Wiring Diagram
EBS01FCE
EC
TBWB0477E
EC-1199
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
100
Stop lamp switch
101
GY/L
ASCD brake switch
DATA (DC Voltage)
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
BATTERY VOLTAGE
(11 - 14V)

depressed
Approximately 0V
EBS01FCO

With CONSULT-II
Select BRAKE SW in DATA MONITOR mode with CONSULT-II.
3. Check BRAKE SW indication under the following conditions.
1.
2.
CONDITION
INDICATION
When brake pedal is slightly depressed
ON
When brake pedal is fully released
OFF
PBIB0472E
Without CONSULT-II
Condition
Voltage
battery voltage
Approximately 0V
OK or NG
OK
>> GO TO 2.
NG
>> GO TO 3.
MBIB1097E
EC-1200
http://vnx.su

With CONSULT-II
Check BRAKE SW2 indication in DATA MONITOR mode.
EC
CONDITION
INDICATION
When brake pedal and/or clutch pedal is fully depressed
ON
When brake pedal and clutch pedal are slightly released
OFF
SEC013D
1.
2.
Without CONSULT-II
G
Condition
Voltage
When brake pedal and/or clutch pedal is slightly depressed
Approximately 0V
When brake pedal and clutch pedal are fully released
Battery voltage
I
PBIB1677E
OK or NG
OK
>> GO TO 14.
NG
>> GO TO 7.
EC-1201
http://vnx.su


1.
2.

Disconnect stop lamp switch harness connector (1).
ASCD brake switch harness connector (2)
ASCD clutch switch harness connector (3)
PBIB2878E
3.
Check voltage between stop lamp switch terminal 1 and ground

with CONSULT -II or tester.
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
PBIB0117E

15A fuse
1.
2.


OK or NG
OK
>> GO TO 6.
NG

OK or NG
OK
>> GO TO 14.
NG
EC-1202
http://vnx.su


1.
2.
3.

Disconnect ASCD brake switch (2) harness connector.
Stop lamp switch (1)
ASCD clutch switch (3)
EC
D
PBIB2878E
4.

F

OK or NG
OK
>> GO TO 12.
NG
>> GO TO 8.
H
PBIB0857E
1.
2.

Disconnect ASCD clutch switch harness connector (3).
Stop lamp switch harness connector (1)
PBIB2878E
3.
4.

OK or NG
OK
>> GO TO 10.
NG
>> GO TO 9.
PBIB0799E
EC-1203
http://vnx.su


10A fuse
1.
2.


OK or NG
OK
>> GO TO 11.
NG

OK or NG
OK
>> GO TO 14.
NG
1.
2.
3.

Check harness continuity between ECM terminal 101 and ASCD brake switch terminal 2.

OK or NG
OK
>> GO TO 13.
NG

OK or NG
OK
>> GO TO 14.
NG

>> INSPECTION END
EBS01FCP
ASCD BRAKE SWITCH

1.
EC-1204
http://vnx.su

2.
3.

Condition
When brake pedal is fully released.

When brake pedal is slightly depressed.
Continuity
EC
Should exist.
Should not exist.

SEC023D
ASCD CLUTCH SWITCH

1.
2.
3.

Check harness continuity between ASCD clutch switch terminals 1 and 2 under the following conditions.
Condition
When clutch pedal is fully released.

When clutch pedal is slightly depressed.
Continuity
Should exist.
Should not exist.

H
SEC024D
STOP LAMP SWITCH

1.
2.
3.

Check harness continuity between stop lamp switch terminals 1
and 2 under the following conditions.
K
Condition
Continuity
Should not exist.
Should exist.
If NG, adjust stop lamp switch installation, refer to BR-6,

M
PBIB0118E
EC-1205
http://vnx.su
DTC P0563 BATTERY VOLTAGE


PFP:24410
EBS011BS

DTC No.
P0563
0563
Battery voltage high

An excessively high voltage from the battery is
sent to ECM.
Possible cause
Battery
Battery terminal
Alternator
EBS011BT
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITH GST
EBS011BU
1. INSPECTION START
Are jumper cables connected for the jump starting?
Yes or No
Yes
>> GO TO 3.
No
>> GO TO 2.
2. CHECK BATTERY AND ALTERNATOR

Check that the proper type of battery and alternator is installed.
Refer to, SC-3, "BATTERY" and SC-12, "CHARGING SYSTEM" .
OK or NG
OK
>> GO TO 5.
NG
>> Replace with a proper one.
EC-1206
http://vnx.su

3. CHECK JUMPER CABLES INSTALLATION
Check that the jumper cables are connected in the correct sequence.
EC
D
SEF439Z
OK or NG
OK
>> GO TO 4.
NG
>> Reconnect jumper cables properly.
4. CHECK BATTERY FOR BOOSTER

Check that the battery for the booster is a 12V battery.
OK or NG
OK
>> GO TO 5.
NG
>> Change the vehicle for booster.
5. PERFORM DTC CONFIRMATION PROCEDURE AGAIN

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.
6. REPLACE ECM
1.
2.
3.
Replace ECM.
>> INSPECTION END
7. CHECK ELECTRICAL PARTS DAMAGE

Check the following for damage.
Wiring harness and harness connectors for burn
Fuses for short

OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace malfunctioning part.
EC-1207
http://vnx.su
DTC P0580, P0581 ASCD STEERING SWITCH


PFP:25551
EBS01F9V
PBIB2877E
1.
2.
4.
SET/COAST switch
5.
MAIN switch
3.
CANCEL switch
EBS01F9W

MONITOR ITEM
MAIN SW
CANCEL SW
RESUME/ACC SW
SET SW
CONDITION
Ignition switch: ON
Ignition switch: ON
Ignition switch: ON
Ignition switch: ON
SPECIFICATION
OFF
ON
OFF
ON
Released
OFF
Pressed
ON
OFF
ON
EC-1208
http://vnx.su

EBS01F9Y
A
MI will not light up for these diagnoses.
NOTE:
If DTC P0580 or P0581 is displayed with DTC P0606, first perform the trouble diagnosis for DTC P0605. EC
DTC No.
Trouble Diagnosis
Name
Possible Cause
P0580
0580

circuit low input

stuck ON.
P0581
0581

circuit high input
An excessively high voltage signal from the

ASCD steering switch is sent to ECM.
ECM
EBS01F9Z
NOTE:
WITH CONSULT-II
1.
2.
3.
4.
5.
6.
7.
8.

Press SET COAST switch for at least 10 seconds, then release it and wait at least 10 seconds.
WITH GST
EC-1209
http://vnx.su

Wiring Diagram
EBS01FA0
LHD MODELS
TBWB0475E
EC-1210
http://vnx.su

RHD MODELS
A
EC
TBWB0476E
EC-1211
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
102
PU*1
W/R*2
103
B/OR

ground
*1: LHD models

*2: RHD models
EC-1212
http://vnx.su
DATA
(DC Voltage)
Approximately 4.3V
Approximately 0.3V
Approximately 1.3V
Approximately 3.3V
Approximately 2.3V
Approximately 0.3V

EBS01FA1

1.
2.

EC
J
PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1213
http://vnx.su


With CONSULT-II
2. Select MAIN SW, RESUME/ACC SW, SET SW and CANCEL SW in DATA MONITOR mode with
CONSULT-II.
Switch
Monitor item
MAIN
MAIN SW
CANCEL
CANCEL SW
RESUME/ACCELERATE
RESUME/ACC SW
Condition
Indication
Pressed
ON
Released
OFF
Pressed
ON
Released
OFF
Pressed
ON
Released
OFF
Pressed
ON
Released
OFF
SEC006D
SET/COAST
SET SW
Without CONSULT-II
Switch
MAIN
CANCEL
RESUME/ACCELERATE
SET/COAST
Condition
Voltage (V)
Pressed
Approx. 0.3
Released
Approx. 4.3
Pressed
Approx. 1.3
Released
Approx. 4.3
Pressed
Approx. 3.3
Released
Approx. 4.3
Pressed
Approx. 2.3
Released
Approx. 4.3
MBIB0043E
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 3.
1.
2.
3.
4.

Disconnect ASCD steering switch (1) harness connector.

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
EC-1214
http://vnx.su
PBIB2879E

EC
1.
E

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

OK or NG
OK
>> GO TO 8.
NG

>> INSPECTION END
EBS01FA2

1.
2.
Disconnect ASCD steering switch.

Switch
MAIN
CANCEL
RESUME/ACCELERATE
Condition
Resistance ()
Pressed
Approx. 0
Released
Approx. 4,000
Pressed
Approx. 250
Released
Approx. 4,000
Pressed
Approx. 1,480
Released
Approx. 4,000
EC-1215
http://vnx.su
PBIB2880E

Switch
SET/COAST
Condition
Resistance ()
Pressed
Approx. 660
Released
Approx. 4,000
EC-1216
http://vnx.su
DTC P0605 ECM

DTC P0605 ECM

Description
PFP:23710
A
EBS011BV

EC
D
MBIB0625E

DTC No.
P0605
0605

(ROM)
EBS011BW

ECM ROM is malfunctioning.
Possible cause
ECM
EBS011BX
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITH GST
EC-1217
http://vnx.su
DTC P0605 ECM

EBS011BY
1. INSPECTION START
1.
2.
3.
4.
5.
With CONSULT-II
Touch ERASE.
With GST
3. Touch ERASE.
5. Is DTC P0605 displayed again?
Yes or No
Yes
>> GO TO 2.
No
>> INSPECTION END
2. REPLACE ECM
1.
2.
3.
Replace ECM.
>> INSPECTION END
EC-1218
http://vnx.su
DTC P0606 ECM

DTC P0606 ECM

Description
PFP:23710
A
EBS011BZ

EC
D
MBIB0625E

DTC No.
P0606
0606

(Processor)
EBS011C0

Possible cause
ECM
EBS011C1
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITH GST
EC-1219
http://vnx.su
DTC P0606 ECM

EBS011C2
1. INSPECTION START
1.
2.
3.
4.
5.
With CONSULT-II
Touch ERASE.
With GST
3. Touch ERASE.
5. Is DTC P0606 displayed again?
Yes or No
Yes
>> GO TO 2.
No
>> INSPECTION END
2. REPLACE ECM
1.
2.
3.
Replace ECM.
>> INSPECTION END
EC-1220
http://vnx.su
DTC P0628, P0629 FUEL PUMP


Description
PFP:16700
A
EBS011C3
To control the amount of the fuel inhalation of the fuel pump, a plunger is built into the fuel pump. When the
amount of the fuel inhalation of fuel increases, the fuel pump raises the fuel exhalation pressure. As a result, EC
the fuel injection pressure is raised. When the load of the engine increases, the ECM sends a signal to the fuel
pump to raise the injection pressure.
EBS011C4

MONITOR ITEM
CONDITION
No-load
PUMP CURRENT
SPECIFICATION
Idle
1,700 - 1,900 mA
2,000 rpm
1,600 - 1,800 mA

DTC No.
EBS011C6
P0628
0628
Fuel pump control circuit

low input
ECM detects a control circuit for the fuel pump is

open or short to ground.
P0629
0629

high output

short to power.
Possible cause
(The fuel pump circuit is open or
shorted.)
Fuel pump
EBS011C7
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

M
SEF817Y
WITH GST
EC-1221
http://vnx.su

Wiring Diagram
EBS011C8
TBWA0574E
EC-1222
http://vnx.su

A
CAUTION:
EC
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA
C
[Engine is running]
Warm-up condition
Idle speed
0 - 12.5V
NOTE:
idle.
E
MBIB0885E
10
Y/L

0 - 12.5V
F
[Engine is running]
Warm-up condition
G
MBIB0886E
H
[Engine is running]
Warm-up condition
Idle speed
0.5 - 1.0V
NOTE:
idle.
J
MBIB0887E
29
Fuel pump
0.5 - 1.0V
K
[Engine is running]
Warm-up condition
L
MBIB0888E
EC-1223
http://vnx.su

EBS011C9
1. CHECK ECM OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1.
2.
3.

Disconnect ECM harness connector and fuel pump harness
connector.
Check harness continuity between ECM terminal 10 and fuel
pump terminal 2.

OK or NG
OK
>> GO TO 2.
NG
PBIB1943E
2. CHECK FUEL PUMP GROUND CIRCUIT FOR OPEN AND SHORT

1.
Check harness continuity between ECM terminal 29 and fuel pump terminal 1.

OK or NG
OK
>> GO TO 3.
NG
3. CHECK FUEL PUMP

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

1.
2.
Replace fuel pump.

>> INSPECTION END

>> INSPECTION END
EC-1224
http://vnx.su

EBS011CA
FUEL PUMP
1.
Check continuity between fuel supply pump terminals 1 and 2.

2.
EC
If NG, replace fuel pump.
D
SEF807Z
EBS011CB
FUEL PUMP

F
EC-1225
http://vnx.su
DTC P0642, P0643 SENSOR POWER SUPPLY


DTC No.
PFP:18002
EBS011CF
P0642
0642
Sensor power supply circuit low input
ECM detects a voltage of power source for sensor is excessively low.
P0643
0643
Sensor power supply circuit high input
ECM detects a voltage of power source for Sensor is excessively high.
Possible cause
(The APP sensor 1 power supply circuit is shorted.)

EBS011CG
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITH GST
EC-1226
http://vnx.su

Wiring Diagram
EBS011V5
EC
TBWA0731E
EC-1227
http://vnx.su

CAUTION:
TERMINAL
NO.
82
WIRE
COLOR
B
ITEM
CONDITION
DATA
Approximately 5.3V
EBS011CI

1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1228
http://vnx.su


1.
2.

connector.
EC
D
PBIB1893E
3.


F
OK or NG
OK
>> GO TO 3.
NG
PBIB0914E
3. CHECK APP SENSOR

I

OK or NG
OK
>> GO TO 4.
NG

>> INSPECTION END
EC-1229
http://vnx.su


DTC No.
PFP:18002
EBS011CO
P0652
Sensor power supply circuit low
P0653
0653
Possible cause
(APP sensor 2 power supply circuit is
shorted.)
(Crankshaft position sensor circuit is
shorted.)
(Camshaft position sensor circuit is
shorted.)
(Fuel rail pressure sensor circuit is
shorted.)
(Turbocharger boost sensor circuit is
shorted.)


EBS011CP
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITH GST
EC-1230
http://vnx.su

Wiring Diagram
EBS011CQ
EC
TBWB0645E
EC-1231
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
DATA
(DC Voltage)
CONDITION
44
L/W
Approximately 5.3V
45
G/OR
Camshaft position sensor power supply
Approximately 5.3V
63
Fuel rail pressure sensor power supply
Approximately 5.3V
64
Turbocharger boost sensor power supply
Approximately 5.3V
90

power supply
Approximately 5.3V
EBS011CR

1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1232
http://vnx.su


1.
2.

connector.
EC
D
PBIB1893E
3.


F
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.
PBIB0915E
3. CHECK SENSOR POWER SUPPLY CIRCUITS

Harness for short to power and short to ground, between the following terminals.
ECM terminal
Sensor terminal
90
EC-1094
44
Crankshaft position sensor terminal 1
EC-1149
45
Camshaft position sensor terminal 3
EC-1161
63
Fuel rail pressure sensor terminal 1
EC-1104
64
Turbocharger boost sensor terminal 1
EC-1144
ECM pin terminal.

OK or NG
OK
>> GO TO 4.
NG
4. CHECK COMPONENTS
Crankshaft position sensor (Refer to EC-1153, "Component Inspection" .)
Camshaft position sensor (Refer to EC-1165, "Component Inspection" .)
Fuel rail pressure sensor (Refer to EC-1107, "Component Inspection" .)
Turbocharger boost sensor (Refer to EC-1147, "Component Inspection" .)

OK or NG
OK
>> GO TO 5.
NG
EC-1233
http://vnx.su

5. CHECK APP SENSOR

OK or NG
OK
>> GO TO 6.
NG

>> INSPECTION END
EC-1234
http://vnx.su
DTC P0686 ECM RELAY

DTC P0686 ECM RELAY

PFP:25230
A
EBS011CV

DTC No.
P0686
0686

ECM relay circuit
EC
Possible cause
(The ECM relay circuit is shorted.)
ECM relay
ECM detects ECM relay is stuck closed even if

ignition switch OFF.
EBS011CW
NOTE:
WITH CONSULT-II
1.
2.
3.
4.
5.
Turn ignition switch ON and then turn OFF.

SEF817Y
WITH GST
K
EC-1235
http://vnx.su
DTC P0686 ECM RELAY

Wiring Diagram
EBS011V8
TBWA0576E
EC-1236
http://vnx.su
DTC P0686 ECM RELAY

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
105

switch OFF

113

switch OFF
119
120
Y
R
EC
DATA
(DC Voltage)
C
Approximately 1.2V
D
BATTERY VOLTAGE
(11 - 14V)
E
Approximately 1.2V
F
BATTERY VOLTAGE
(11 - 14V)
BATTERY VOLTAGE
(11 - 14V)
H
EBS011CY
1. CHECK ECM OUTPUT SIGNAL CIRCUIT FOR SHORT TO GROUND

I
1.
2.
3.

Check harness continuity between ECM terminals 105, 113 and ground.

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

Harness for open or short between ECM and ECM relay

EC-1237
http://vnx.su
DTC P0686 ECM RELAY

3. CHECK ECM INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1.
2.

Check harness continuity between ECM terminal 119 and ECM
relay terminal 5, ECM terminals 120 and ECM relay terminal 7.

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
PBIB1899E


5. CHECK ECM RELAY

OK or NG
OK
>> GO TO 6.
NG

>> INSPECTION END
EBS011CZ
ECM RELAY
1.
2.

Condition
Continuity
Yes
OFF
No
3.

PBIB0077E
EC-1238
http://vnx.su


Description
PFP:47850
A
EBS011D0
EC
EBS011D1

DTC No.
P1211
1211

TCS control unit

Possible cause
TCS related parts
E
EBS011D2
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

J
SEF817Y
WITH GST
Follow the procedure WITH CONSLT-II above.
EBS011D3
Go to BRC-58, "TROUBLE DIAGNOSIS" (models with ESP system) or BRC-11, "TROUBLE DIAGNOSIS"
(model without ESP system).
M
EC-1239
http://vnx.su


Description
PFP:47850
EBS011D4
NOTE:
If DTC P1212 is displayed with DTC U1000, first perform the trouble diagnosis for DTC U1000.
Refer to EC-1050, "DTC U1000 CAN COMMUNICATION LINE" .
Be sure to erase the malfunction information such as DTC not only for ESP/TCS/ABS control unit
but also for ECM after TCS related repair.
EBS011D5

DTC No.
P1212
1212
TCS communication line
ECM can not receive the information from ESP/

TCS/ABS control unit continuously.
Possible cause
(The CAN communication line is
open or shorted.)
Dead (Weak) battery

EBS011D6
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITH GST
EBS011D7
EC-1240
http://vnx.su
DTC P1260 - P1267 FUEL INJECTOR ADJUSTMENT RESISTOR


Description
PFP:16600
A
EBS011D8
The fuel injector adjustment resistor is built into the fuel injector. The resistance is constant and individual.
ECM uses the individual resistance to determine the fuel injection pulse.
EC

DTC No.
EBS011DA
Possible cause
P1260
1260

adjustment resistor low
input
An excessively low voltage from the No. 1 cylinder fuel injector adjustment resistor is sent to
ECM.
P1261
1261

adjustment resistor high
input
An excessively high voltage from the No. 1 cylinder fuel injector adjustment resistor is sent to
ECM.
P1262
1262

input
ECM.
P1263
1263

input
ECM.
P1264
1264

input
ECM.
(The fuel injector adjustment resistor
P1265
1265

input
ECM.
P1266
1266

input
ECM.
P1267
1267

input
ECM.
EC-1241
http://vnx.su

EBS011DB
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITH GST
EC-1242
http://vnx.su

Wiring Diagram
EBS011DC
EC
TBWA0575E
EC-1243
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
59
W/B
60
Y/B
61
G/B
62
R/B
78
ITEM
DATA
(DC Voltage)
CONDITION

resistor No. 1
resistor No. 3
resistor No. 4
resistor No. 2
0.5 - 5.1V
resistors.)

resistor ground
Approximately 0.3V
EBS011DD

1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1244
http://vnx.su

2. CHECK FUEL INJECTOR ADJUSTMENT RESISTOR POWER SUPPLY CIRCUIT

1.
2.
Disconnect fuel injector harness connector of malfunctioning

cylinder.
EC
D
PBIB1896E
3.
Check voltage between fuel injector terminal 2 and ground with

OK or NG
OK
>> GO TO 3.
NG
MBIB0186E
3. CHECK FUEL INJECTOR ADJUSTMENT RESISTOR GROUND CIRCUIT

1.
2.
3.

Check harness continuity between fuel injector terminal 1 and ECM terminal 78.

OK or NG
OK
>> GO TO 4.
NG
4. CHECK FUEL INJECTOR ADJUSTMENT RESISTOR

M

OK or NG
OK
>> GO TO 5.
NG

>> INSPECTION END
EBS011DE
FUEL INJECTOR ADJUSTMENT RESISTOR

1.
EC-1245
http://vnx.su

2.

PBIB0415E
EBS011DF
FUEL INJECTOR
EC-1246
http://vnx.su


PFP:16600
A
EBS011DG
allows fuel to flow through the fuel injector into the intake cylinder.
The amount of fuel injected depends upon the injection pulse duration. Pulse duration is the length of time the fuel injector remains
open. The ECM controls the injection pulse duration based on
engine fuel needs.
EC
D
PBIB0465E
EBS011DH

MONITOR ITEM
MAIN INJ WID
CONDITION
No-load
0.68 - 0.78 msec
Idle speed

0.78 - 0.88 msec
G
EBS011DJ

DTC No.
SPECIFICATION
P1268
1268
The valve built into No. 1 cylinder fuel injector is

not closed properly (stuck open) when the injector is not energized.
P1269
1269

P1270
1270

P1271
1271

Possible cause
Fuel injector
EC-1247
http://vnx.su

EBS011DK
CAUTION:
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

with CONSULT-II.
Restart engine and let it idle for about 15 minutes.
Drive vehicle and maintain the following conditions for at least
60 seconds.
CKPSRPM
700 - 2000 rpm (A constant rotation is maintained)
COOLAN TEMP/S
Less than 75C (167F)
Shift lever
Suitable position
Accelerator pedal
PBIB2156E
5.
WITH GST
EC-1248
http://vnx.su

Wiring Diagram
EBS011DL
EC
TBWA0569E
EC-1249
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
[Engine is running]
W/B
G/B

Warm-up condition
Idle speed
DATA
5 - 10V
NOTE:
idle.
MBIB0883E
5 - 10V
[Engine is running]
Warm-up condition
MBIB0884E
[Engine is running]
21
22
23
24
G/R
GY/L
G/R
GY/L
Fuel injector No. 2

Fuel injector No. 2
Fuel injector No. 3
Fuel injector No. 3
Warm-up condition
Idle speed
0 - 9V
NOTE:
idle.
MBIB0881E
0 - 9V
[Engine is running]
Warm-up condition
MBIB0882E
[Engine is running]
40
41
42
43
G/R
GY/L
G/R
GY/L
Fuel injector No. 4

Fuel injector No. 4
Fuel injector No. 1
Fuel injector No. 1
Warm-up condition
Idle speed
0 - 9V
NOTE:
idle.
MBIB0881E
0 - 9V
[Engine is running]
Warm-up condition
MBIB0882E
EC-1250
http://vnx.su

EBS011DM
1. CHECK FUEL INJECOR POWER SUPPLY CIRCUIT FOR OPEN AND SHORT
1.
2.
3.
4.

Terminal
DTC
EC
Cylinder
ECM
Fuel injector
P1268
No.1
P1269
No.2
P1270
No.3
P1271
No.4
PBIB1896E

OK or NG
OK
>> GO TO 2.
NG

1.
Terminal
DTC
Cylinder
ECM
Fuel injector
P1268
42, 43
No.1
P1269
21, 22
No.2
P1270
23, 24
No.3
P1271
40, 41
No.4

OK or NG
OK
>> GO TO 3.
NG

OK or NG
OK
>> GO TO 4.
NG
EC-1251
http://vnx.su


1.
2.
3.
4.
5.
6.
7.
8.
With CONSULT-II
Touch ERASE.
With GST
6. Touch ERASE.
7. Perform EC-1248, "DTC Confirmation Procedure" .
Yes or No
Yes
>> Replace fuel injector of malfunctioning cylinder.
No
>> GO TO 5.

>> INSPECTION END
EBS011DN
FUEL INJECTOR
1.
2.

3.
PBIB0406E
EBS011DO
FUEL INJECTOR
EC-1252
http://vnx.su
DTC P1272 FUEL PUMP

DTC P1272 FUEL PUMP

Description
PFP:16700
A
EBS011DP
When the fuel pressure in fuel rail increases to excessively high, fuel
pressure relief valve opens to carry excess fuel to the return hose.
EC
D
PBIB1900E
EBS012AQ

MONITOR ITEM
CONDITION
No-load
PUMP CURRENT
Idle
1,700 - 1,900 mA
2,000 rpm
1,600 - 1,800 mA

DTC No.
P1272
1272
EBS011DQ
Fuel rail pressure relief

valve open
SPECIFICATION
Fuel rail pressure relief valve is open

because of fuel pressure control system
malfunction.
Possible cause
(Fuel pump circuit is open or shorted.)
Fuel pump
Air mixed with fuel
Lack of fuel
K
EBS011DR
WITH CONSULT-II
4.
NOTE:
1.
2.
3.

least 5 seconds, then release the accelerator pedal.
SEF817Y
WITH GST
EC-1253
http://vnx.su
DTC P1272 FUEL PUMP

Wiring Diagram
EBS012AJ
TBWA0574E
EC-1254
http://vnx.su
DTC P1272 FUEL PUMP

A
CAUTION:
EC
TERMINAL
NO.
WIRE
COLOR
ITEM
DATA
CONDITION
C
[Engine is running]
Warm-up condition
Idle speed
0 - 12.5V
NOTE:
idle.
E
MBIB0885E
10
Y/L

0 - 12.5V
F
[Engine is running]
Warm-up condition
G
MBIB0886E
H
[Engine is running]
Warm-up condition
Idle speed
0.5 - 1.0V
NOTE:
idle.
J
MBIB0887E
29
Fuel pump
0.5 - 1.0V
K
[Engine is running]
Warm-up condition
L
MBIB0888E
EBS011DS

OK or NG
OK
>> GO TO 2.
NG
EC-1255
http://vnx.su
DTC P1272 FUEL PUMP


NOTE:
With CONSULT-II
5. Touch ERASE.
With GST
5. Touch ERASE.
Yes or No
Yes
>> GO TO 3.
No
>> INSPECTION END
3. CHECK FUEL PUMP POWER SUPPLY CIRCUIT FOR OPEN AND SHORT
1.
2.

connectors.
PBIB1943E
3.

OK or NG
OK
>> GO TO 4.
NG
EC-1256
http://vnx.su
DTC P1272 FUEL PUMP


1.
EC

OK or NG
OK
>> GO TO 5.
NG
5. CHECK FUEL PUMP

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 8.

OK or NG
OK
>> GO TO 7.
NG

OK or NG
OK
>> GO TO 8.
NG

1.
2.
Replace fuel pump.

>> INSPECTION END
EBS012AK
FUEL PUMP
1.

2.
SEF807Z
EC-1257
http://vnx.su
DTC P1272 FUEL PUMP

EBS011DT
FUEL RAIL
FUEL PUMP
EC-1258
http://vnx.su
DTC P1273 FUEL PUMP

DTC P1273 FUEL PUMP

Description
PFP:16700
A
EBS011DU
amount of the fuel inhalation of fuel pump increases, the fuel raises the fuel exhalation pressure. As a result, EC
EBS011DV

MONITOR ITEM
CONDITION
No-load
PUMP CURRENT
SPECIFICATION
Idle
1,700 - 1,900 mA
2,000 rpm
1,600 - 1,800 mA

DTC No.
P1273
1273
Fuel pump insufficient flow
EBS011DX
ECM detects the abnormal pulse of fuel pressure.
Fuel pump
Air mixed with fuel
Lack of fuel
H
EBS011DY
NOTE:
4.
WITH CONSULT-II
1.
2.
3.
Possible cause

SEF817Y
WITH GST
EC-1259
http://vnx.su
DTC P1273 FUEL PUMP

Wiring Diagram
EBS011DZ
TBWA0574E
EC-1260
http://vnx.su
DTC P1273 FUEL PUMP

A
CAUTION:
EC
TERMINAL
NO.
WIRE
COLOR
ITEM
DATA
CONDITION
C
[Engine is running]
Warm-up condition
Idle speed
0 - 12.5V
NOTE:
idle.
E
MBIB0885E
10
Y/L

0 - 12.5V
F
[Engine is running]
Warm-up condition
G
MBIB0886E
H
[Engine is running]
Warm-up condition
Idle speed
0.5 - 1.0V
NOTE:
idle.
J
MBIB0887E
29
Fuel pump
0.5 - 1.0V
K
[Engine is running]
Warm-up condition
L
MBIB0888E
EBS011E0

OK or NG
OK
>> GO TO 2.
NG
EC-1261
http://vnx.su
DTC P1273 FUEL PUMP


NOTE:
With CONSULT-II
5. Touch ERASE.
With GST
5. Touch ERASE.
Yes or No
Yes
>> GO TO 3.
No
>> INSPECTION END
1.
2.
3.

connectors.
pump terminal 2.

OK or NG
OK
>> GO TO 4.
NG

1.

OK or NG
OK
>> GO TO 5.
NG
EC-1262
http://vnx.su
PBIB1943E
DTC P1273 FUEL PUMP


OK or NG
OK
>> GO TO 6.
NG
EC
6. CHECK FUEL PUMP

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.
1.
2.
Replace fuel pump.

Perform Fuel Pump Learning Valve Clearing. Refer to EC-989, "Fuel Pump Learning Value Clearing" .
>> INSPECTION END

G

>> INSPECTION END
EBS011E1
FUEL PUMP
1.

J

2.

K
L
SEF807Z
EBS011E2
FUEL PUMP
EC-1263
http://vnx.su
DTC P1274 FUEL PUMP

DTC P1274 FUEL PUMP

Description
PFP:16700
EBS011E3
amount of the fuel inhalation of fuel increases, the fuel pump raises the fuel exhalation pressure. As a result,
EBS011E4

MONITOR ITEM
CONDITION
No-load
PUMP CURRENT
SPECIFICATION
Idle
1,700 - 1,900 mA
2,000 rpm
1,600 - 1,800 mA
EBS011E6

DTC No.
P1274
1274
Fuel pump protection

value.
Possible cause
shorted.)
Fuel pump

EBS011E7
NOTE:
WITH CONSULT-II
1.
2.
3.
4.
Tuning ignition switch ON.

Start engine and let idle for at least 5 seconds.
SEF817Y
WITH GST
EC-1264
http://vnx.su
DTC P1274 FUEL PUMP

Wiring Diagram
EBS011E8
EC
TBWA0574E
EC-1265
http://vnx.su
DTC P1274 FUEL PUMP

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
[Engine is running]
Warm-up condition
Idle speed
DATA
0 - 12.5V
NOTE:
idle.
MBIB0885E
10
Y/L

0 - 12.5V
[Engine is running]
Warm-up condition
MBIB0886E
[Engine is running]
Warm-up condition
Idle speed
0.5 - 1.0V
NOTE:
idle.
MBIB0887E
29
Fuel pump
0.5 - 1.0V
[Engine is running]
Warm-up condition
MBIB0888E
EC-1266
http://vnx.su
DTC P1274 FUEL PUMP

EBS011E9

1.
2.
3.

connectors.
pump terminal 2.
EC

OK or NG
OK
>> GO TO 2.
NG
PBIB1943E

1.

OK or NG
OK
>> GO TO 3.
NG

J

OK or NG
OK
>> GO TO 4.
NG
4. CHECK FUEL PUMP

L

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

1.
2.
Replace fuel pump.

>> INSPECTION END

>> INSPECTION END
EC-1267
http://vnx.su
DTC P1274 FUEL PUMP

EBS011EA
FUEL PUMP
1.
Check continuity between fuel pump terminals 1 and 2.

2.
SEF807Z
EBS011EB
FUEL PUMP
EC-1268
http://vnx.su
DTC P1275 FUEL PUMP

DTC P1275 FUEL PUMP

Description
PFP:16700
A
EBS011EC
the fuel injection pressure is raised. When the load of the engine increases, the ECM sends a signal to fuel
EBS011ED

MONITOR ITEM
CONDITION
No-load
PUMP CURRENT
SPECIFICATION
Idle
1,700 - 1,900 mA
2,000 rpm
1,600 - 1,800 mA
EBS011EF

DTC No.
P1275
1275
Fuel pump exchange

value.
Possible cause
shorted.)
Fuel pump

EBS011EG
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITH GST
EC-1269
http://vnx.su
DTC P1275 FUEL PUMP

Wiring Diagram
EBS011EH
TBWA0574E
EC-1270
http://vnx.su
DTC P1275 FUEL PUMP

A
CAUTION:
EC
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA
C
[Engine is running]
Warm-up condition
Idle speed
0 - 12.5V
NOTE:
idle.
E
MBIB0885E
10
Y/L

0 - 12.5V
F
[Engine is running]
Warm-up condition
G
MBIB0886E
H
[Engine is running]
Warm-up condition
Idle speed
0.5 - 1.0V
NOTE:
idle.
J
MBIB0887E
29
Fuel pump
0.5 - 1.0V
K
[Engine is running]
Warm-up condition
L
MBIB0888E
EC-1271
http://vnx.su
DTC P1275 FUEL PUMP

EBS011EI

1.
2.
3.

connectors.
pump terminal 2.

OK or NG
OK
>> GO TO 2.
NG
PBIB1943E

1.

OK or NG
OK
>> GO TO 3.
NG

OK or NG
OK
>> GO TO 4.
NG
4. CHECK FUEL PUMP

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

1.
2.
Replace fuel pump.

>> INSPECTION END

>> INSPECTION END
EC-1272
http://vnx.su
DTC P1275 FUEL PUMP

EBS011EJ
FUEL PUMP
1.

2.
EC
D
SEF807Z
EBS011EK
FUEL PUMP

F
EC-1273
http://vnx.su


Description
PFP:18002
EBS011EL

PBIB1741E
EBS011EM

MONITOR ITEM
ACCEL POS SEN*
ACCEL SEN 2*
CONDITION
SPECIFICATION
Ignition switch: ON
(Engine stopped)
0.2 - 0.7V
3.9 - 4.9V
Ignition switch: ON
(Engine stopped)
0.1 - 0.4V
1.9 - 2.4V
EBS011EO

DTC No.
P2135
2135

sensor 1, 2 signal correlation
Possible cause
(The APP sensor circuit is open or
shorted.)
The correlation between APP sensor 1 signal

and APP sensor 2 signal is out of the normal
range.
EBS011EP
NOTE:
WITH CONSULT-II
1.
2.
3.
4.
5.

Depress accelerator pedal slowly spending 5 seconds, and then
release it slowly spending 5 seconds.
SEF817Y
WITH GST
EC-1274
http://vnx.su

Wiring Diagram
EBS011EQ
EC
TBWA0730E
EC-1275
http://vnx.su

CAUTION:
TERMINAL
NO.
82
WIRE
COLOR
B
ITEM
CONDITION
DATA
Approximately 5.3V
83

sensor 1
Engine stopped
0.5 - 1.0V
Engine stopped
4.2 - 5.2V
84

sensor 1 ground
Approximately 0.3V
85
Sensor ground
Approximately 0.3V
90

Approximately 5.3V
91
92

sensor 2

sensor 2 ground
Engine stopped
0.4 - 0.7V
Engine stopped
EC-1276
http://vnx.su
2.2 - 2.7V
Approximately 0.3V

EBS011ER

1.
2.

EC
J
PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1277
http://vnx.su

2. CHECK APP SENSOR POWER SUPPLY CIRCUIT

1.
2.

connector.
PBIB1893E
3.
Check voltage between APP sensor terminals 4, 6 and ground

OK or NG
OK
>> GO TO 3.
NG
PBIB0560E

1.
2.
3.

Check harness continuity between APP sensor terminals 3 and ECM terminal 84, APP sensor terminal 1

OK or NG
OK
>> GO TO 4.
NG
1.
Check harness continuity between ECM terminal 83 and APP sensor terminal 5, ECM terminal 91 and
APP sensor terminal 2.

OK or NG
OK
>> GO TO 5.
NG
5. CHECK APP SENSOR

OK or NG
OK
>> GO TO 6.
NG
EC-1278
http://vnx.su


EC
>> INSPECTION END
EBS011ES

1.
2.
3.
Terminal
Accelerator pedal
Voltage
83
sensor 1)
Fully released
0.5 - 1.0V
Fully depressed
4.2 - 5.2V
Fully released
0.4 - 0.7V
Fully depressed
2.2 - 2.7V
91
sensor 2)
4.

conditions.
MBIB0615E
EBS011ET
ACCELERATOR PEDAL

I
EC-1279
http://vnx.su
DTC P2146, P2149 FUEL INJECTOR POWER SUPPLY


PFP:16600
EBS011EU
needs.
PBIB0465E
EBS011EV

MONITOR ITEM
MAIN INJ WID
CONDITION
SPECIFICATION
No-load
0.68 - 0.78 msec
Idle speed

0.78 - 0.88 msec

DTC No.
EBS011EX
P2146
2146
No. 1 and 4 cylinder fuel

injector power supply circuit open

through No. 1 and 4 cylinder fuel injector.
P2149
2149


Possible cause
EC-1280
http://vnx.su

EBS011EY
A
NOTE:
EC
TESTING CONDITION
WITH CONSULT-II
1.
2.
3.
4.

F
SEF817Y
WITH GST

H
EC-1281
http://vnx.su

Wiring Diagram
EBS011EZ
TBWA0733E
EC-1282
http://vnx.su

A
CAUTION:
EC
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA
C
[Engine is running]
W/B
G/B

Warm-up condition
Idle speed
5 - 10V
NOTE:
idle.
E
MBIB0883E
5 - 10V
F
[Engine is running]
Warm-up condition
G
MBIB0884E
H
[Engine is running]
21
22
23
24
G/R
GY/L
G/R
GY/L
Fuel injector No. 2

Fuel injector No. 2
Fuel injector No. 3
Fuel injector No. 3
Warm-up condition
Idle speed
0 - 9V
NOTE:
idle.
J
MBIB0881E
0 - 9V
K
[Engine is running]
Warm-up condition
L
MBIB0882E
[Engine is running]
40
41
42
43
G/R
GY/L
G/R
GY/L
Fuel injector No. 4

Fuel injector No. 4
Fuel injector No. 1
Fuel injector No. 1
Warm-up condition
Idle speed
0 - 9V
NOTE:
idle.
MBIB0881E
0 - 9V
[Engine is running]
Warm-up condition
MBIB0882E
EC-1283
http://vnx.su

EBS011F0
1. CHECK FUEL INJECOR POWER CIRCUIT FOR OPEN AND SHORT

1.
2.
3.
4.

Terminal
Cylinder
ECM
Fuel injector
No.1
No.2
No.3
No.4
PBIB1896E

OK or NG
OK
>> GO TO 2.
NG

>> INSPECTION END
EC-1284
http://vnx.su
DTC P2147, P2148 FUEL INJECTOR CIRCUIT


PFP:16600
A
EBS011F3
engine fuel needs.
EC
D
PBIB0465E
EBS011F4

MONITOR ITEM
MAIN INJ WID
CONDITION
No-load
0.68 - 0.78 msec
Idle speed

0.78 - 0.88 msec

DTC No.
SPECIFICATION
G
EBS011F6
P2147
2147
Fuel injector circuit low

input
ECM detects the fuel injector circuit is shorted to

ground.
P2148
2148
Fuel injector circuit high

input

power.
Possible cause
(The fuel injector circuit is shorted.)
EBS011F7
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITH GST
EC-1285
http://vnx.su

Wiring Diagram
EBS011F8
TBWA0569E
EC-1286
http://vnx.su

A
CAUTION:
EC
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA
C
[Engine is running]
W/B
G/B

Warm-up condition
Idle speed
5 - 10V
NOTE:
idle.
E
MBIB0883E
5 - 10V
F
[Engine is running]
Warm-up condition
G
MBIB0884E
H
[Engine is running]
21
22
23
24
G/R
GY/L
G/R
GY/L
Fuel injector No. 2

Fuel injector No. 2
Fuel injector No. 3
Fuel injector No. 3
Warm-up condition
Idle speed
0 - 9V
NOTE:
idle.
J
MBIB0881E
0 - 9V
K
[Engine is running]
Warm-up condition
L
MBIB0882E
[Engine is running]
40
41
42
43
G/R
GY/L
G/R
GY/L
Fuel injector No. 4

Fuel injector No. 4
Fuel injector No. 1
Fuel injector No. 1
Warm-up condition
Idle speed
0 - 9V
NOTE:
idle.
MBIB0881E
0 - 9V
[Engine is running]
Warm-up condition
MBIB0882E
EC-1287
http://vnx.su

EBS011F9

1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1288
http://vnx.su

2. CHECK ECM OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT

1.
2.
3.

EC
Terminal
Cylinder
Fuel injector
ECM
42, 43
3
No.1
Should exist
42,43
Should exist
Should not exist
21, 22
Should not exist
Should exist
21, 22
Should exist
Should not exist
23, 24
Should not exist
Should exist
23, 24
Should exist
5
40, 41
3
No.4
Should not exist

Should exist
40, 41
Should exist
Should not exist
D
PBIB1896E
No.3
Should not exist
No.2
Continuity
Should not exist

OK or NG
OK
>> GO TO 3.
NG

OK or NG
OK
>> GO TO 4.
NG

>> INSPECTION END
EBS011FA
FUEL INJECTOR
1.
EC-1289
http://vnx.su

2.

3.
PBIB0406E
EBS011FB
FUEL INJECTOR
EC-1290
http://vnx.su
DTC P2228, P2229 BARO SENSOR


Description
PFP:23731
A
EBS011FC
The barometric pressure sensor is built into ECM. The sensor

detects ambient barometric pressure and sends the voltage signal to
the microcomputer.
EC
D
MBIB0625E

DTC No.
EBS011FD
P2228
2228
Barometric pressure sensor circuit low input
An excessively low voltage from the barometric

pressure sensor (built-into ECM) is sent to ECM.
P2229
2229
Barometric pressure sensor circuit high input
An excessively high voltage from the barometric

Possible cause
ECM
G
EBS011FE
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF058Y
WITH GST
EC-1291
http://vnx.su

EBS011FF
1. INSPECTION START
1.
2.
3.
4.
5.
With CONSULT-II
Touch ERASE.
Is 1st trip DTC P2228 or P2229 displayed again?
With GST
3. Touch ERASE.
5. Is 1st trip DTC P2228 or P2229 displayed again?
Yes or No
Yes
>> GO TO 2.
No
>> INSPECTION END
2. REPLACE ECM
1.
2.
3.
Replace ECM.
>> INSPECTION END
EC-1292
http://vnx.su
GLOW CONTROL SYSTEM

GLOW CONTROL SYSTEM

Description
PFP:25230
A
EBS011FG
SYSTEM DESCRIPTION
Sensor
Input Signal to ECM
ECM Function
Engine speed
Glow control
EC
Actuator
Glow lamp
Glow relay
Glow plugs
When engine coolant temperature is more than approximately 80C (176F), the glow relay turns off.
When coolant temperature is lower than approximately 80C (176F):
Ignition switch ON
After ignition switch has turned to ON, the glow relay turns ON for a certain period of time in relation to
engine coolant temperature, allowing current to flow through glow plug.
Cranking
The glow relay turns ON, allowing current to flow through glow plug.
Starting
After engine has started, current continues to flow through glow plug (after-glow mode) for a certain period
in relation to engine coolant temperature.
The glow indicator lamp turns ON for a certain period of time in relation to engine coolant temperature at the
time glow relay is turned ON.
Glow Plug
The glow plug is provided with a ceramic heating element to obtain a

high-temperature resistance. It glows in response to a signal sent
from the ECM, allowing current to flow through the glow plug via the
glow relay.
K
SEF376Y
EC-1293
http://vnx.su
GLOW CONTROL SYSTEM

Wiring Diagram
EBS011FI
LHD MODELS
TBWA0577E
EC-1294
http://vnx.su
GLOW CONTROL SYSTEM

RHD MODELS
A
EC
TBWA0578E
EC-1295
http://vnx.su
GLOW CONTROL SYSTEM

EBS011FJ
1. INSPECTION START
Check fuel level, fuel supplying system, starter motor, etc.
OK or NG
OK
>> GO TO 2.
NG
>> Correct.
2. CHECK INSTALLATION
Check that glow plug nut and all glow plug connecting plate nuts are
installed properly.
OK or NG
OK
>> GO TO 3.
NG
>> Install properly.
SEF392YA
3. CHECK GLOW INDICATOR LAMP OPERATION

1.
2.
3.
4.
5.
With CONSULT-II
Select COOLAN TEMP/S in DATA MONITOR mode with
CONSULT-II.
Confirm that COOLAN TEMP/S indicates below 80C (176F).
If it indicates above 80C (176F), cool down engine.
ON.
Make sure that glow indicator lamp is turned ON for 1.5 seconds
or more after turning ignition switch ON, and then glow indicator
lamp turned OFF.
SEF013Y
Without CONSULT-II
2. Confirm that the voltage between ECM terminal 51 (engine coolant temperature sensor signal) and ground is above 1.53V.
If it is below 1.53V, cool down engine.
ON.
4. Make sure that glow indicator lamp is turned ON for 1.5 seconds
lamp turned OFF.
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 5.
EC-1296
http://vnx.su
SEF006P
GLOW CONTROL SYSTEM

4. CHECK GLOW CONTROL SYSTEM OVERALL FUNCTION

1.
2.
3.
4.
5.
With CONSULT-ll
CONSULT-II.
Confirm that COOLAN TEMP/S indicates approximately 25C
(77F). If NG, cool down engine.
Set voltmeter probe between glow plug and engine body.
EC
SEF013Y
6.
Check the voltage between glow plug and engine body under
the following conditions.
Conditions
Voltage
For 20 seconds after turning ignition switch ON
Battery voltage
More than 20 seconds after turning ignition

switch ON
Approx. 0V
H
PBIB0425E
1.
2.
3.
4.
5.
Without CONSULT-II
Confirm that the voltage between ECM terminal 51 (engine coolant temperature sensor signal) and ground is above 3.62V.
If it is below 3.62V, cool down engine.
L
Conditions
Voltage
SEF006P
Battery voltage

switch ON
Approx. 0V
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 7.
5. CHECK DTC
Check that DTC U1000 is not displayed.
Yes or No
Yes
>> Perform trouble diagnoses for DTC U1000, refer to EC-1050, "DTC U1000 CAN COMMUNICATION LINE" .
No
>> GO TO 6.
EC-1297
http://vnx.su
GLOW CONTROL SYSTEM

6. CHECK COMBINATON METER OPERATION

Does combination meter operate normally?
Yes or No
Yes
>> GO TO 14.
No
>> Check combination meter circuit. Refer to DI-4, "COMBINATION METERS" .

1.
2.

MBIB0078E
3.
Check voltage between glow relay terminals 1, 3 and ground

OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.
PBIB1413E

60A fusible link
Harness for open or short between glow relay and battery

9. CHECK GLOW RELAY OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.


OK or NG
OK
>> GO TO 11.
NG
>> GO TO 10.
EC-1298
http://vnx.su
GLOW CONTROL SYSTEM

Harness for open or short between glow relay and ECM

EC
11. CHECK HARNESS CONTINUITY BETWEEN GLOW RELAY AND GLOW PLUG FOR OPEN AND
SHORT
1.
2.
Disconnect glow plug harness connector.

Check harness continuity between glow relay terminal 5 and glow plug harness connector.

OK or NG
OK
>> GO TO 12.
NG
12. CHECK GLOW RELAY

OK or NG
OK
>> GO TO 13.
NG
13. CHECK GLOW PLUG

J

OK or NG
OK
>> GO TO 14.
NG
>> Replace glow plug.

L

>> INSPECTION END
EC-1299
http://vnx.su
GLOW CONTROL SYSTEM

EBS011FK
GLOW RELAY
Conditions
Continuity
Yes
No current supply
No
PBIB0428E
GLOW PLUG
1.
2.
Remove glow plug connecting plate.

Check glow plug resistance.
Resistance: Approximately 0.8 [at 25C (77F)]
NOTE:
Do not bump glow plug heating element. If it is bumped,
replace glow plug with a new one.
If glow plug is dropped from a height of 10 cm (3.94 in) or
higher, replace with a new one.
If glow plug installation hole is contaminated with carbon, remove it with a reamer or suitable tool.
Hand-tighten glow plug by turning it two or three times,
then tighten using a tool to specified torque.
PBIB0429E
: 20.1 N-m (2.1 kg-m, 15 ft-lb)
EBS011FL
GLOW PLUG
Refer to EM-159, "GLOW PLUG" .
EC-1300
http://vnx.su
BRAKE SWITCH
BRAKE SWITCH
Description
PFP:25230
A
EBS011FZ
STOP LAMP SWITCH

The stop lamp switch (1) is installed to brake pedal bracket. The
switch senses brake pedal position and sends an ON-OFF signal to
the ECM. The ECM uses the signal to control the fuel injection control system.
EC
PBIB2883E
ASCD BRAKE SWITCH (MODELS WITH ASCD)

When depress on the brake pedal, ASCD brake switch is turned OFF and stop lamp switch is turned ON. ECM
detects the state of the brake pedal by this input of two kinds (ON/OFF signal)
EBS011WF

MONITOR ITEM
BRAKE SW
BRAKE SW2
CONDITION
Ignition switch: ON
Ignition switch: ON
SPECIFICATION
OFF

depressed
ON

Fully released
OFF

ON
EC-1301
http://vnx.su
BRAKE SWITCH
Wiring Diagram
EBS011G1
MODELS WITHOUT ASCD
TBWA0580E
EC-1302
http://vnx.su
BRAKE SWITCH
MODELS WITH ASCD
A
EC
TBWB0685E
EC-1303
http://vnx.su
BRAKE SWITCH
CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
100
Stop lamp switch
101
GY/L
ASCD brake switch
DATA (DC Voltage)
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
BATTERY VOLTAGE
(11 - 14V)

depressed
Approximately 0V
EBS011G2

With CONSULT-II
1.
2.
CONDITION
INDICATION
ON
OFF
PBIB0472E
Without CONSULT-II
Condition
Voltage
battery voltage
Approximately 0V
OK or NG
OK (Models with ASCD)>>GO TO 2.
OK (Models without ASCD)>>INSPECTION END
NG
>> GO TO 3.
EC-1304
http://vnx.su
MBIB1097E
BRAKE SWITCH
With CONSULT-II
EC
CONDITION
INDICATION
ON
OFF
SEC013D
1.
2.
Without CONSULT-II
G
Condition
Voltage
Approximately 0V
Battery voltage
I
PBIB1677E
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 7.
EC-1305
http://vnx.su
BRAKE SWITCH

1.
2.

PBIB2878E
3.

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
PBIB0117E

15A fuse
1.
2.


OK or NG
OK
>> GO TO 6.
NG

OK or NG
OK
>> GO TO 14.
NG
EC-1306
http://vnx.su
BRAKE SWITCH

1.
2.
3.

EC
D
PBIB2878E
4.

F

OK or NG
OK
>> GO TO 12.
NG
>> GO TO 8.
H
PBIB0857E
1.
2.

PBIB2878E
3.
4.

OK or NG
OK
>> GO TO 10.
NG
>> GO TO 9.
PBIB0799E
EC-1307
http://vnx.su
BRAKE SWITCH

10A fuse
1.
2.


OK or NG
OK
>> GO TO 11.
NG

OK or NG
OK
>> GO TO 14.
NG
1.
2.
3.


OK or NG
OK
>> GO TO 13.
NG

OK or NG
OK
>> GO TO 14.
NG

>> INSPECTION END
EBS011G3
ASCD BRAKE SWITCH

1.
EC-1308
http://vnx.su
BRAKE SWITCH
2.
3.

Condition

Continuity
EC
Should exist.
Should not exist.

SEC023D
ASCD CLUTCH SWITCH

1.
2.
3.

Condition

Continuity
Should exist.
Should not exist.

H
SEC024D
STOP LAMP SWITCH

1.
2.

Check continuity between stop lamp switch terminals 1 and 2
Conditions

When Brake pedal is slightly depressed.
Continuity
Should not exist.
Should exist.

PBIB0118E
EC-1309
http://vnx.su
PNP SWITCH
PNP SWITCH
Description
PFP:32006
EBS011G4
When the gear position is in Neutral, park/neutral position is ON. ECM detects the position because the continuity of the line (the ON signal) exists.
EBS011G5

MONITOR ITEM
P/N POSI SW
CONDITION
Ignition switch: ON
SPECIFICATION
ON
Except above
OFF
EC-1310
http://vnx.su
PNP SWITCH
Wiring Diagram
EBS011G7
EC
TBWA0581E
EC-1311
http://vnx.su
PNP SWITCH
CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
110
G/OR
switch
DATA
(DC Voltage)
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
EBS011G8

With CONSULT-II
Select P/N POSI SW in DATA MONITOR mode with CONSULT-II.
3. Check P/N POSI SW signal under the following conditions.
1.
2.
Shift lever position
P/N POSI SW
Neutral position
ON
Except the above position
OFF
SEF212Y
Without CONSULT-II
Neutral position
Voltage
Approximately 0V
Battery voltage
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
PBIB1947E
EC-1312
http://vnx.su
PNP SWITCH

1.
2.
3.

Disconnect park/neutral position (PNP) switch harness connector.
Check harness continuity between PNP switch terminal 2 and
ground.
EC

OK or NG
OK
>> GO TO 3.
NG
1.
2.

Check harness continuity between ECM terminal 110 and PNP switch terminal 1.
D
PBIB1903E

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

5. CHECK PARK/NEUTRAL POSITION SWITCH

Refer to MT-13, "POSITION SWITCH" .
OK or NG
OK
>> GO TO 6.
NG
>> Replace park/neutral position switch.

>> INSPECTION END
EC-1313
http://vnx.su
PSP SWITCH
PSP SWITCH
PFP:49761
EBS011G9
The power steering pressure switch is attached to the power steering high-pressure tube and detects a power steering load.
When a power steering load is detected, it signals the ECM. The
ECM adjusts the fuel injector pulse width to increase the idle speed
and adjust for the increased load.
PBIB1904E
EBS011GA

MONITOR ITEM
PW/ST SIGNAL
CONDITION

engine
SPECIFICATION

(Forward direction)
OFF
ON
EC-1314
http://vnx.su
PSP SWITCH
Wiring Diagram
EBS011GC
EC
TBWA0583E
EC-1315
http://vnx.su
PSP SWITCH
CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
[Engine is running]
111
P/B

switch
[Engine is running]
DATA
(DC Voltage)
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
EBS011GD

1.
2.
With CONSULT-II
Start engine.
Check PW/ST SIGNAL in DATA MONITOR mode with CONSULT-II under the following conditions.
Conditions
PW/ST SIGNAL
OFF
ON
PBIB0434E
Without CONSULT-II
1. Start engine.
Conditions
Voltage
Battery voltage
Approximately 0V
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
PBIB1948E
EC-1316
http://vnx.su
PSP SWITCH
2. CHECK POWER STEERING PRESSURE SWITCH GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Disconnect power steering pressure switch harness connector.
Check harness continuity between power steering pressure
switch terminal 2 and ground. Refer to Wiring Diagram.
EC

OK or NG
OK
>> GO TO 3.
NG
D
PBIB1904E
3. CHECK POWER STEERING PRESSURE SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.

Check harness continuity between ECM terminal 111 and power steering pressure switch terminal 1.

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
Harness for open and short between power steering pressure switch and ECM
5. CHECK POWER STEERING PRESSURE SWITCH

L

OK or NG
OK
>> GO TO 6.
NG
>> Replace power steering pressure switch.

>> INSPECTION END
EBS011GE
POWER STEERING PRESSURE SWITCH

1.
Disconnect power steering pressure switch harness connector and then start engine.
EC-1317
http://vnx.su
PSP SWITCH
2.
Check continuity between power steering pressure switch terminal 1 and 2 under the following conditions.
Conditions
Continuity
Steering wheel is being fully turned.
Yes
No
MBIB0624E
EBS0128B
EC-1318
http://vnx.su
FUEL TRANSPORT PUMP

FUEL TRANSPORT PUMP

Description
PFP:17020
A
EBS011PD
SYSTEM DESCRIPTION
Sensor
Input Signal to ECM
Engine speed
Fuel level switch
Fuel level
ECM function
Actuator
EC
C
Condition
Engine is running.
Operates
Engine is stopped.
Stops
The remainder of the fuel in the fuel tank is less than specified value.
Stops
Fuel supply entrance of fuel tank is at the left side of fuel tank. The duel at the right side of the fuel tank is sent
to the left side of the fuel tank by fuel transport pump.
When the ECM receives engine revolution signal from the crankshaft position sensor, it knows that the engine
is rotating, and causes the pump operate. If the remainder of the fuel at the right side of the fuel tank
decreases, fuel level switch sends a signal to the ECM. When the ECM receives a signal from the fuel level
switch, the ECM stops the operation of the pump.
The ECM does not directly drive the fuel transport pump. It controls the ON/OFF fuel transport pump relay,
which in turn controls the fuel transport pump.
J
PBIB1887E
Fuel Transport Pump
Fuel transport pump sends the fuel from right side of fuel tank to left
side.
PBIB0469E
Fuel Level Switch

Fuel level switch is assembled in sub fuel level sensor unit. When the remainder of the fuel at the right side of
the fuel tank is less than specified value, the switch is turned OFF.
EC-1319
http://vnx.su
FUEL TRANSPORT PUMP

Wiring Diagram
EBS011PF
LHD MODELS
TBWA0590E
EC-1320
http://vnx.su
FUEL TRANSPORT PUMP

RHD MODELS
A
EC
TBWA0591E
EC-1321
http://vnx.su
FUEL TRANSPORT PUMP

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
14
W/PU
Fuel level switch
[Engine is running]
39
B/OR
DATA
(DC Voltage)
CONDITION
[Engine is running]
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
EBS011PG

1.
2.
3.
4.
5.

Disconnect sub fuel level sensor unit harness connector.
Remove sub fuel level sensor unit.
Reconnect sub fuel level sensor unit harness connector.
PBIB1944E
6.
Soak fuel level switch in fuel and check operating sound of fuel
transport pump.
Operating sound should exist.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
PBIB2015E
EC-1322
http://vnx.su
FUEL TRANSPORT PUMP

2. CHECK FUEL TRASPORT PUMP FUNCTION

1.
2.
3.
4.
5.

Install suitable harness between ECM harness connector terminal 39 and ground.
Listen the fuel transport pump operating sound.
EC

D
OK or NG
OK
>> GO TO 11.
NG
>> GO TO 3.
PBIB2016E
3. CHECK FUEL TRASPORT PUMP RELAY POWER SUPPLY CIRCUIT

1.
2.
3.
4.

Disconnect fuel transport pump relay.
J
PBIB1933E
5.
Check voltage between fuel transport pump relay terminals 1, 5


L
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
PBIB0471E
4. DETECT MALFUNCTIONING PERT

Fuse block (J/B) connectors M1
15A fuse
Harness for open or short between fuse and fuel transport pump relay
EC-1323
http://vnx.su
FUEL TRANSPORT PUMP

5. CHECK FUEL TRANSPORT PUMP POWER SUPPLY AND GROUND CIRCUIT FOR OPEN AND
SHORT
1.
2.
3.

Disconnect fuel transport pump harness connector.
Check harness continuity between fuel transport pump relay terminal 3 and fuel transport pump terminal 1 and between fuel
transport pump terminal 2 and ground. Refer to Wiring Diagram.

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.
PBIB1931E

Harness connector B22, B128
Harness for open or short between fuel transport pump relay and fuel transport pump
Harness for open or short between fuel transport pump and ground
7. CHECK FUEL TRANSPORT PUMP RELAY OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.

Check harness continuity between ECM terminal 39 and fuel transport pump relay terminal 2. Refer to
Wiring Diagram.

OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.
8. DETECT MALFUNSTIONING PART

Harness connector M17, B1 (LHD models)
Harness connector M18, B2 (RHD models)
Harness connector M63, F30
Harness for open or short between ECM and fuel transport pump relay
9. CHECK FUEL TRANSPORT PUMP RELAY

OK or NG
OK
>> GO TO 10.
NG
>> Replace fuel transport pump relay.
EC-1324
http://vnx.su
FUEL TRANSPORT PUMP

10. CHECK TRANSPORT PUMP

OK or NG
OK
>> GO TO 14.
NG
>> Replace fuel transport pump.
EC
11. CHECK FUEL LEVEL SWITCH POWER SUPPLY AND GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.
4.

Check harness continuity between ECM terminal 14 and sub
fuel level sensor unit terminal 2, between sub fuel level sensor
unit terminal 4 and ground. Refer to Wiring Diagram.

OK or NG
OK
>> GO TO 13.
NG
>> GO TO 12.
G
PBIB1944E
Harness connector F30, M63
Harness connectors M18, B2 (RHD models)
Harness for open or short between ECM and sub fuel level sensor unit
Harness for open or short between sub fuel level sensor unit and ground.
13. CHECK FUEL LEVEL SWITCH

L

OK or NG
OK
>> GO TO 14.
NG
>> Replace sub fuel level sensor unit.

Refer to EC-1040, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT"
>> INSPECTION END
EC-1325
http://vnx.su
FUEL TRANSPORT PUMP

EBS011PH
FUEL TRANSPORT PUMP RELAY

Check continuity between terminals 3 and 5 under the following conitions.
Conditions
Continuity
Yes
No current supply
No
PBIB0098E
FUEL TRANSPORT PUMP

1.
2.
3.
Remove fuel transport pump.

Apply battery voltage between fuel transport pump terminal 1 and 2.
Check operating sound of fuel transport pump under the following conditions.
Conditions
Operating sound
12V direct current supply between fuel transport pump

terminals 1 and 2
Yes
No current supply
No
4.
Listen fuel transport pump operating sound.
FUEL LEVEL SWITCH

1.
2.
Check continuity between sub fuel level sensor unit terminal 2
Conditions
Continuity
Fuel level switch is soaked in fuel.
Yes
Fuel level switch is not soaked in fuel.
No
PBIB2015E
EBS011PI
FUEL TRANSPORT PUMP

Refer to FL-23, "FUEL TANK" .
SUB FUEL LEVEL SENSOR UNIT

Refer to FL-19, "FUEL LEVEL SENSOR UNIT" .
EC-1326
http://vnx.su


System Description
PFP:18930
A
EBS01F8C

Sensor
Input signal to ECM
ASCD brake switch
Stop lamp switch
ASCD clutch switch
Combination meter
Vehicle speed
ECM function
Actuator
EC
BASIC ASCD SYSTEM

h (25 MPH) and 185 km/h (115 MPH).
ECM controls fuel injection value to regulate engine speed.
SET OPERATION
MPH), press SET switch. (Then SET indicator in combination meter illuminates.)
ACCEL OPERATION
If the RESUME/ACCELERATE switch is depressed during cruise control driving, increase the vehicle speed
until the switch is released or vehicle speed reaches maximum speed controlled by the system.
CANCEL OPERATION
CANCEL switch is depressed
More than 2 switches at ASCD steering switch are depressed at the same time (Set speed will be
cleared.).
Vehicle speed increased to 13 km/h higher than the set speed
Vehicle speed decreased to 13 km/h lower than the set speed
ESP system is operated

COAST OPERATION
When the SET/COAST switch is depressed during cruise control driving, decrease vehicle set speed until the
RESUME OPERATION
When the RESUME/ACCELERATE switch is depressed after cancel operation other than depressing MAIN
switch is performed, vehicle speed will return to last set speed. To resume vehicle set speed, vehicle condition
must meet following conditions.
Brake pedal is released
Clutch pedal is released
EC-1327
http://vnx.su

EBS01F8D

Refer to EC-1208 .
ASCD BRAKE SWITCH

ASCD CLUTCH SWITCH

STOP LAMP SWITCH

ASCD INDICATOR
Refer to EC-1329 .
EC-1328
http://vnx.su
ASCD INDICATOR
ASCD INDICATOR
PFP:24814
A
EBS01F8E
ASCD indicator lamp illuminates to indicate ASCD operation status. The Lamp has two indicators, CRUISE
and SET, and is integrated in combination meter.
EC
SET indicator illuminates when the following conditions are met.
C
ASCD setting.
D
E
EC-1329
http://vnx.su
ASCD INDICATOR
Wiring DiagramLHD Models
EBS01F8F
TBWB0478E
EC-1330
http://vnx.su
ASCD INDICATOR
Wiring DiagramRHD Models
EBS01F8G
EC
TBWB0479E
EC-1331
http://vnx.su
ASCD INDICATOR
EBS01F8H

ASCD INDICATOR
CRUISE LAMP
SET LAMP
CONDITION
SPECIFICATION
MAIN switch: Pressed at the

first timeat the 2nd time
ONOFF
MAIN switch: ON
COAST/SET switch pressed
ON
When vehicle speed is

between 40 km/h (25 MPH)
and 185 km/h (115 MPH)
COAST/SET switch released
OFF
Ignition switch: ON
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
2. CHECK DTC
OK or NG
OK
>> Perform trouble diagnoses for DTC U1000. Refer to EC-1050, "DTC U1000 CAN COMMUNICATION LINE" .
NG
>> GO TO 3.
3. CHECK COMBINATION METER OPERATION

Yes or No
Yes
>> GO TO 4.
No

>> INSPECTION END
EC-1332
http://vnx.su
START SIGNAL
START SIGNAL
Wiring Diagram
PFP:48750
A
EBS011GG
EC
TBWA0582E
EC-1333
http://vnx.su
START SIGNAL
EBS011GH
1. CHECK START SIGNAL OVERALL FUNCTION

1.
2.
With CONSULT-II
Check START SIGNAL in DATA MONITOR mode with CONSULT-II under the following conditions.
Condition
START SIGNAL
Ignition switch ON
OFF
Ignition switch START
ON
PBIB0433E
Without CONSULT-II
Condition
Ignition switch ON
Voltage
Approximately 0V
Battery voltage
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
PBIB1949E
2. CHECK START SIGNAL INPUT SIGNAL CIRCUIT

1.
2.
3.

Disconnect ECM harness connector and ignition switch harness connector.
Check harness continuity between ECM terminal 99 and ignition switch terminal 6.

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

10A fuse
Fuse block (J/B) connectors M1, E102
Harness for open or short between ECM and ignition switch

EC-1334
http://vnx.su
START SIGNAL

EC
>> INSPECTION END
EC-1335
http://vnx.su


Wiring Diagram
PFP:24814
EBS011GI
LHD MODELS
TBWA0585E
EC-1336
http://vnx.su

RHD MODELS
A
EC
TBWA0586E
EC-1337
http://vnx.su


General Specifications
Engine
PFP:00100
EBS011GJ
YD22DDTi
725 25 rpm
Idle speed
Maximum engine speed
4,900 rpm
EBS011GK
Supply voltage
Approx. 0.4V
Idle (Engine is warmed up to normal operating temperature.)
1.5 - 2.0V
2.2 - 2.7V

Temperature C (F)
EBS011GL
Resistance k
20 (68)
2.1 - 2.9
50 (122)
0.68 - 1.00
90 (194)
0.236 - 0.260
Fuel Rail Pressure Sensor
EBS011GM
Supply voltage
Approximately 5V
1.7 - 2.0V
2.0 - 2.3V
Glow Plug
EBS011GN
Approximately 0.8
EBS011GO
13 - 17
Crankshaft Position Sensor
EBS011GP
Camshaft Position Sensor
EBS011GQ
EC-1338
http://vnx.su
INDEX FOR DTC

[YD (WITHOUT EURO-OBD)]
INDEX FOR DTC

Alphabetical Index
PFP:00024
A
EBS011WP
EC
NOTE:
C
Items
DTC
MI lighting
up
Reference page
0122
EC-1441
P0123
0123
EC-1441
APP SEN 2/CIRCUIT
P0222
0222
EC-1478
APP SEN 2/CIRCUIT
P0223
0223
EC-1478
APP SENSOR
P2135
2135
EC-1607
BARO SEN/CIRC
P2228
2228
EC-1624
BARO SEN/CIRC
P2229
2229
EC-1624
BATTERY VOLTAGE
P0563
0563
EC-1538
BRAKE SW/CIRCUIT
P0504
0504
EC-1528
CAN COMM CIRCUIT
U1000
1000*2
EC-1411
CKP SEN/CIRCUIT
P0335
0335
EC-1497
CONSULT-II
ECM*
APP SEN 1/CIRCUIT
P0122
APP SEN 1/CIRCUIT
CKP SENSOR
P0336
0336
EC-1503
CMP SEN/CIRCUIT
P0340
0340
EC-1509
CMP SENSOR
P0341
0341
EC-1515
CMP/CKP RELATION
P0016
0016
EC-1414
CYL1 INJECTOR
P0201
0201
EC-1459
CYL2 INJECTOR
P0202
0202
EC-1459
CYL3 INJECTOR
P0203
0203
EC-1459
CYL4 INJECTOR
P0204
0204
EC-1459
ECM
P0605
0605
EC-1549
ECM
P0606
0606
EC-1551
ECM RELAY
P0686
0686
EC-1567
ECT SEN/CIRC
P0117
0117
EC-1435
ECT SEN/CIRC
P0118
0118
EC-1435
ENG OVER TEMP
P0217
0217
EC-1465
FRP RELIEF VALVE
P1272
1272
EC-1585
FRP SEN/CIRC
P0192
0192
EC-1452
FRP SEN/CIRC
P0193
0193
EC-1452
FUEL LEAK
P0093
0093
EC-1420
FUEL PUMP
P0089
0089
EC-1418
FUEL PUMP
P1273
1273
EC-1592
FUEL PUMP
P1274
1274
EC-1597
FUEL PUMP
P1275
1275
EC-1602
FUEL PUMP/CIRC
P0628
0628
EC-1553
FUEL PUMP/CIRC
P0629
0629
EC-1553
FUEL TEMP SEN/CIRC
P0182
0182
EC-1448
EC-1339
http://vnx.su
INDEX FOR DTC

Items
DTC
CONSULT-II
ECM*
MI lighting
up
FUEL TEMP SEN/CIRC
P0183
0183
EC-1448
HIGH FUEL PRESS
P0088
0088
EC-1416
IAT SEN/CIRCUIT
P0112
0112
EC-1429
IAT SEN/CIRCUIT
P0113
0113
EC-1429
INJ ADJ RES/CIRC1
P1260
1260
EC-1573
INJ ADJ RES/CIRC1
P1261
1261
EC-1573
INJ ADJ RES/CIRC2
P1262
1262
EC-1573
INJ ADJ RES/CIRC2
P1263
1263
EC-1573
INJ ADJ RES/CIRC3
P1264
1264
EC-1573
INJ ADJ RES/CIRC3
P1265
1265
EC-1573
INJ ADJ RES/CIRC4
P1266
1266
EC-1573
INJ ADJ RES/CIRC4
P1267
1267
EC-1573
INJ PWR/CIRC
P2146
2146
EC-1614
INJ PWR/CIRC
P2149
2149
EC-1614
INJECTOR
P0200
0200
EC-1457
INJECTOR/CIRC
P2147
2147
EC-1618
INJECTOR/CIRC
P2148
2148
EC-1618
INJECTOR 1
P1268
1268
EC-1579
INJECTOR 2
P1269
1269
EC-1579
INJECTOR 3
P1270
1270
EC-1579
INJECTOR 4
P1271
1271
EC-1579
MAF SEN/CIRCUIT
P0102
0102
EC-1424
MAF SEN/CIRCUIT
P0103
0103
EC-1424
P1610 - P1617
1610 - 1617
EC-1360
NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.
P0000
0000
SENSOR PWR/CIRC1
P0642
0642
EC-1558
SENSOR PWR/CIRC1
P0643
0643
EC-1558
SENSOR PWR/CIRC2
P0652
0652
EC-1562
SENSOR PWR/CIRC2
P0653
0653
EC-1562
STRG SW/CIRC
P0580
0580
EC-1540
STRG SW/CIRC
P0581
0581
EC-1540
TC BOOST SEN/CIRC
P0237
0237
EC-1491
TC BOOST SEN/CIRC
P0238
0238
EC-1491
TC SYSTEM
P0234
0234
EC-1485
TCS/CIRC
P1212
1212
EC-1572
TCS C/U FUNCTN
P1211
1211
EC-1571
VEHICLE SPEED
P0501
0501
EC-1522
VEHICLE SPEED
P0502
0502
EC-1524
VEHICLE SPEED
P0503
0503
EC-1526
NATS MALFUNCTION

EC-1340
http://vnx.su
Reference page
INDEX FOR DTC

DTC No. Index
EBS011WQ
A
NOTE:
If DTC U1000 is displayed with other DTC, first perform the trouble diagnosis for DTC U1000. Refer to EC
DTC
CONSULT-II
ECM*1
U1000
1000*2
Items
C
MI lighting up
Reference page
CAN COMM CIRCUIT
EC-1411
P0000
0000
NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.
P0016
0016
CMP/CKP RELATION
EC-1414
P0088
0088
HIGH FUEL PRESS
EC-1416
P0089
0089
FUEL PUMP
EC-1418
P0093
0093
FUEL LEAK
EC-1420
P0102
0102
MAF SEN/CIRCUIT
EC-1424
P0103
0103
MAF SEN/CIRCUIT
EC-1424
P0112
0112
IAT SEN/CIRCUIT
EC-1429
P0113
0113
IAT SEN/CIRCUIT
EC-1429
P0117
0117
ECT SEN/CIRC
EC-1435
P0118
0118
ECT SEN/CIRC
EC-1435
P0122
0122
APP SEN 1/CIRCUIT
EC-1441
P0123
0123
APP SEN 1/CIRCUIT
EC-1441
P0182
0182
FUEL TEMP SEN/CIRC
EC-1448
P0183
0183
FUEL TEMP SEN/CIRC
EC-1448
P0192
0192
FRP SEN/CIRC
EC-1452
P0193
0193
FRP SEN/CIRC
EC-1452
P0200
0200
INJECTOR
EC-1457
P0201
0201
CYL1 INJECTOR
EC-1459
P0202
0202
CYL2 INJECTOR
EC-1459
P0203
0203
CYL3 INJECTOR
EC-1459
P0204
0204
CYL4 INJECTOR
EC-1459
P0217
0217
ENG OVER TEMP
EC-1465
P0222
0222
APP SEN 2/CIRCUIT
EC-1478
P0223
0223
APP SEN 2/CIRCUIT
EC-1478
P0234
0234
TC SYSTEM
EC-1485
P0237
0237
TC BOOST SEN/CIRC
EC-1491
P0238
0238
TC BOOST SEN/CIRC
EC-1491
P0335
0335
CKP SEN/CIRCUIT
EC-1497
P0336
0336
CKP SENSOR
EC-1503
P0340
0340
CMP SEN/CIRCUIT
EC-1509
P0341
0341
CMP SENSOR
EC-1515
P0501
0501
VEHICLE SPEED
EC-1522
P0502
0502
VEHICLE SPEED
EC-1524
P0503
0503
VEHICLE SPEED
EC-1526
EC-1341
http://vnx.su
INDEX FOR DTC

DTC
Items
MI lighting up
Reference page
BRAKE SW/CIRCUIT
EC-1528
CONSULT-II
ECM*
P0504
0504
P0563
0563
BATTERY VOLTAGE
EC-1538
P0580
0580
STRG SW/CIRC
EC-1540
P0581
0581
STRG SW/CIRC
EC-1540
P0605
0605
ECM
EC-1549
P0606
0606
ECM
EC-1551
P0628
0628
FUEL PUMP/CIRC
EC-1553
P0629
0629
FUEL PUMP/CIRC
EC-1553
P0642
0642
SENSOR PWR/CIRC1
EC-1558
P0643
0643
SENSOR PWR/CIRC1
EC-1558
P0652
0652
SENSOR PWR/CIRC2
EC-1562
P0653
0653
SENSOR PWR/CIRC2
EC-1562
P0686
0686
ECM RELAY
EC-1567
P1211
1211
TCS C/U FUNCTN
EC-1571
P1212
1212
TCS/CIRC
EC-1572
P1260
1260
INJ ADJ RES/CIRC1
EC-1573
P1261
1261
INJ ADJ RES/CIRC1
EC-1573
P1262
1262
INJ ADJ RES/CIRC2
EC-1573
P1263
1263
INJ ADJ RES/CIRC2
EC-1573
P1264
1264
INJ ADJ RES/CIRC3
EC-1573
P1265
1265
INJ ADJ RES/CIRC3
EC-1573
P1266
1266
INJ ADJ RES/CIRC4
EC-1573
P1267
1267
INJ ADJ RES/CIRC4
EC-1573
P1268
1268
INJECTOR 1
EC-1579
P1269
1269
INJECTOR 2
EC-1579
P1270
1270
INJECTOR 3
EC-1579
P1271
1271
INJECTOR 4
EC-1579
P1272
1272
FRP RELIEF VALVE
EC-1585
P1273
1273
FUEL PUMP
EC-1592
P1274
1274
FUEL PUMP
EC-1597
P1275
1275
FUEL PUMP
EC-1602
P1610 - P1617
1610 - 1617
NATS MALFUNTION
EC-1360
P2135
2135
APP SENSOR
EC-1607
P2146
2146
INJ PWR/CIRC
EC-1614
P2147
2147
INJECTOR/CIRC
EC-1618
P2148
2148
INJECTOR/CIRC
EC-1618
P2149
2149
INJ PWR/CIRC
EC-1614
P2228
2228
BARO SEN/CIRC
EC-1624
P2229
2229
BARO SEN/CIRC
EC-1624

EC-1342
http://vnx.su
PRECAUTIONS
PRECAUTIONS
PFP:00001
BELT PRE-TENSIONER
EBS011WR
C
WARNING:
E
harness connectors.
F
EBS011WS
CAUTION:
may cause the MI to light up due to the malfunction of the fuel system, etc.
Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM
before returning the vehicle to the customer.
Precautions
EBS011WT

running.
switch is turned off.
SEF289H
EC-1343
http://vnx.su
PRECAUTIONS
MBIB0625E

figure.
PBIB1512E

break).
damage to IC's.
Keep engine control system harness at least 10cm (4 in)
operation of IC's, etc.
Before replacing ECM, perform ECM Terminals and Reference Value inspection and make sure ECM functions properly. Refer to EC-1385, "ECM Terminals And Reference
Value" .
Do not shock or jar the camshaft position sensor, crankshaft position sensor.
EC-1344
http://vnx.su
SEF291H
MEF040D
PRECAUTIONS

EC
C
SAT652J

the ground.
Do not disassemble fuel pump.
If NG, take proper action.
SEF348N
Do not depress accelerator pedal when staring.

Immediately after staring, do not rev up engine unnecessarily.
SEF709Y

control units.
Adjust the antenna and feeder line so that the standingwave
radio can be kept smaller.
EC-1345
http://vnx.su
SEF708Y
PRECAUTIONS

When you read Wiring diagrams, refer to the following:
GI-14, "How to Read Wiring Diagrams".

GI-10, "HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES".
GI-23, "How to Perform Efficient Diagnosis for an Electrical Incident".
EC-1346
http://vnx.su
EBS011WU
PREPARATION
PREPARATION
PFP:00002
A
EBS011WV
Tool number
Tool name
Description
EG17650301
Radiator cap tester
adapter
EC

a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
S-NT564
KV109E0010
Break-out box
F
S-NT825
KV109E0080
Y-cable adapter
H
S-NT826
EBS011WW
Tool name
Description
Socket wrench

temperature sensor
S-NT705
EC-1347
http://vnx.su


System Diagram
PFP:23710
EBS011WX
PBIB2884E
EC-1348
http://vnx.su

Vacuum Hose Drawing
EBS011WY
EC
PBIB2019E
Refer to EC-1348, "System Diagram" for Vacuum Control System.
EC-1349
http://vnx.su

System Chart
EBS011WZ
Input (Sensor)
ECM Function
Output (Actuator)
Fuel injection timing control
Fuel cut control
Glow control system
Glow relay and glow indicator lamp*2
Malfunction indicator (MI)*2
EGR volume control
Cooling fan control
Cooling fan relay

Vehicle speed sensor*1

valve
ESP/TCS/ABS control unit*1
Ignition switch
Stop lamp switch
Air conditioner switch*1
Battery voltage
Fuel level switch
*1: The input signal is sent to the ECM through CAN communication line.
*2: The output signal is sent from the ECM through CAN communication line.
Fuel Injection Control System
EBS011X0
SYSTEM DESCRIPTION
Three types of fuel injection control are provided to accommodate engine operating conditions; normal control,
idle control and start control. The ECM determines the appropriate fuel injection control. Under each control,
the amount of fuel injected is adjusted to improve engine performance.
Pulse signals are sent to fuel injectors according to the input signals to adjust the amount of fuel injected to
preset value.
START CONTROL
Sensor
Input Signal to ECM
Engine speed
Piston position
Ignition switch
Start signal
Fuel rail pressure
ECM Function
Fuel injection
control (start
control)
Actuator
Fuel injector
Fuel pump
When the ECM receives a start signal from the ignition switch, the
ECM adapts the fuel injection system for the start control. The
amount of fuel injected at engine starting is a preset program value
in the ECM. The program is determined by the engine speed, engine
coolant temperature and fuel rail pressure.
For better startability under cool engine conditions, the lower the
coolant temperature becomes, the greater the amount of fuel
injected. The ECM ends the start control when the engine speed
reaches the specific value, and shifts the control to the normal or idle
control.
SEF648S
EC-1350
http://vnx.su

IDLE CONTROL
Sensor
A
Input Signal to ECM
Engine speed
Battery
Battery voltage
Fuel rail pressure
Vehicle speed
Air conditioner signal
ECM Function
Actuator
EC
Fuel injection
control (Idle
control)
Fuel injector
Fuel pump
When the ECM determines that the engine speed is at idle, the fuel injection system is adapted for the idle
control. The ECM regulates the amount of fuel injected corresponding to changes in load applied to the engine
to keep engine speed constant. The ECM also provides the system with a fast idle control in response to the
engine coolant temperature signal.
NORMAL CONTROL
Sensor
Input Signal to ECM
Engine speed
Accelerator position
Fuel rail pressure
ECM Function
Fuel injection
control (Normal control)
Actuator
Fuel injector
Fuel pump
The amount of fuel injected under normal driving conditions is determined according to sensor signals. The crankshaft position sensor
detects engine speed, the accelerator pedal position sensor detects
accelerator pedal position and fuel rail pressure sensor detects fuel
rail pressure. These sensors send signals to the ECM.
The fuel injection data, predetermined by correlation between various engine speeds, accelerator pedal positions and fuel rail pressure are stored in the ECM memory, forming a map. The ECM
determines the optimal amount of fuel to be injected using the sensor signals in comparison with the map.
SEF649S
MAXIMUM AMOUNT CONTROL

Sensor
Input Signal to ECM
Engine speed
ECM Function
Fuel injection
control (Maximum amount
control)
Actuator
Fuel Injector
The maximum injection amount is controlled to an optimum by the engine speed, intake air amount, engine
coolant temperature, and accelerator opening in accordance with the driving conditions.
This prevents the oversupply of the injection amount caused by decreased air density at a high altitude or during a system failure.
EC-1351
http://vnx.su

DECELERATION CONTROL
Sensor
Input Signal to ECM
Engine speed
ECM Function
Fuel injection
control (Deceleration control)
Actuator
Fuel injector
Fuel pump
The ECM sends a fuel cut signal to the fuel injectors and fuel pump during deceleration for better fuel efficiency. The ECM determines the time of deceleration according to signals from the accelerator pedal position
sensor and crankshaft position sensor.
Fuel Injection Timing Control System
EBS011X1
DESCRIPTION
The target fuel injection timing in accordance with the engine speed and the fuel injection amount are recorded
as a map in the ECM beforehand. The ECM determines the optimum injection timing using sensor signals
accordance with the map.
EBS011X2
INPUT / OUTPUT SIGNAL CHART

Sensor
Input Signal to ECM
ECM Function
Actuator
Accelerator pedal opening angle
Vehicle speed
Air conditioner
cut control
SYSTEM DESCRIPTION
This system improves acceleration when the air conditioner is used.
When the accelerator pedal is fully depressed, the air conditioner is turned off for a few seconds.
When engine coolant temperature becomes excessively high, the air conditioner is turned off. This continues
until the engine coolant temperature returns to normal.
Fuel Cut Control (At No Load & High Engine Speed)
EBS011X3

Sensor
Input Signal to ECM
Vehicle speed
Engine speed
ECM Function
Fuel cut control
Actuator
Fuel injector
based on engine speed. Fuel cut will be operated until the engine speed reaches 1,500 rpm, then fuel cut will
be cancelled.
NOTE:
This function is different from deceleration control listed under EC-1350, "Fuel Injection Control System" .
EC-1352
http://vnx.su

Crankcase Ventilation System
EBS011X4
DESCRIPTION
In this system, blow-by gas is sucked into the air duct after oil separation by oil separator in the rocker cover.
EC
G
PBIB0590E
INSPECTION
Ventilation Hose
1.
2.

K
SEC692
CAN Communication
EBS01FD6
SYSTEM DESCRIPTION
CAN COMMUNICATION UNIT

Go to CAN system, when selecting your CAN system type from the following table.
Body type
Wagon
Axle
4WD
Engine
YD22DDTi
Transmission
M/T
Brake control
ECM
ABS
ESP
EC-1353
http://vnx.su

Body type
Wagon
Axle
4WD
Engine
YD22DDTi
Transmission
M/T
Brake control
ABS
ESP
Steering angle sensor
4WD control unit
: Applicable
Models Without ESP

SYSTEM DIAGRAM
PKIA6458E

Signals
ABS actuator and

electric unit
(control unit)
4WD control unit
Combination meter
ECM
Engine speed signal
MI signal
R
R
R
R
R
R

EC-1354
http://vnx.su

Signals
ABS actuator and

electric unit
(control unit)
ECM
4WD control unit
Combination meter
A/C switch signal
EC
Models With ESP

SYSTEM DIAGRAM
PKIA9634E
Signals
ECM
ESP/TCS/ABS
control unit
Steering angle
sensor

A/C switch signal
Combination
meter

4WD control
unit
Engine speed signal
R
R
R
R
MI signal

R
T
T
T
EC-1355
http://vnx.su

4WD control
unit
Combination
meter
Signals
A/C switch signal
ECM
Steering angle
sensor

ESP/TCS/ABS
control unit
T
T
Engine speed signal
R
R
R
R
MI signal

R
T
T

R
R
EC-1356
http://vnx.su


Fuel Filter
PFP:00018
A
EBS011X6
DESCRIPTION
A water draining cock is on the lower side and a priming pump for bleeding air is on the upper side.
EC
AIR BLEEDING
Pump the priming pump to bleed air.
When air is bled completely, the pumping of the priming pump

suddenly becomes heavy. Stop the operation at that time.
If it is difficult to bleed air by the pumping of the priming pump

(the pumping of the priming pump does not become heavy), disconnect the fuel supply hose between the fuel filter and the fuel
gallery. Then, perform the operation described above, and make
sure that fuel comes out. (Use a pan, etc. so as not to spill fuel.
Do not let fuel get on engine and other parts.) After that, connect
the hose, then bleed air again.
Start engine and let it idle for at least 1 minute after performing
air bleeding.
E
PBIB1932E
WATER DRAINING
1.
a.
b.
2.
3.
4.
Remove the fuel filter, filter bracket, protector assembly from the dash panel as follows.
Remove the air cleaner case (upper), air duct assembly, and vacuum hose for brake booster (between the
vacuum pump and vacuum pipe).
CAUTION:
After the duct is removed, cover the opening with gum tape, etc. to prevent foreign object from
getting into the engine during the operation.
Remove the mounting nuts on the dash panel, then remove the fuel filter, filter bracket, and protector
assembly from the dash panel.
It is not necessary to disconnect the fuel hose.
Using a tool such as a pliers, loosen the water draining cock at
the bottom of the fuel filter.
Loosening drain cock four to five turns causes water to
start draining.
Do not remove drain cock by loosening it excessively.
If water dose not drain properly, move the priming up and down.
CAUTION:
When the water is drained, the fuel is also drained. Use a
pan, etc. to avoid fuel adherence to the rubber parts such as
the engine mount insulator.
Do not over-tighten the water draining cock. This will damSMA825B
age the cock thread, resulting in water or fuel leak.
Bleed air of the fuel filter. Refer to EC-1357, "AIR BLEEDING" .
Start the engine.
Fuel Pump Learning Value Clearing
EBS011X7
DESCRIPTION
In order to always keep optimum fuel pressure in fuel rail, the ECM controls fuel pump in high precision with
monitoring the signal of fuel rail pressure sensor.
Accordingly, the ECM always learns characteristic value of fuel pump. Fuel Pump Learning Value Clearing is
an operating to clear the value of the fuel pump learning.
It must be performed after the fuel pump is changed. When the ECM is replaced with brand new one, the Fuel
Pump Learning Value Clearing is not necessary to be performed. If the ECM to be replaced has the possibility
of learning the characteristic value of fuel pump, the Fuel Pump Learning Value Clearing is necessary to be
performed after the ECM has been replaced.
OPERATION PROCEDURE
NOTE:
When removing fuel pump, perform Fuel Pump Learning Value Clearing before starting engine.
EC-1357
http://vnx.su

With CONSULT-II
1.
2.

Select PUMP LEARNT CLEAR in ACTIVE TEST mode with
CONSULT-II.
MBIB0896E
3.
Touch CLEAR and wait a few seconds.
MBIB0893E
4.
Make sure that CMPLT is displayed on CONSULT-II screen.
MBIB0894E
Without CONSULT-II
Fuel pump learning value can be erased from the back up memory in the ECM by the same operation as erasing DTC.In detail, refer to EC-1359, "Without CONSULT-II" .
EC-1358
http://vnx.su


DTC and MI Detection Logic
PFP:00028
A
EBS011X8
When a malfunction is detected, the malfunction (DTC) and freeze frame data are stored in the ECM memory.
The MI will light up each time the ECM detects malfunction. For diagnostic items causing the MI to light up, EC
refer to EC-1339, "INDEX FOR DTC" .
EBS011X9
HOW TO READ DTC
The DTC can be read by the following methods.
With CONSULT-II
CONSULT-II displays the DTC in "SELF-DIAG RESULTS" mode. Example: P0117, P0335, P1260, etc.
Without CONSULT-II
Example: 0117, 0335, 1260, etc.
Output of a DTC indicates a malfunction. However, the Diagnostic Test Mode II does not indicate
whether the malfunction is still occurring or has occurred in the past and has returned to normal.
CONSULT-II can identify malfunction status as shown below. Therefore, using CONSULT-II (if available) is recommended.
HOW TO ERASE DTC

With CONSULT-II
1.
2.
3.
4.
If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least 5
Touch ENGINE.
Touch SELF-DIAG RESULTS.
PBIB2452E
Without CONSULT-II
1.
2.
3.
EC-1359
http://vnx.su

hours.
Freeze frame data
Fuel pump learning value
Others
Freeze Frame Data
EBS011XA
The ECM records the driving conditions such as calculated load value, engine coolant temperature, engine
speed, vehicle speed and intake manifold pressure at the moment a malfunction is detected.
The data, stored together with the DTC data, are called freeze frame data and displayed on CONSULT-II. For
details, see EC-1394 .
Only one set of freeze frame data can be stored in the ECM. If freeze frame data is stored in the ECM memory
and another freeze frame data occurs later, the first (original) freeze frame data remains unchanged in the
ECM memory.
Freeze frame data (along with the DTCs) are cleared when the ECM memory is erased. Procedures for clearing the ECM memory are described in EC-1359, "HOW TO ERASE DTC" .
EBS011XB

the ON position or "NATS MALFUNCTION" is displayed on
"SELF-DIAG RESULTS" screen, perform self-diagnostic
Refer to NATS (Nissan Anti-Theft System) in BL section.
before touching "ERASE" in "SELF-DAIG RESULTS" mode
with CONSULT-II.
SEF543X
Regarding the procedure of NATS initialization and NATS ignition key ID registration, refer to CONSULT-II operation manual, NATS.
EBS01F88
DESCRIPTION
If the MI does not light up, refer to EC-1682, "MI & DATA LINK
CONNECTORS" .
SAT652J

The on board diagnostic system has the following three functions.
EC-1360
http://vnx.su

Diagnostic Test
Mode
KEY and ENG.

Status
Function
Mode I
Ignition switch in
ON position
BULB CHECK

circuit, etc.).
If the MI does not come on, check MI circuit. (See EC1682, "MI & DATA LINK CONNECTORS" .)
Engine stopped
EC
D
Engine running
MALFUNCTION
WARNING
This is a usual driving condition. When ECM detects a malfunction, the MI will light up to inform the driver that a malfunction has been detected.
E
Mode II
Ignition switch in
ON position
SELF-DIAGNOSTIC
RESULTS
This function allows DTCs to be read.
Engine stopped

NOTE:
has a malfunction.

1.
2.
a.
b.
3.
4.
blinking.
PBIB0092E
EC-1361
http://vnx.su

1.
2.
3.

In this mode, the MI on the instrument panel should stay ON. If it remains OFF, check the bulb. Refer to EC1682, "MI & DATA LINK CONNECTORS" .

MI
Condition
ON
OFF
No malfunction.

In this mode, the DTC is indicated by the number of blinks of the MI as shown below. A DTC will be used as an
example for how to read a code.
PBIA3905E

The DTC can be erased from the back up memory in the ECM by depressing accelerator pedal. Refer to EC1362, "How to Erase Diagnostic Test Mode II (Self-diagnostic Results)" .
EC-1362
http://vnx.su

Relationship Between MI, DTC, CONSULT-II and Driving Patterns
EBS01F89
EC
MBIB0622E
*1: When a malfunction is detected, MI

will light up.
*2: MI will not light up after ignition

*4: Other screens except SELF-DIAG*5: The DTC will not be displayed any
NOSTIC RESULTS & DATA MONIlonger after vehicle is driven 40 times
TOR (AUTO TRIG) cannot display
(Driving pattern A) without the same
the malfunction. DATA MONITOR
malfunction. (The DTC still remain in
(AUTO TRIG) can display the malECM.)
function at the moment it is detected.
EC-1363
http://vnx.su
*3: When a malfunction is detected for

the first time, the DTC will be stored
in ECM.

DRIVING PATTERN A
MBIB0923E
The counter will be cleared when the malfunction is detected regardless of (1) - (4).
The counter will be counted up when (1) - (4) are satisfied without the same malfunction.
The DTC will not be displayed after the counter reaches 40.
EC-1364
http://vnx.su
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS
PFP:00004
A
EBS011XD
INTRODUCTION
The engine has an ECM to control major systems such as fuel injection control, fuel injection timing control, glow control system, etc.
The ECM accepts input signals from sensors and instantly actuators.
It is essential that both input and output signals are proper and stable. At the same time, it is important that there are no malfunctions
such as vacuum leaks, or other malfunctions with the engine.
EC
MEF036D
It is much more difficult to diagnose a malfunction that occurs intermittently rather than continuously. Most intermittent malfunctions are
H
SEF233G
test with CONSULT-II or a circuit tester connected should be performed. Follow the EC-1366, "WORK FLOW" .
on next page should be used.
Start your diagnosis by looking for conventional incidents first. This
will help troubleshoot driveability incidents on an electronically controlled engine vehicle.
L
SEF234G
EC-1365
http://vnx.su
TROUBLE DIAGNOSIS
WORK FLOW
PBIB0477E
*1

RESULTS is other than 0, perform EC-1401, "TROUBLE DIAGNOSIS FOR INTERMITTENT
INCIDENT" .
*4

*2

INCIDENT" .
EC-1366
http://vnx.su

Refer to EC-1402, "POWER SUPPLY AND GROUND CIRCUIT" .
TROUBLE DIAGNOSIS
STEP
DESCRIPTION
STEP I
Get detailed information about the conditions and the environment when the incident/symptom occurred using the
EC-1367, "DIAGNOSTIC WORK SHEET" .
STEP II
Before confirming the concern, check and write down (print out using CONSULT-II) the DTC and the freeze frame
data, then erase the DTC. The DTC and the freeze frame data can be used when duplicating the incident at STEP III
& IV. Refer to EC-1360 .
Study the relationship between the cause, specified by DTC, and the symptom described by the customer. (The
Symptom Matrix Chart will be useful. Refer toEC-1374 ) Also check related service bulletins for information.
STEP III
The DIAGNOSTIC WORK SHEET and the freeze frame data are useful to verify the incident. Connect CONSULT-II to
the vehicle in DATA MONITOR (AUTO TRIG) mode and check real time diagnosis results.
STEP IV
Try to detect the DTC by driving in (or performing) the DTC Confirmation Procedure. Check and read the DTC and the
freeze frame data by using CONSULT-II.
During the DTC verification, be sure to connect CONSULT-II to the vehicle in DATA MONITOR (AUTO TRIG) mode
and check real time diagnosis results.
In case the DTC Confirmation Procedure is not available, perform the Overall Function Check instead. The DTC cannot be displayed by this check, however, this simplified check is an effective alternative.
The NG result of the Overall Function Check is the same as the DTC detection.
STEP V
If the malfunction code is indicated, proceed to Trouble Diagnosis for DTC PXXXX.
If the normal code is indicated, proceed to the Basic Inspection, EC-1369 . Then perform inspections according to the
Symptom Matrix Chart. Refer to EC-1374 .
STEP VI
Gently shake the related connectors, components or wiring harness with CONSULT-II set in DATA MONITOR (AUTO
TRIG) mode.
Refer to EC-1385 or EC-1398 .
inspection is also required for the circuit check in the Diagnostic Procedure. For details, refer to GI-23, "How to Perform Efficient Diagnosis for an Electrical Incident" , Circuit Inspection.
If the malfunctioning part cannot be detected, perform EC-1401, "TROUBLE DIAGNOSIS FOR INTERMITTENT
INCIDENT" .
STEP VII
Perform the DTC Confirmation Procedure and confirm the normal code (DTC P0000) is detected. If the incident is still
detected in the final check, perform STEP VI by using a different method from the previous one.
Before returning the vehicle to the customer, be sure to erase the unnecessary (already fixed) DTC in ECM. (Refer to
EC-1359 .)
DIAGNOSTIC WORK SHEET

In general, each customer feels differently about an incident. It is
Utilize a diagnostic worksheet like the one shown below in order to
organize all the information for troubleshooting.
SEF907L
EC-1367
http://vnx.su
EC
TROUBLE DIAGNOSIS
Worksheet Sample
MTBL0533
EBS012AT
chart.
NOTE:
EC-1368
http://vnx.su
TROUBLE DIAGNOSIS
Priority
1
U1000 CAN communication line
P0016 Crankshaft position - camshaft position correlation
P0182 P0183 Fuel pump temperature sensor
P0192 P0193 Fuel rail pressure sensor
P0237 P0238 Turbocharger boost sensor
P0335 P0336 Crankshaft position sensor
P0340 P0341 Camshaft position sensor
P0563 Battery voltage
P0605 P0606 ECM
P0642 P0643 P0652 P0653 Sensor power supply
P1260 - P1267 Fuel injector adjustment resistor
P1610 - P1617 NATS
P2228 P2229 Barometric pressure sensor
P0089 P0628 P0629 P1272 - P1275 Fuel pump
P0200 - P0204 P1268 - P1271 P2146 - P2149 Fuel injector
P0686 ECM relay
P0088 P0093 Fuel system
P0234 Turbocharger system
P0501 P0502 P0503 ASCD vehicle speed sensor
P0504 ASCD brake switch
P0580 P0581 ASCD steering switch
EC
Basic Inspection
EBS011XF
Precaution:
Perform Basic Inspection without electrical or mechanical loads applied;
only small lamps.
Rear defogger switch is OFF.
EC-1369
http://vnx.su
TROUBLE DIAGNOSIS
1. INSPECTION START
1.
2.
3.
4.
Check service records for any recent repairs that may indicate a related malfunction.
Check the current need for scheduled maintenance, especially for fuel filter and air cleaner filter. Refer to
MA-7, "Periodic Maintenance" .
Vacuum hoses for splits, kinks, or improper connections
Wiring for improper connections, pinches, or cuts
>> GO TO 2.
SEF142I
2. PREPARATION FOR CHECKING IDLE SPEED

With CONSULT-II
Connect CONSULT-II to the data link connector.
Without CONSULT-II
Install diesel tacho tester to the vehicle.
>> GO TO 3.
3. CHECK IDLE SPEED

With CONSULT-II
2. Read idle speed.
72525 rpm
SEF817Y
Without CONSULT-II
Read idle speed.
72525 rpm
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 4.
EC-1370
http://vnx.su
TROUBLE DIAGNOSIS
OK or NG
OK
>> GO TO 5.
NG
EC
5. BLEED AIR FROM FUEL SYSTEM

1.
2.
Stop engine.
Use priming pump to bleed air from fuel system. Refer to EC-1357, "AIR BLEEDING" .
>> GO TO 6.
E

1.
2.
3.
With CONSULT-II
Select CKPSRPM (TDC) in DATA MONITOR mode with CONSULT-II.
Read idle speed.
72525 rpm
H
SEF817Y
Without CONSULT-II
Read idle speed.
72525 rpm
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 7.
7. DRAIN WATER FROM FUEL FILTER
Drain water from fuel filter. Refer to EC-1357, "WATER DRAINING" .

>> GO TO 8.
EC-1371
http://vnx.su
TROUBLE DIAGNOSIS

With CONSULT-II
3. Read idle speed.
72525 rpm
SEF817Y
Without CONSULT-II
Read idle speed.
72525 rpm
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 9.
9. CHECK AIR CLEANER FILTER

Check air cleaner filter for clogging or breaks.
OK or NG
OK
>> GO TO 10.
NG
>> Replace air cleaner filter.
10. CHECK BATTERY VOLTAGE

Check battery voltage.
Voltage: More than 12.13V
OK or NG
OK
>> GO TO 12.
NG
>> GO TO 11.
11. CHECK BATTERY

Refer to SC-3, "BATTERY" .
OK or NG
OK
>> Check charging system. Refer to SC-12, "CHARGING SYSTEM" .
NG

OK or NG
OK
>> GO TO 13.
NG
>> Follow the instruction of CHECKING COMPRESSION PRESSURE.
EC-1372
http://vnx.su
TROUBLE DIAGNOSIS
With CONSULT-II
3. Read idle speed.
EC
72525 rpm
E
SEF817Y
Without CONSULT-II
Read idle speed.
72525 rpm
OK or NG
OK
>> INSPECTION END
NG
>> 1. Replace fuel injector.
2. GO TO 3.
EC-1373
http://vnx.su
TROUBLE DIAGNOSIS
EBS011XG
LOW IDLE
HI IDLE
AB
Fuel pump
Fuel injector
Glow control system
Engine body
Fuel transport pump
POOR ACCELERATION
KNOCK/DETONATION
AD
LACK OF POWER
AC
WHEN DECELERATING
AA
DURING DRIVING
AT IDLE
ENGINE STALL
Reference page
SYMPTOM
AE
AF
EC-1459
1
3
EC-1626
4
EM-219
EC-1665
EGR system
EC-1634
EM-139
EC-1420
Fuel pump circuit
EC-1553
EC-1459
ENGINE CONTROL

1
1
EC-1424
1

EC-1435
LAN-4
EC-1441
EC-1452
EC-1374
http://vnx.su
TROUBLE DIAGNOSIS
LOW IDLE
HI IDLE
POOR ACCELERATION
LACK OF POWER
KNOCK/DETONATION
WHEN DECELERATING
DURING DRIVING
AT IDLE
I
AB
AC
AD
AE
1
AF
1
EC-1497
ENGINE CONTROL
EC-1642

valve circuit
EC-1642
EC-1679
EC-1402
EC-1402
EC-1465

Glow relay circuit
1
1

EC-1634
EC-1626
1
2
EC-1509
EC
AA
E
ENGINE STALL
Reference page
SYMPTOM
EC-1567
2
EC-1549,
EC-1624
EC-1360

EC-1375
http://vnx.su
TROUBLE DIAGNOSIS
Fuel pump
Fuel injector
AP
Glow control system

Engine body

AM

AL

AK
WHITE SMOKE

AJ
BLACK SMOKE
IDLING VIBRATION
AH
ROUGH IDLE/HUNTING
AG
Reference page
SYMPTOM
EC-1459
HA
4
1
EC-1626
EM-219
Fuel transport pump
EC-1665
EGR system
EC-1634
EM-139
ENGINE CONTROL
EC-1420
Fuel pump circuit
EC-1592
EC-1459
EC-1424
EC-1435
LAN-4
EC-1441
EC-1452

1
1

EC-1376
http://vnx.su
TROUBLE DIAGNOSIS
WHITE SMOKE
BLACK SMOKE
AL
AK
AJ
AH
AG
ENGINE CONTROL
IDLING VIBRATION
ROUGH IDLE/HUNTING
Reference page
SYMPTOM
EC
F
AM
AP
HA
1
EC-1497
EC-1509
EC-1491
Turbocharger boost control solenoid valve circuit
EC-1642
EC-1679
EC-1402
2
1
Glow relay circuit
EC-1626

2
EC-1634
1
EC-1402
EC-1465
EC-1567
EC1549,EC1624
EC-1360
EC-1377
http://vnx.su
TROUBLE DIAGNOSIS
EBS01FD7
PBIB1888E
EC-1378
http://vnx.su
TROUBLE DIAGNOSIS
A
EC
PBIB1938E
EC-1379
http://vnx.su
TROUBLE DIAGNOSIS
PBIB1939E
EC-1380
http://vnx.su
TROUBLE DIAGNOSIS
A
EC
PBIB1940E
EC-1381
http://vnx.su
TROUBLE DIAGNOSIS
PBIB2881E
1.
2.
3.
CANSEL switch
4.
SET/COAST switch
5.
MAIN switch
6.
Stop lamp switch harness connector
7.
ASCD brake switch harness connector
8.
ASCD clutch switch harness connector
EC-1382
http://vnx.su
TROUBLE DIAGNOSIS
Circuit Diagram
EBS01FD8
EC
TBWB0473E
EC-1383
http://vnx.su
TROUBLE DIAGNOSIS
TBWB0474E
EC-1384
http://vnx.su
TROUBLE DIAGNOSIS
EBS011XJ
EC
MBIB0045E
ECM Terminals And Reference Value
EBS01FD9
PREPARATION
1.
2.

remove glove box.
H
PBIB1899E
3.
4.

levers as far as they will go as shown in the figure.
PBIB1512E

CAUTION:
TERMINAL
NO.
1
2
3
WIRE
COLOR
B
B
B
ITEM
ECM ground
CONDITION
[Engine is running]
Idle speed
EC-1385
http://vnx.su
DATA
Approximately 0V
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
[Engine is running]
W/B
G/B

Warm-up condition
Idle speed
DATA
5 - 10V
NOTE:
idle.
MBIB0883E
5 - 10V
[Engine is running]
Warm-up condition
MBIB0884E
Warm-up condition
Idle speed
0 - 12.5V
NOTE:
idle.
6
MBIB0889E

solenoid valve
0 - 12.5V
Warm-up condition
MBIB0890E
[Engine is running]
Warm-up condition
Idle speed
0 - 12.5V
NOTE:
idle.
MBIB0885E
10
Y/L

0 - 12.5V
[Engine is running]
Warm-up condition
MBIB0886E
14
W/PU
Fuel level switch
EC-1386
http://vnx.su
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
[Engine is running]
19
Air conditioner switch is OFF
Both air conditioner switch and blower fan

switch are ON (Compressor is operating)
[Engine is running]
G/R
GY/L
G/R
GY/L
Fuel injector No. 2

Fuel injector No. 2
Fuel injector No. 3
Fuel injector No. 3
BATTERY VOLTAGE
(11 - 14V)
EC
[Engine is running]
21
22
23
24
DATA
Warm-up condition
Idle speed
Approximately 0.1V
C
0 - 9V
NOTE:
idle.
E
MBIB0881E
0 - 9V
[Engine is running]
Warm-up condition
MBIB0882E
25
26
27
28
GY
W/L
OR/B
GY/B
[Engine is running]
Warm-up condition
Idle speed
[Engine is running]
Warm-up condition
Idle speed
0.1 - 14V
control valve.)
0.5 - 1.0V
MBIB0887E
NOTE:
idle.
29
Fuel pump
0.5 - 1.0V
[Engine is running]
Warm-up condition
MBIB0888E
[Engine is running]
34
LG/B
[Engine is running]
BATTERY VOLTAGE
(11 - 14V)
Approximately 0.1V
[Engine is running]
36
LG
[Engine is running]
EC-1387
http://vnx.su
BATTERY VOLTAGE
(11 - 14V)
Approximately 0.1V
TROUBLE DIAGNOSIS
TERMINAL
NO.
37
WIRE
COLOR
W/R
ITEM
Glow relay

[Engine is running]
39
B/OR
[Engine is running]
[Engine is running]
40
41
42
43
G/R
GY/L
G/R
GY/L
Fuel injector No. 4

Fuel injector No. 4
Fuel injector No. 1
Fuel injector No. 1
DATA
CONDITION
Warm-up condition
Idle speed
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
0 - 9V
NOTE:
idle.
MBIB0881E
0 - 9V
[Engine is running]
Warm-up condition
MBIB0882E
44
L/W
Approximately 5.3V
45
G/OR

power supply
Approximately 5.3V
[Engine is running]
Warm-up condition
Idle speed
0 - 6V
NOTE:
idle.
MBIB0879E
46

0 - 6V
[Engine is running]
Warm-up condition
MBIB0880E
EC-1388
http://vnx.su
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
[Engine is running]
Warm-up condition
Idle speed
DATA
0 - 6V
EC
NOTE:
idle.
C
MBIB0877E
47
G/R
0 - 6V
[Engine is running]
Warm-up condition
F
MBIB0878E
[Engine is running]
48
49
50
51
Y/R
R
PU
L/OR
Warm-up condition
Idle speed
1.7 - 2.0V
2.0 - 2.3V

pump temperature

coolant temperature
2.3 - 2.6V
2.5 - 2.8V
1.8 - 2.3V
[Engine is running]

sensor
Warm-up condition
[Engine is running]
Warm-up condition
[Engine is running]
Warm-up condition
[Engine is running]
52
Warm-up condition
Idle speed
[Engine is running]
Warm-up condition
[Engine is running]
54
55
59
W/B
60
Y/B
61
G/B
62
R/B

resistor No. 1
resistor No. 3
resistor No. 4
resistor No. 2
Warm-up condition
Idle speed
[Engine is running]
Warm-up condition
[Engine is running]
Warm-up condition
EC-1389
http://vnx.su
2.5 - 3.0V

air temperature
0.5 - 5.1V
resistors.)
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA
63

power supply
Approximately 5.3V
64

power supply
Approximately 5.3V
65
L/R
Approximately 0.3V
66
G/Y

ground
Approximately 0.3V
67
Sensor ground
Approximately 0.3V
68

ground
Approximately 0.3V
69

sensor ground
Approximately 0.3V
70
Engine coolant temperature sensor ground
Approximately 0.3V
71

ground
Approximately 0.3V
73

ground
Approximately 0.3V
74
Intake air temperature sensor ground
Approximately 0.3V
78

resistor ground
Approximately 0.3V
82

Approximately 5.3V
83

sensor 1
Engine stopped
0.5 - 1.0V
Engine stopped
4.2 - 5.2V
84

sensor 1 ground
Approximately 0.3V
85
Sensor ground
Approximately 0.3V
87
GY/R

89
LG
Data link connector
90

CONSULT-II is disconnected.
Approximately 0V - Battery voltage (11 - 14V)

Approximately 5.3V
91

sensor 2
Engine stopped
0.4 - 0.7V
Engine stopped
EC-1390
http://vnx.su
2.2 - 2.7V
TROUBLE DIAGNOSIS
TERMINAL
NO.
92
95
99
WIRE
COLOR
Y
G/R
B/Y
ITEM
sensor 2 ground
CONDITION
Approximately 0.3V

Approximately 0.3V
[Ignition switch START]
BATTERY VOLTAGE
(11 - 14V)
Start signal
100
Stop lamp switch
101
GY/L
ASCD brake switch

depressed
PU*1
W/R*2
103
B/OR

ground

switch OFF
107
108
W/R
W/R
Ignition switch
switch

110
G/OR
[Engine is running]
111
P/B

switch
EC
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
BATTERY VOLTAGE
(11 - 14V)
Approximately 0V
G
Approximately 4.3V
H
Approximately 0.3V
Approximately 1.3V
Approximately 3.3V
Approximately 2.3V
K
105
102
DATA
[Engine is running]
EC-1391
http://vnx.su
Approximately 0.3V
L
Approximately 1.2V
M
BATTERY VOLTAGE
(11 - 14V)
BATTERY VOLTAGE
(11 - 14V)
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
TROUBLE DIAGNOSIS
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
113

switch OFF
114
ECM ground
[Engine is running]
DATA
Approximately 1.2V
BATTERY VOLTAGE
(11 - 14V)
Approximately 0V
Idle speed
119
120
Y
R
BATTERY VOLTAGE
(11 - 14V)
121
W/L

(Back-up)
BATTERY VOLTAGE
(11 - 14V)
*1: LHD models
*2: RHD models
EBS011XL
FUNCTION
Function
Self-diagnostic results such as DTCs and freeze frame data can be read and erased quickly.*
Data monitor

monitor
Active test
Function test
ECM part number
Freeze frame data
1.
2.
3.

Connect CONSULT-II to data link connector, which is located
under the driver side dash panel.
MBIB0156E
EC-1392
http://vnx.su
TROUBLE DIAGNOSIS
4.

A
EC
C
BCIA0029E
5.
Touch ENGINE.
Link Connector (DLC) Circuit"
G
BCIA0030E
6.

procedure.
BCIA0031E
EC-1393
http://vnx.su
TROUBLE DIAGNOSIS
SELF-DIAG RESULTS
Item
INPUT
OUTPUT
DATA MONITOR
DTC
FREEZE
FRAME
DATA
Battery voltage
ACTIVE
TEST
Stop lamp switch
Barometric pressure sensor (built-into ECM)
ASCD brake switch
ASCD clutch switch
Fuel pump
Fuel injector
Glow relay
Cooling fan relay

X: Applicable
SELF-DIAGNOSTIC MODE
Regarding items detected in SELF-DIAG RESULTS mode, refer to EC-1339, "INDEX FOR DTC" .
Freeze Frame Data

Freeze frame data item
Description
DIAG TROUBLE CODE

[PXXXX]
The engine control component part/control system has a trouble code, it is displayed as PXXXX.
(Refer to EC-1339, "INDEX FOR DTC" .)
CAL/LD VALUE [%]
COOLANT TEMP [C] or

[F]
ENGINE SPEED [rpm]
VEHICL SPEED [km/h] or

[mph]
INT MANI PRES [kPa]
The intake manifold pressure at the moment a malfunction is detected is displayed.
EC-1394
http://vnx.su
TROUBLE DIAGNOSIS
DATA MONITOR MODE
MONITOR ITEM
CKPSRPM (TDC) [rpm]
COOLAN TEMP/S
[C] or [F]
VHCL SPEED SE
[km/h] or [mph]
ECM
INPUT
SIGNAL
MAIN
SIGNALS
A
CONDITION
The engine speed computed from the

crankshaft position sensor signal is displayed.
The engine coolant temperature (determined by the signal voltage of the engine
coolant temperature sensor) is displayed.
The vehicle speed computed form the

vehicle speed sensor signal is displayed.
The fuel temperature (determined by the

signal voltage of the fuel pump temperature sensor) is displayed.
FUEL TEMP SEN

[C] or [F]
ACCEL POS SEN [V]
ACCEL SEN 2 [V]
ACT CR PRESS [MPa]

The Fuel rail pressure (determined by the

signal voltage of the fuel rail pressure
sensor) is displayed.
BATTERY VOLT [V]
P/N POSI SW [ON/OFF]
Indicates [ON/OFF] condition from the

park/neutral position switch signal.
START SIGNAL [ON/OFF]

starter signal.

power steering pressure switch signal.

stop lamp switch signal.

ASCD brake switch and ASCD clutch
switch signal.
PW/ST SIGNAL [ON/OFF]
BRAKE SW [ON/OFF]
BRAKE SW2 [ON/OFF]
IGN SW [ON/OFF]
Indicates [ON/OFF] condition from ignition switch signal.

sensor is displayed.
Indicates the actual fuel injection pulse

width compensated by ECM according to
the input signals.
Indicates the fuel pump power supply

current from the ECM.
The glow relay control condition (determined by ECM according to the input signal) is displayed.
Indicates the control condition of the

cooling fans (determined by ECM
according to the input signal).
LOW ... Operates at low speed.
HI ... Operates at high speed.
OFF ... Stopped
MAS AIR/FL SE [V]
MAIN INJ WID [msec]
PUMP CURRENT [mA]
GLOW RLY [ON/OFF]
COOLING FAN
[LOW/HI/OFF]
EC-1395
http://vnx.su
SPECIFICATION
EC
When the engine coolant temperature circuit is open or short, ECM

enters fail-safe mode. The engine
coolant temperature determined
by the ECM is displayed.
F
These signals are converted by
ECM internally. Thus, they differ
from ECM terminals voltage.
TROUBLE DIAGNOSIS
ECM
INPUT
SIGNAL
MONITOR ITEM
MAIN
SIGNALS
Indicates the EGR volume control value

computed by the ECM according to the
input signals.
The opening becomes larger as the

value increases.
The intake air volume computed from the

mass air flow sensor signal is displayed.
The barometric pressure (determined by

the signal voltage from the absolute pressure sensor built into the ECM) is displayed.
Turbocharger boost (determined by the

signal voltage from the turbocharger
boost sensor) is displayed.
The cylinder being injected is displayed.

EGR VOL CON/V [step]
INT/A VOLUME [mg/]
BARO SEN [kPa]
CONDITION
INT/M PRES SE [kPa]
CYL COUNT [1/2/3/4]
SET SW
[ON/OFF]

RESUME/ACC SW
[ON/OFF]
Indicates [ON/OFF] condition from

RESUME/ACCELERATE switch signal.
CANCEL SW
[ON/OFF]
Indicates [ON/OFF] condition from CANCEL switch signal.
MAIN SW
[ON/OFF]

switch signal.
SPECIFICATION
Voltage [V]

ones.
They are the same figures as an
actual piece of data which was
just previously measured. [Hz] or
[%]
Frequency [msec], [Hz] or

[%]
Voltage, frequency, duty cycle or pulse
width measured by the probe.
DUTY-HI
DUTY-LOW
PLS WIDTH-HI
PLS WIDTH-LOW
NOTE:
ACTIVE TEST MODE

TEST ITEM
POWER BALANCE
COOLING FAN *
CONDITION

engine.
A/C switch: OFF

a time using CONSULT-II
Ignition switch: ON
Operate the cooling fan at LOW,

HI speed and turn OFF using
CONSULT-II.
JUDGEMENT
Cooling fan moves at LOW, HI

speed and stops.
EC-1396
http://vnx.su
CHECK ITEM (REMEDY)
Compression
Fuel injector
Cooling fan motor
Cooling fan relay
TROUBLE DIAGNOSIS
TEST ITEM
ENG COOLANT
TEMP
GLOW RLY
EGR VOL CONT/

V
PRES REGULATOR
PUMP LEANT
CLEAR
CONDITION

trouble condition

stopped)
Turn the glow relay ON and OFF

using CONSULT-II and listen to
operating sound.
Ignition switch: ON
Change EGR volume control

valve opening step using CONSULT-II.
JUDGEMENT
CHECK ITEM (REMEDY)
Fuel injector
Glow relay makes the operating

sound.
Glow relay
EGR volume control valve makes

an operating sound.

CHECK ITEM.
EC
Ignition switch: ON
Change fuel rail pressure using

CONSULT-II
This mode is used for performing Fuel Pump Learning Value Clearing. Refer to EC-1357, "Fuel Pump Learning
Value Clearing" .
Fuel line
Fuel pressure relief valve
Fuel leaks.
REAL TIME DIAGNOSIS IN DATA MONITOR MODE

mode.
The malfunction will be identified on the CONSULT-II screen in

real time.
In other words, DTC will be displayed if the malfunction is
detected by ECM.
At the moment a malfunction is detected by ECM, MONITOR
in DATA MONITOR screen is changed to Recording Data ...
xx% as shown in the figure, and the data after the malfunction
detection is recorded. Then when the percentage reached
100%, REAL-TIME DIAG screen is displayed. If STOP is
touched on the screen during Recording Data ... xx%, REALPBIB0480E
TIME DIAG screen is also displayed.
The recording time after the malfunction detection and the recording speed can be changed by TRIGGER POINT and Recording Speed. Refer to CONSULT-II OPERATION MANUAL.
DTC will not be displayed automatically on CONSULT-II screen

even though a malfunction is detected by ECM.
DATA MONITOR can be performed continuously even though a
malfunction is detected.
Use these triggers as follows:
1. AUTO TRIG
While trying to detect the DTC by performing the DTC Confirmation Procedure, be sure to select to DATA MONITOR (AUTO
TRIG) mode. You can confirm the malfunction at the moment it
SEF707X
is detected.
When you are inspecting the circuit by gently shaking (or twisting) the suspicious connectors, components
and harness in the DTC Confirmation Procedure, the moment a malfunction is found the DTC will be displayed. Refer to GI-23, "How to Perform Efficient Diagnosis for an Electrical Incident" , INCIDENT SIMULATION TESTS.
2. MANU TRIG
EC-1397
http://vnx.su
TROUBLE DIAGNOSIS
TRIG. By selecting MANU TRIG you can monitor and store the data. The data can be utilized for further
diagnosis, such as a comparison with the value for the normal operating condition.
SEF720X
FUNCTION TEST
This mode is used to inform customers of their vehicle condition of periodic maintenance.
EBS011XN
Remarks:
MONITOR ITEM
CONDITION
CKPS-RPM (TDC)
COOLAN TEMP/S
VHCL SPEED SE
FUEL TEMP SEN
ACCEL POS SEN*
ACCEL SEN 2*

indication.

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

Ignition switch: ON
(Engine stopped)
Accelerator pedal: fully released
0.2 - 0.7V
Accelerator pedal: fully depressed
3.9 - 4.9V
Ignition switch: ON
(Engine stopped)
Accelerator pedal: fully released
0.1 - 0.4V
Accelerator pedal: fully depressed
1.9 - 2.4V
Idle
1.5 - 2.0V
2,000 rpm
2.2 - 2.7V
No-load
MAS AIR/FL SE*
BATTERY VOLT
SPECIFICATION
EC-1398
http://vnx.su
11 - 14V
TROUBLE DIAGNOSIS
MONITOR ITEM
CONDITION
P/N POSI SW
START SIGNAL
PW/ST SIGNAL
BRAKE SW
IGN SW
GLOW RLY
Ignition switch: ON
ON
Except above
OFF
No-load
OFF ON OFF
Steering wheel is in neutral position. (Forward direction)
OFF
ON
OFF
ON
ON OFF
Idle
20 - 30 MPa
2,000 rpm
45 - 55 MPa
No-load
0.68 - 0.78 msec
Idle speed

0.78 - 0.88 msec
Idle
1,700 - 1,900 mA
2,000 rpm
1,600 - 1,800 mA
No-load
OFF
LOW
HI
More than 10 steps

rpm
0 step
No-load
Engine: After warming up, idle the engine
150 - 450 mg/st
Idle
Approx. 100 kPa
2,800 rpm
Approx. 126 kPa
No-load
4,000 rpm
Approx. 106 kPa

Altitude
Approx. 0m: Approx. 100.62 kPa
(1.0062 bar, 1.026 kg/cm2 , 14.59
psi)
BARO SEN
kPa (0.8895 bar, 0.907 kg/cm2 ,

12.90 psi)
Ignition switch: ON
kPa (0.8316 bar, 0.848 kg/cm2 ,

12.06 psi)
kPa (0.7836 bar, 0.799 kg/cm2 ,
11.36 psi)
CYL COUNT
EC
1342
Engine is running
NOTE:
EC-1399
http://vnx.su
INT/M PRES SE [kPa]
EGR VOL CON/V
INT/A VOLUME

the engine
Ignition switch: ON OFF
PUMP CURRENT
COOLING FAN

ACT CR PRESS
MAIN INJ WID
Ignition switch: ON
SPECIFICATION
TROUBLE DIAGNOSIS
EBS011XO
ACCEL POS SEN, CKPSRPM (TDC), MAS AIR/FL SE

Below is the data for ACCEL POS SEN, CKPSRPM (TDC) and MAS AIR/FL SE when revving engine
quickly up to 3,000 rpm under no load after warming up engine to the normal operating temperature.
SEF321Y
EC-1400
http://vnx.su


Description
PFP:00006
A
EBS011XP
Intermittent incidents may occur. In many cases, the incident resolves itself (the part or circuit function returns
to normal without intervention). It is important to realize that the symptoms described in the customer's com- EC
plaint often do not recur on DTC visits. Realize also that the most frequent cause of intermittent incidents
occurrences is poor electrical connections. Because of this, the conditions under which the incident occurred
may not be clear. Therefore, circuit checks made as part of the standard diagnostic procedure may not indiC
cate the specific malfunctioning area.
COMMON INTERMITTENT INCIDENTS REPORT SITUATIONS

STEP in Work Flow
Situation
II
The CONSULT-II is used. The SELF-DIAG RESULTS screen shows time data other than 0.
III
IV
DTC does not appear during the DTC Confirmation Procedure.
VI
The Diagnostic Procedure for XXXX does not indicate the malfunctioning area.
EBS011XQ
1. INSPECTION START
Erase DTCs. Refer to EC-1359, "HOW TO ERASE DTC" .
>> GO TO 2.
H

OK or NG
OK
>> GO TO 3.
NG
Perform GI-23, "How to Perform Efficient Diagnosis for an Electrical Incident" , INCIDENT SIMULATION
TESTS.
OK or NG
OK
>> INSPECTION END
NG
EC-1401
http://vnx.su


Wiring Diagram
PFP:24110
EBS011XS
TBWA0563E
EC-1402
http://vnx.su

CAUTION:
TERMINAL
NO.
1
2
3
WIRE
COLOR
B
B
B
ITEM
ECM ground
CONDITION
[Engine is running]
Idle speed

105

switch OFF
107
108
W/R
W/R
Ignition switch

113

switch OFF
114
ECM ground
[Engine is running]
Idle speed
DATA
EC
C
Approximately 0V
D
Approximately 1.2V
E
BATTERY VOLTAGE
(11 - 14V)
BATTERY VOLTAGE
(11 - 14V)
G
Approximately 1.2V
H
BATTERY VOLTAGE
(11 - 14V)
I
Approximately 0V
119
120
Y
R
BATTERY VOLTAGE
(11 - 14V)
121
W/L

(Back-up)
BATTERY VOLTAGE
(11 - 14V)
EBS011XT
1. INSPECTION START
L
Start engine.
Is engine running?
Yes or No
Yes
>> GO TO 6.
No
>> GO TO 2.

1.
2.

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.
MBIB0610E
EC-1403
http://vnx.su


10A fuse


1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 5.
NG

1.
2.
3.

Check harness continuity between ECM terminals 1, 2, 3, 114 and body ground. Refer to Wiring Diagram.

OK or NG
OK
>> GO TO 6.
NG
EC-1404
http://vnx.su


1.
2.
3.

Voltage:
EC

drop to approximately 0V.
MBIB0611E
OK or NG
OK
>> GO TO 13.
NG (Battery voltage does not exist)>>GO TO 7.
NG (Battery voltage exists for more then a few seconds)>>GO TO 9.

1.
PBIB1899E
2.
Check voltage between relay terminals 1, 3, 6 and ground with

L

OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.
PBIB1886E

20A fuse

EC-1405
http://vnx.su


1.
2.

Check harness continuity between ECM terminals 105, 113 and ECM relay terminal 2. Refer to Wiring
Diagram.

OK or NG
OK
>> GO TO 11.
NG
>> GO TO 10.



1.
Check harness continuity between ECM terminal 119 and ECM relay terminal 5, ECM terminal 120 and
ECM relay terminal 7. Refer to Wiring Diagram.

OK or NG
OK
>> GO TO 13.
NG
>> GO TO 12.


13. CHECK ECM RELAY

OK or NG
OK
>> GO TO 14.
NG
EC-1406
http://vnx.su

EC

OK or NG
OK
>> GO TO 16.
NG
>> GO TO 15.
D
MBIB0026E
20A fuse
H
EC-1407
http://vnx.su


1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 17.
NG

1.
Check harness continuity between ECM terminals 1, 2, 3, 114 and body ground. Refer to Wiring Diagram.

OK or NG
OK
>> GO TO 18.
NG

>> INSPECTION END
EC-1408
http://vnx.su

EBS011XU
ECM RELAY
1.
2.

EC
Condition
Continuity
Yes
OFF
No
3.

D
PBIB0077E
EC-1409
http://vnx.su

Ground Inspection
EBS011XV
PBIB1870E
EC-1410
http://vnx.su


Description
PFP:23710
A
EBS011XW
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many elec- EC
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
C
EBS011XX

DTC No.
Trouble diagnosis
name
U1000
1000
CAN communication
line
ECM can not communicate to other control

unit.
ECM can not communicate for more than the
specified time.
Possible cause
shorted)
EBS011XY
NOTE:
1. Turn ignition switch ON and wait at least 3 seconds.
2. Select DATA MONITOR mode with CONSULT-II.
K
SEF817Y
EC-1411
http://vnx.su

Wiring Diagram
EBS011XZ
TBWA0564E
EC-1412
http://vnx.su

EBS011Y0
EC
EC-1413
http://vnx.su


PFP:10328
EBS011Y1

DTC No.
P0016
0016
Trouble diagnosis
name
Crankshaft position camshaft position correlation
The correlation between crankshaft position sensor signal and camshaft position sensor signal is
out of the normal range.
Possible cause
Timing chain
Signal plate
EBS011Y2
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EBS011Y3

OK or NG
OK
>> GO TO 2.
NG
2. CHECK SPROCKET
OK or NG
OK
>> GO TO 3.
NG
>> Remove debris and clean the signal plate or replace sprocket.

OK or NG
OK
>> GO TO 4.
NG
EC-1414
http://vnx.su

4. CHECK GEAR TOOTH

OK or NG
OK
>> GO TO 5.
NG
5. CHECK TIMING CHAIN
EC
Refer to EM-190, "SECONDARY TIMING CHAIN" , EM-195, "PRIMARY TIMING CHAIN" and EM-160, "VACUUM PUMP" .
OK or NG
OK
>> GO TO 6.
NG
>> Replace timing chain.

>> INSPECTION END

G
EC-1415
http://vnx.su


DTC No.
P0088
0088
PFP:17520
EBS011Y4
Fuel rail pressure too high

Fuel pressure is too much higher than the specified value.
Possible cause
Fuel pump
Fuel injector

EBS011Y5
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.
5.

EBS011Y6

OK or NG
OK
>> GO TO 2.
NG

OK or NG
OK
>> GO TO 3.
NG
3. CHECK FUEL PUMP

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
EC-1416
http://vnx.su


1.
2.
Replace fuel pump.

EC
>> INSPECTION END

D
>> INSPECTION END
EBS011Y7
FUEL INJECTOR
FUEL PUMP

G
EC-1417
http://vnx.su
DTC P0089 FUEL PUMP

DTC P0089 FUEL PUMP

PFP:16700
EBS011Y8

DTC No.
P0089
0089
Fuel pump performance

value.
Possible cause
Fuel pump
Air mixed with fuel
Lack of fuel
EBS011Y9
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.
5.

EBS011YA

OK or NG
OK
>> GO TO 2.
NG
EC-1418
http://vnx.su
DTC P0089 FUEL PUMP

A
NOTE:
EC
With CONSULT-II
C
D
5. Touch ERASE.
7. Is DTC detected again?
E
Without CONSULT-II
2. Perform Fuel Pump Learning Value Clearing. Refer to EC-1357, "Fuel Pump Learning Value Clearing" .
F
4. Erase the Diagnostic Test Mode II (Self-diagnostic results) memory. Refer to EC-1362 .
G
Yes or No
H
Yes
>> GO TO 3.
No
>> INSPECTION END

OK or NG
OK
>> GO TO 4.
NG
4. CHECK FUEL PUMP

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

1.
2.
Replace Fuel pump.

>> INSPECTION END

>> INSPECTION END
EBS011YB
FUEL PUMP
EC-1419
http://vnx.su


DTC No.
P0093
0093
Fuel system leak
PFP:17520
EBS011YC
ECM detects a fuel system leak.

(The relation between the output voltage to the
fuel pump and input voltage from the fuel rail
pressure sensor is out of the normal range.)
Possible cause
Fuel pump
Fuel rail
Fuel pipe
Air mixed with fuel
Lack of fuel
EBS011YD
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

least 5 seconds.
SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.
Start engine and keep engine speed more than 4,000 rpm for at least 5 seconds.
EBS011YE

OK or NG
OK
>> GO TO 2.
NG
EC-1420
http://vnx.su

A
NOTE:
EC
With CONSULT-II
C
D
5. Touch ERASE.
E
Without CONSULT-II
F
G
Yes or No
H
Yes
>> GO TO 3.
No
>> INSPECTION END
3. CHECK FUEL LINE FOR LEAK
1.
2.
Start engine.
Visually check the following for fuel leak.
Fuel tube from fuel pump to fuel rail
Fuel rail
Fuel tube from fuel rail to fuel injector

3. Also check for improper connection or pinches.
OK or NG
OK
>> GO TO 4.
NG
>> Repair malfunctioning part.
4. CHECK FUEL RAIL PRESSURE RELIEF VALVE

OK or NG
OK
>> GO TO 5.
NG

OK or NG
OK
>> GO TO 6.
NG
EC-1421
http://vnx.su


1.
2.
Replace fuel pump.

>> INSPECTION END
EBS0123V
FUEL RAIL PRESSURE RELIEF VALVE

With CONSULT-II
WARNING:
PBIB1941E
5.
6.
7.
8.
Select PRES REGULATOR in ACTIVE TEST MODE with

CONSULT-II.
Start engine and keep engine speed 2,000 rpm.
Raise fuel pressure to 160 MPa with touching UP or Qu on
the CONSULT-II screen.
Confirm that the fuel does not come out from the fuel rail pressure relief valve.
WARNING:
PBIB0587E
Without CONSULT-II
WARNING:
4. Start engine and keep engine speed more than 4,000 rpm for at
least 5 seconds.
5. Confirm that the fuel does not come out from the fuel rail pressure relief valve.
WARNING:
EC-1422
http://vnx.su
PBIB1941E

EBS011YF
FUEL RAIL
FUEL PUMP
EC
EC-1423
http://vnx.su


PFP:22680
EBS011YG
the heat loss.
PBIB1604E
EBS011YH

MONITOR ITEM
CONDITION
No-load
MAS AIR/FL SE*
SPECIFICATION
Idle
1.5 - 2.0V
2,000 rpm
2.2 - 2.7V
This signal is converted by ECM internally. Thus, it differs from ECM terminal voltage.
EBS011YJ

DTC No.
P0102
0102

low input

sent to ECM.
P0103
0103

high input

sent to ECM.
Possible cause
shorted.)

EBS011YK
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-1424
http://vnx.su

Wiring Diagram
EBS011YL
EC
TBWA0565E
EC-1425
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
DATA
(DC Voltage)
CONDITION
[Engine is running]
54
Warm-up condition
Idle speed
1.8 - 2.3V
[Engine is running]
Warm-up condition
2.5 - 3.0V
67
Sensor ground
Approximately 0.3V
73

ground
Approximately 0.3V
EBS011YM

1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1426
http://vnx.su


1.
2.

EC
D
PBIB1891E
3.


F
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.
PBIB1168E


1.
2.
3.


OK or NG
OK
>> GO TO 5.
NG
EC-1427
http://vnx.su


1.
Diagram.

OK or NG
OK
>> GO TO 6.
NG

OK or NG
OK
>> GO TO 7.
NG

>> INSPECTION END
EBS011YN

1.
2.
3.

signal) and ground.
Condition
Voltage V
Approx. 0.7

1.8 - 2.3
2.5 - 3.0
4.
SEF865T
EBS011YO

EC-1428
http://vnx.su


PFP:22630
A
EBS011YP
the ECM.
EC
D
PBIB1604E
<Reference data>
Intake air
temperature C (F)
Voltage*
Resistance
25 (77)
2.4
1.800 - 2.200
80 (176)
0.8
0.283 - 0.359
CAUTION:
SEF012P
EBS011YQ

DTC No.
P0112
0112
Intake air temperature sensor circuit low input

sent to ECM.
P0113
0113
Intake air temperature sensor circuit high input

sent to ECM.
Possible cause
shorted.)

EBS011YR
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITHOUT CONSULT-II
1.
EC-1429
http://vnx.su

2.
3.
4.
EC-1430
http://vnx.su

Wiring Diagram
EBS011YS
EC
TBWA0587E
EC-1431
http://vnx.su

EBS011YT

1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1432
http://vnx.su


1.
2.

EC
D
PBIB1891E
3.


F
OK or NG
OK
>> GO TO 3.
NG
PBIB1169E
1.
2.
3.

Check harness continuity between MAF sensor terminal 6 and ECM terminal 74. Refer to Wiring Diagram.

OK or NG
OK
>> GO TO 4.
NG

OK or NG
OK
>> GO TO 5.
NG

>> INSPECTION END
EC-1433
http://vnx.su

EBS011YU

1.
2.

Resistance k
25 (77)
1.800 - 2.200
sensor).
PBIB1604E
SEF012P
EBS011YV

EC-1434
http://vnx.su


Description
PFP:22630
A
EBS011YW

EC
D
SEF594K
<Reference data>
Voltage* (V)
Resistance (k)
10 (14)
4.7
7.0 - 11.4
20 (68)
3.8
2.1 - 2.9
50 (122)
2.6
0.68 - 1.00
90 (194)
1.3
0.236 - 0.260
*: These data are reference values and measured between ECM terminal 51 (Engine
SEF012P
CAUTION:
EBS011YX

DTC No.
Possible cause
P0117
0117
Engine coolant temperature sensor circuit low

input

sent to ECM.
P0118
0118
Engine coolant temperature sensor circuit high

input
shorted.)

sent to ECM.
EBS011YY
NOTE:
WITH CONSULT-II
1.
EC-1435
http://vnx.su

2.
3.
4.

SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-1436
http://vnx.su

Wiring Diagram
EBS011YZ
EC
TBWA0566E
EC-1437
http://vnx.su

EBS011Z0

1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1438
http://vnx.su


1.
2.

EC
D
PBIB1892E
3.


F
OK or NG
OK
>> GO TO 3.
NG
PBIB0152E

1.
2.
3.

Check harness continuity between ECT sensor terminal 2 and ECM terminal 70. Refer to Wiring Diagram.

OK or NG
OK
>> GO TO 4.
NG

OK or NG
OK
>> GO TO 5.
NG

>> INSPECTION END
EC-1439
http://vnx.su

EBS011Z1

1.

PBIB2005E
<Reference data>
2.
Resistance k
20 (68)
2.1 - 2.9
50 (122)
0.68 - 1.00
90 (194)
0.236 - 0.260
SEF012P
EBS011Z2

Refer to EM-206, "CYLINDER HEAD" .
EC-1440
http://vnx.su


Description
PFP:18002
A
EBS011Z3

of the accelerator pedal assembly. The ECM uses the signal to
determine the amount of fuel to be injected.
EC
D
PBIB1741E
EBS011Z4

MONITOR ITEM
ACCEL POS SEN*
ACCEL SEN 2*
CONDITION
SPECIFICATION
Ignition switch: ON
(Engine stopped)
0.2 - 0.7V
3.9 - 4.9V
Ignition switch: ON
(Engine stopped)
0.1 - 0.4V
1.9 - 2.4V
EBS011Z6

DTC No.
P0122
0122


1 is sent to ECM.
P0123
0123

An excessively high voltage from the APP sensor

1 is sent to ECM.
I
Possible cause
shorted.)
WITH CONSULT-II
WITHOUT CONSULT-II
EC-1441
http://vnx.su

SEF817Y
1.
2.
3.
EBS011Z7
NOTE:
1.
2.
3.
4.

4.
EC-1442
http://vnx.su

Wiring Diagram
EBS011Z8
EC
TBWA0567E
EC-1443
http://vnx.su

CAUTION:
TERMINAL
NO.
82
WIRE
COLOR
B
ITEM
CONDITION
DATA
Approximately 5.3V
83

sensor 1
Engine stopped
0.5 - 1.0V
Engine stopped
4.2 - 5.2V
84

sensor 1 ground
Approximately 0.3V
85
Sensor ground
Approximately 0.3V
90

Approximately 5.3V
91
92

sensor 2

sensor 2 ground
Engine stopped
0.4 - 0.7V
Engine stopped
EC-1444
http://vnx.su
2.2 - 2.7V
Approximately 0.3V

EBS011Z9

1.
2.

EC
J
PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1445
http://vnx.su


1.
2.

connector.
PBIB1893E
3.

OK or NG
OK
>> GO TO 3.
NG
PBIB0914E

1.
2.
3.


OK or NG
OK
>> GO TO 4.
NG
1.

OK or NG
OK
>> GO TO 5.
NG
5. CHECK APP SENSOR

OK or NG
OK
>> GO TO 6.
NG
EC-1446
http://vnx.su


EC
>> INSPECTION END
EBS011ZA

1.
2.
3.
Terminal
Accelerator pedal
Voltage
83
sensor 1)
Fully released
0.5 - 1.0V
Fully depressed
4.2 - 5.2V
Fully released
0.4 - 0.7V
Fully depressed
2.2 - 2.7V
91
sensor 2)
4.

conditions.
MBIB0615E
EBS011ZB
ACCELERATOR PEDAL

I
EC-1447
http://vnx.su


Description
PFP:16700
EBS011ZC
Fuel pump temperature sensor is built in the fuel pump. The sensor detects the fuel temperature in the fuel
pump and calibrates the fuel injection amount change by fuel temperature.
EBS011ZD

MONITOR ITEM
FUEL TEMP SEN
CONDITION
SPECIFICATION
EBS011ZF

DTC No.
P0182
0182


sent to ECM.
P0183
0183


sent to ECM.
Possible cause
shorted.)

EBS011ZG
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.

If DTC is detected, go to EC-1450, "Diagnostic Procedure"
EC-1448
http://vnx.su

Wiring Diagram
EBS011ZH
EC
TBWA0572E
EC-1449
http://vnx.su

CAUTION:
TERMINAL
NO.
50
69
WIRE
COLOR
PU
ITEM

sensor
sensor ground
CONDITION
[Engine is running]
Warm-up condition
DATA
pump temperature
Approximately 0.3V
EBS011ZI

1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1450
http://vnx.su

2. CHECK FUEL PUMP TEMPERATURE SENSOR POWER SUPPLY CIRCUIT

1.
2.
Disconnect fuel pump temperature sensor harness connector.

EC
D
PBIB1942E
3.
Check voltage between fuel pump temperature sensor terminal


F
OK or NG
OK
>> GO TO 3.
NG
PBIB0420E
3. CHECK FUEL PUMP TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Check harness continuity between fuel pump temperature sensor terminal 2 and ECM terminal 69.

K

OK or NG
OK
>> GO TO 4.
NG

M

OK or NG
OK
>> GO TO 5.
NG

1.
2.
Replace fuel pump.

>> INSPECTION END
EBS011ZJ
FUEL PUMP
EC-1451
http://vnx.su


Description
PFP:16638
EBS011ZK
The fuel rail pressure (FRP) sensor is placed to the fuel rail. It measures the fuel pressure in the fuel rail. The
sensor sends voltage signal to the ECM. As the pressure increases, the voltage rises.
The ECM controls the fuel pressure in the fuel rail by the inlet throttling device. The ECM uses the signal from
fuel rail pressure sensor as a feedback signal.
EBS011ZL

MONITOR
CONDITION
No-load
ACT CR PRESS
SPECIFICATOIN
Idle
20 - 30 MPa
2,000 rpm
45 - 55 MPa
EBS011ZN

DTC No.
P0192
0192

circuit low input

sent to ECM.
P0193
0193
Fuel rail temperature sensor circuit high input

sent to ECM.
Possible cause
shorted.)
Fuel rail temperature sensor

EBS011ZO
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-1452
http://vnx.su

Wiring Diagram
EBS011ZP
EC
TBWA0568E
EC-1453
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA
[Engine is running]
48
49
Y/R
R
Warm-up condition
Idle speed
1.7 - 2.0V
[Engine is running]
Warm-up condition
2.0 - 2.3V
63

power supply
Approximately 5.3V
67
Sensor ground
Approximately 0.3V
68

ground
Approximately 0.3V
EBS011ZQ
1. CHECK GROUND CONNECTION

1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1454
http://vnx.su

2. CHECK FUEL RAIL PRESSURE SENSOR POWER SUPPLY CIRCUIT

1.
2.
Disconnect fuel rail pressure sensor harness connector.

EC
D
PBIB1894E
3.
Check voltage between fuel rail pressure sensor terminal 1 and


F
OK or NG
OK
>> GO TO 3.
NG
PBIB0405E
3. CHECK FUEL RAIL PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Check harness continuity between fuel rail pressure sensor terminal 3 and ECM terminal 68.

OK or NG
OK
>> GO TO 4.
NG
4. CHECK FUEL RAIL PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
Check harness continuity between ECM terminals 48, 49 and fuel rail pressure sensor terminal 2.

OK or NG
OK
>> GO TO 4.
NG

OK or NG
OK
>> GO TO 6.
NG
EC-1455
http://vnx.su


>> INSPECTION END
EBS011ZR
FUEL RAIL PRESSURE SENSOR

1.
2.
3.
Reconnect harness connector disconnected.

Check voltage between ECM terminals 48, 49 (Fuel rail pressure sensor signal) and ground under the following conditions.
Condition
Voltage V
Idle
1.7 - 2.0
2,000 rpm
2.0 - 2.3
4.
5.
If the voltage is out of specification, disconnect fuel rail pressure

sensor harness connector and connect it again. Then repeat
above check.
If NG, replace fuel rail.
MBIB0613E
EBS011ZS
FUEL RAIL
EC-1456
http://vnx.su


DTC No.
P0200
0200

circuit
PFP:16600
A
EBS011ZT

ECM detects a voltage of power source for the
fuel injector is excessively high or low.
Possible cause
EC
ECM
EBS011ZU
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

H
SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.

J
EBS011ZV
1. INSPECTION START
1.
2.
3.
4.
5.
With CONSULT-II
Touch ERASE.
Is DTC P0200 displayed again?
Without CONSULT-II
4. Is DTC 0200 displayed again?
Yes or No
Yes
>> GO TO 2.
No
>> INSPECTION END
EC-1457
http://vnx.su

2. REPLACE ECM
1.
2.
3.
Replace ECM.
>> INSPECTION END
EC-1458
http://vnx.su


PFP:16600
A
EBS011ZW
needs.
EC
D
PBIB0465E
EBS011ZX

MONITOR ITEM
MAIN INJ WID
CONDITION
SPECIFICATION
No-load
0.68 - 0.78 msec
Idle speed

0.78 - 0.88 msec
G
EBS011ZZ

DTC No.
Possible cause
P0201
0201

circuit open

P0202
0202

circuit open

P0203
0203

circuit open

Fuel injector
P0204
0204

circuit open

EC-1459
http://vnx.su

EBS01200
NOTE:
TESTING CONDITION
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-1460
http://vnx.su

Wiring Diagram
EBS01201
EC
TBWA0569E
EC-1461
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
[Engine is running]
W/B
G/B

Warm-up condition
Idle speed
DATA
5 - 10V
NOTE:
idle.
MBIB0883E
5 - 10V
[Engine is running]
Warm-up condition
MBIB0884E
[Engine is running]
21
22
23
24
G/R
GY/L
G/R
GY/L
Fuel injector No. 2

Fuel injector No. 2
Fuel injector No. 3
Fuel injector No. 3
Warm-up condition
Idle speed
0 - 9V
NOTE:
idle.
MBIB0881E
0 - 9V
[Engine is running]
Warm-up condition
MBIB0882E
[Engine is running]
40
41
42
43
G/R
GY/L
G/R
GY/L
Fuel injector No. 4

Fuel injector No. 4
Fuel injector No. 1
Fuel injector No. 1
Warm-up condition
Idle speed
0 - 9V
NOTE:
idle.
MBIB0881E
0 - 9V
[Engine is running]
Warm-up condition
MBIB0882E
EC-1462
http://vnx.su

EBS01202
1. CHECK FUEL INJECTOR POWER SUPPLY FOR OPEN AND SHORT CIRCUIT
1.
2.
3.
4.

Terminal
DTC
EC
Cylinder
ECM
Fuel injector
P0201
No.1
P0202
No.2
P0203
No.3
P0204
No.4
PBIB1896E

OK or NG
OK
>> GO TO 2.
NG
2. CHECK FUEL INJECOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
Terminal
DTC
Cylinder
ECM
Fuel injector
P0201
42, 43
No.1
P0202
21, 22
No.2
P0203
23, 24
No.3
P0204
40, 41
No.4

OK or NG
OK
>> GO TO 3.
NG

OK or NG
OK
>> GO TO 4.
NG
EC-1463
http://vnx.su


1.
2.
3.
4.
5.
6.
7.
8.
With CONSULT-II
Touch ERASE.
Perform DTC Confirmation Procedure, EC-1460, "DTC Confirmation Procedure" .
Without CONSULT-II
6. Perform DTC Confirmation Procedure, EC-1460, "DTC Confirmation Procedure" .
Yes or No
OK
>> Replace fuel injector or malfunctioning cylinder.
NG
>> GO TO 5.

>> INSPECTION END
EBS01203
FUEL INJECTOR
1.
2.

3.
PBIB0406E
EBS01204
FUEL INJECTOR
EC-1464
http://vnx.su


System Description
PFP:21481
A
EBS01205
COOLING FAN CONTROL

Sensor
Input signal to ECM
Vehicle speed
ECM function
Cooling fan
control
Actuator
EC
Cooling fan relay
*: These signals are sent to the ECM through CAN communication line.
The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, air conditioner ON signal. The control system has 3-step control [HIGH/LOW/OFF].
OPERATION
E
SEF421Z
EBS01206

MONITOR ITEM
COOLING FAN
I
CONDITION
SPECIFICATION
OFF
LOW
HI

DTC No.
P0217
0217
Engine over temperature

(Overheat)
EBS01208
Possible cause
shorted.)
Cooling fan
Cooling fan system does not operate properly

(Overheat).
Radiator hose
Radiator

Radiator cap
Water pump
Thermostat

range.

EC-1465
http://vnx.su

EBS01209
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could be caused by high
pressure fluid escaping from the radiator.
Wrap a thick cloth around cap. Carefully remove the cap by turning it a quarter turn to allow builtup pressure to escape. Then turn the cap all the way off.
WITH CONSULT-II
1.
2.
3.

SEF621W
4.
5.

SEF111X
WITHOUT CONSULT-II
1.
2.
3.
4.
5.
6.
7.

Start engine.
Set temperature control lever to full cold position.
Run engine at idle for a few minutes with air conditioner operating.
EC-1466
http://vnx.su
SEF621W

8.
Make sure that cooling fans operates at low speed.

harness connector.
EC
C
SEC163BA
G
MEC475B
EC-1467
http://vnx.su

Wiring Diagram
EBS0120A
TBWA0573E
EC-1468
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA
[Engine is running]
34
LG/B
[Engine is running]
EC
BATTERY VOLTAGE
(11 - 14V)
D
Approximately 0.1V
[Engine is running]
36
LG
[Engine is running]
BATTERY VOLTAGE
(11 - 14V)
Approximately 0.1V
F
EBS0120B
With CONSULT-II
1. Disconnect cooling fan relays -2 and -3.
K
PBIB1935E
2.
3.

Perform COOLING FAN in ACTIVE TEST mode with CONSULT-II and touch LOW on the CONSULT-II screen.
OK or NG
OK
>> GO TO 2.
NG
SEF784Z
EC-1469
http://vnx.su


With CONSULT-II
2. Reconnect cooling fan relays-2 and -3.
4. Touch HIGHon the CONSULT-II screen.
5. Make sure that cooling fans-1 and -2 operate at higher speed
than low speed.
OK or NG
OK
>> GO TO 3.
NG
SEF785Z

CAUTION:
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
SLC754A

Hose
Radiator

EC-1470
http://vnx.su

pressure.
EC
Radiator cap relief pressure:

59 - 98 kPa (0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2 , 9 - 14 psi)
OK or NG
OK
>> GO TO 6.
NG
D
SLC755A
6. CHECK THERMOSTAT
1.
2.
3.
Remove thermostat.
Valve opening temperature:

80 - 84 C (176 - 183 F)
Valve lift:
More than 10 mm/95 C (0.39 in/203 F)
Check if valve is closed at 5C (9F) below valve opening temperature. For details, refer to CO-45, "THERMOSTAT AND
WATER PIPING" .
OK or NG
OK
>> GO TO 7.
NG
4.

OK or NG
OK
>> GO TO 8.
NG
I
SLC343

>> INSPECTION END
EC-1471
http://vnx.su

PROCEDURE A

1.
2.
3.

PBIB1935E
4.

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
PBIB0422E

10A fuse
40A fusible links
EC-1472
http://vnx.su

3. CHECK COOLING FAN GROUND CIRCUIT FOR OPEN AND SHORT

1.
2.
3.

EC
D
PBIB1895E

OK or NG
OK
>> GO TO 4.
NG
1.
2.


OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.


OK or NG
OK
>> GO TO 7.
NG

OK or NG
OK
>> GO TO 8.
NG
EC-1473
http://vnx.su


>> INSPECTION END
PROCEDURE B
1. CHECK COOLING FAN RELAYS-2 AND -3 POWER SUPPLY CIRCUIT

1.
2.
3.

Disconnect cooling fan relay-2 and -3.
PBIB1935E
4.
Check voltage between cooling fan relays-2, -3 terminals 1, 3

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
PBIB0251E

10A fuse
40A fusible links
Harness for open or short between cooling fan relays-2, -3 and fuse
Harness for open or short between cooling fan relays-2, -3 and battery
EC-1474
http://vnx.su

3. CHECK COOLING FAN RELAY GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Cooling fan relay-2 terminal 7 and ground.
EC

4.
5.

Cooling fan relay-3 terminal 7 and ground
PBIB1895E

OK or NG
OK
>> GO TO 4.
NG
1.
2.

Check harness continuity between cooling fan relay-2 terminal 2 and ECM terminal 34, cooling fan relay-3
terminal 2 and ECM terminal 34.

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

M
6. CHECK COOLING FAN RELAYS-2 AND -3

OK or NG
OK
>> GO TO 7.
NG
EC-1475
http://vnx.su


OK or NG
OK
>> GO TO 7.
NG

>> INSPECTION END

Engine
Step
OFF
Inspection item
Blocked radiator
Blocked condenser
Blocked bumper
EBS0120C
Equipment
Standard
Reference page
Visual
No blocking
Coolant mixture
Coolant tester
See MA-19, "Engine

Coolant Mixture Ratio" .
Coolant level
Visual

See CO-32, "LEVEL

CHECK" .
Radiator cap
Pressure tester
59 - 98 kPa
(0.59 - 0.98 bar, 0.6 - 1.0
See MA-33, "CHECKING

RADIATOR CAP" .

ON*2
Coolant leaks
Visual
No leaks
See CO-32, "CHECKING

RADIATOR SYSTEM
FOR LEAKS" .
ON*2
Thermostat
Touch the upper and

See CO-45, "THERMOSTAT AND WATER PIPING" , and CO-35,

"RADIATOR" .
ON*1
Cooling fan
CONSULT-II
Operating

DTC P0217 (EC-1465 ).
OFF
Combustion gas leak

Negative
ON*3
Coolant temperature
gauge
Visual
Gauge less than 3/4

when driving
Coolant overflow to
reservoir tank
Visual

and idling
See MA-30, "Changing

Engine Coolant" .
OFF*4
10
Coolant return from

Visual

reservoir tank
See CO-32, "LEVEL

CHECK" .
OFF
11
Cylinder head

gauge
SeeEM-206, "CYLINDER HEAD" .
12
Visual
walls or piston
See EM-223, "CYLINDER BLOCK" .

EC-1476
http://vnx.su

EBS0120D
COOLING FAN RELAY-1, -2 AND -3

Conditions
Continuity
Yes
No current supply
No
EC
If NG, replace relay.
D
SEF745U
COOLING FAN MOTORS-1 AND -2

1.
2.
Disconnect cooling fan motor harness connectors.

check operation.
Terminals
Speed
Cooling fan motor
(+)
(-)
Low
High
1, 2
3, 4
Cooling fan motor should operate.

If NG, replace cooling fan motor.
SEF734W
EC-1477
http://vnx.su


Description
PFP:18002
EBS0120E

PBIB1741E
EBS0120F

MONITOR ITEM
ACCEL POS SEN*
ACCEL SEN 2*
CONDITION
SPECIFICATION
Ignition switch: ON
(Engine stopped)
0.2 - 0.7V
3.9 - 4.9V
Ignition switch: ON
(Engine stopped)
0.1 - 0.4V
1.9 - 2.4V
EBS0120H

DTC No.
P0222
0222


2 is sent to ECM.
P0223
0223

An excessively high voltage from the APP sensor 2 is sent to ECM.
Possible cause
shorted.)

EBS0120I
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITHOUT CONSULT-II
1.
2.
3.

EC-1478
http://vnx.su

4.

A
EC
EC-1479
http://vnx.su

Wiring Diagram
EBS0120J
TBWA0729E
EC-1480
http://vnx.su

CAUTION:
TERMINAL
NO.
82
WIRE
COLOR
B
ITEM
CONDITION
DATA
EC
Approximately 5.3V
0.5 - 1.0V
4.2 - 5.2V
83

sensor 1
Engine stopped
Engine stopped
84

sensor 1 ground
Approximately 0.3V
85
Sensor ground
Approximately 0.3V

90
G
Approximately 5.3V
91
92

sensor 2

sensor 2 ground
Engine stopped
0.4 - 0.7V
Engine stopped
2.2 - 2.7V
J
Approximately 0.3V
EC-1481
http://vnx.su

EBS0120K
1. CHCEK GROUND CONNECTIONS

1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1482
http://vnx.su


1.
2.

connector.
EC
D
PBIB1893E
3.


F
OK or NG
OK
>> GO TO 3.
NG
PBIB0915E

1.
2.
3.


OK or NG
OK
>> GO TO 4.
NG
1.

OK or NG
OK
>> GO TO 5.
NG
5. CHECK APP SENSOR

OK or NG
OK
>> GO TO 6.
NG
EC-1483
http://vnx.su


>> INSPECTION END
EBS0120L

1.
2.
3.

conditions.
Terminal
Accelerator pedal
Voltage
83
sensor 1)
Fully released
0.5 - 1.0V
Fully depressed
4.2 - 5.3V
Fully released
0.4 - 0.7V
Fully depressed
2.2 - 2.7V
91
sensor 2)
4.
MBIB0615E
EBS0120M
ACCELERATOR PEDAL
EC-1484
http://vnx.su
DTC P0234 TC SYSTEM

DTC P0234 TC SYSTEM

Description
PFP:14411
A
EBS0120N
The load from the turbocharger boost control solenoid valve controls
the actuator. By changing the variable nozzle vane opening through
the rods, the intake air volume is adjusted.
EC
D
MBIB0626E

H
PBIB1897E
EBS0120P

DTC No.
P0234
0234
Turbocharger overboost
condition
ECM detects turbocharger boost pressure

is excessively high.
Possible cause
Turbocharger
Vacuum pump
Turbocharger boost control solenoid valve
EBS0120Q
Use this procedure to check the overall function of the turbocharger. During this check, a DTC might not be
confirmed.
2. Make sure that turbocharger control actuator rod moves slightly
PBIB1936E
EC-1485
http://vnx.su
DTC P0234 TC SYSTEM

Wiring Diagram
EBS0120R
TBWA0588E
EC-1486
http://vnx.su
DTC P0234 TC SYSTEM

A
CAUTION:
EC
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA
C
Warm-up condition
Idle speed
0 - 12.5V
NOTE:
idle.
6
E
MBIB0889E

solenoid valve
0 - 12.5V
F
Warm-up condition
G
MBIB0890E
H
EBS0120S
1. CHECK VACUUM SOURCE

1.
2.
3.
4.

Disconnect vacuum hose connected to turbocharger control actuator.
Check vacuum hose for vacuum existence.
Vacuum should exist.

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 2.
PBIB1937E
EC-1487
http://vnx.su
DTC P0234 TC SYSTEM

2. CHECK VACUUM HOSES AND VACUUM GALLERY

1.
2.

Check vacuum hoses and vacuum gallery for clogging, cracks or improper connection.
Refer to EC-1349, "Vacuum Hose Drawing" .
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace vacuum hoses and vacuum gallery.
SEF109L

1.
2.

connector.
PBIB1897E
3.

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
PBIB1945E

Harness for open or short between turbocharger boost control solenoid valve and ECM relay
Harness for open or short between turbocharger boost control solenoid valve and ECM
EC-1488
http://vnx.su
DTC P0234 TC SYSTEM

OPEN AND SHORT
1.
2.
3.

EC
Check harness continuity between ECM terminals 6 and turbocharger boost control solenoid valve terminals 2.
C

OK or NG
OK
>> GO TO 6.
NG
6. CHECK TURBOCHARGE BOOST CONTROL SOLENOID VALVE

F

OK or NG
OK
>> GO TO 7.
NG
7. CHECK VACUUM PUMP

H

OK or NG
OK
>> GO TO 8.
NG
>> Replace vacuum pump assembly.
8. CHECK TURBOCHARGER BOOST CONTROL ACTUATOR
1.
2.
3.

Install a vacuum pump to turbocharger boost control actuator.
Make sure that the turbocharger boost control actuator rod
moves smoothly when applying vacuum of -53.3kPa (-533mbar,
-400mmHg, -15.75inHg) and releasing it.
OK or NG
OK
>> GO TO 9.
NG
>> Replace turbocharger assembly.
MBIB1022E

OK or NG
OK
>> GO TO 10.
NG

>> INSPECTION END
EC-1489
http://vnx.su
DTC P0234 TC SYSTEM

EBS0120T

1.
2.

connector.
PBIB1897E
3.
CONDITIONS

between A and B

between A and C

Yes
No
No supply
No
Yes
EC-1490
http://vnx.su
MBIB0996E


PFP:22365
A
EBS0120U
The turbocharger boost sensor detects pressure in the exit side of

the charge air cooler. The sensor output voltage to the ECM
increases as pressure increases.
EC
D
MBIB0614E
H
MBIB0899E
EBS0120V

MONITOR ITEM
CONDITION
SPECIFICATION
Idle
Approx. 100 kPa
2,800 rpm
Approx. 126 kPa
No-load
4,000 rpm
Approx. 106 kPa
INT/M PRES SE [kPa]
EBS0120X

DTC No.
P0237
0237

circuit low input

sent to ECM.
P0238
0238

circuit high input

sent to ECM.
Possible cause
shorted.)
EBS0120Y
NOTE:
WITH CONSULT-II
1.
EC-1491
http://vnx.su

2.
3.
4.

SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-1492
http://vnx.su

Wiring Diagram
EBS0120Z
EC
TBWA0589E
EC-1493
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
DATA
(DC Voltage)
CONDITION
[Engine is running]
52
Warm-up condition
Idle speed
2.3 - 2.6V
[Engine is running]
Warm-up condition
2.5 - 2.8V
64

power supply
Approximately 5.3V
71

ground
Approximately 0.3V
EBS01210

1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1494
http://vnx.su

2. CHECK TURBOCHARGER BOOST SENSOR POWER SUPPLY CIRCUIT

1.
2.
Disconnect turbocharge boost sensor harness connector.

EC
D
PBIB1898E
3.
Check voltage between turbocharge boost sensor terminal 1


F
OK or NG
OK
>> GO TO 3.
NG
MBIB0072E
3. CHECK TURBOCHAGER BOOST SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Check harness continuity between turbocharger boost sensor terminal 3 and ECM terminal 71.

OK or NG
OK
>> GO TO 4.
NG
4. CHECK TURBOCHAGER BOOST SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
Check harness continuity between ECM terminals 52 and turbocharger boost sensor terminal 2. Refer to
Wiring Diagram.

OK or NG
OK
>> GO TO 5.
NG

OK or NG
OK
>> GO TO 6.
NG
EC-1495
http://vnx.su


>> INSPECTION END
EBS01211
CHECK TURBOCHARGER BOOST SENSOR

1.
2.
3.
4.
Remove turbocharger boost sensor with its harness connected.

Use pump to apply pressure sensor as shown in the figure.
CAUTION:
Always calibrate the pressure pump gauge when using it.
Inspection should be done at room temperature [10-30C (50-86F)].
Check the output voltage between turbocharger boost sensor terminal 2 and ground.
Pressure (Relative to atmospheric pressure)
Voltage V
0 kPa (0 mbar, 0 mmHg, 0 inHg)
Approximately 2.3V
+40 kPa (400 mbar, 300mmHg, 11.81 inHg)
Approximately 2.9V
MBIB0925E
EBS01212
TURBOCHARGER BOOST SENSOR

Refer to EM-141, "CHARGE AIR COOLER" .
EC-1496
http://vnx.su


Description
PFP:23731
A
EBS01213

EC
D
MBIB0619E
EBS01214

MONITOR ITEM
CKPS-RPM (TDC)
CONDITION

indication.


DTC No.
P0335
0335

SPECIFICATION
EBS01216
Possible cause
shorted.)
Crankshaft position sensor signal is not detect

by the ECM when engine is running.
I
EBS01217
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

for 5 seconds.
SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.

If engine could not start, keep ignition switch at START position for 5 seconds.
EC-1497
http://vnx.su

Wiring Diagram
EBS01218
TBWA0570E
EC-1498
http://vnx.su

A
CAUTION:
EC
TERMINAL
NO.
44
WIRE
COLOR
ITEM
CONDITION
DATA
C
L/W
[Engine is running]
Warm-up condition
Idle speed
Approximately 5.3V
0 - 6V
NOTE:
idle.
MBIB0879E
46
0 - 6V
[Engine is running]
Warm-up condition
H
MBIB0880E
65
L/R
67
Sensor ground
Approximately 0.3V
Approximately 0.3V
J
EC-1499
http://vnx.su

EBS01219

1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1500
http://vnx.su


1.
2.

EC
D
PBIB1889E
3.

OK or NG
OK
>> GO TO 3.
NG
PBIB0405E

1.
2.
3.


OK or NG
OK
>> GO TO 4.
NG
1.

OK or NG
OK
>> GO TO 5.
NG

OK or NG
OK
>> GO TO 6.
NG
EC-1501
http://vnx.su


>> INSPECTION END
EBS0121A

1.
2.
3.
4.

Remove the sensor.
MBIB0864E
5.
6.

1 (+) - 2 (-)
Except 0
1 (+) - 3 (-)
Except 0 or
2 (+) - 3 (-)
Except 0
MBIB1009E
EBS0121B

EC-1502
http://vnx.su


Description
PFP:23731
A
EBS0121C

EC
D
MBIB0619E
EBS0121D

MONITOR ITEM
CKPSRPM (TDC)
CONDITION
SPECIFICATION


DTC No.
P0336
0336
Crankshaft position sensor circuit range/performance
EBS0121F
Crankshaft position sensor signal is not in the

normal pattern when engine is running.
Possible cause
shorted.)
Signal plate
EBS0121G
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

for 5 seconds.
SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-1503
http://vnx.su

Wiring Diagram
EBS0121H
TBWA0570E
EC-1504
http://vnx.su

A
CAUTION:
EC
TERMINAL
NO.
44
WIRE
COLOR
ITEM
CONDITION
DATA
C
L/W
[Engine is running]
Warm-up condition
Idle speed
Approximately 5.3V
0 - 6V
NOTE:
idle.
MBIB0879E
46
0 - 6V
[Engine is running]
Warm-up condition
H
MBIB0880E
65
L/R
67
Sensor ground
Approximately 0.3V
Approximately 0.3V
J
EC-1505
http://vnx.su

EBS0121I

1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1506
http://vnx.su


1.
2.

EC
D
PBIB1889E
3.


OK or NG
OK
>> GO TO 3.
NG
PBIB0405E

1.
2.
3.


OK or NG
OK
>> GO TO 4.
NG
1.

OK or NG
OK
>> GO TO 5.
NG

OK or NG
OK
>> GO TO 6.
NG
EC-1507
http://vnx.su

6. CHECK GEAR TOOTH

OK or NG
OK
>> GO TO 7.
NG

>> INSPECTION END
EBS0121J

1.
2.
3.
4.

Remove the sensor.
MBIB0864E
5.
6.

1 (+) - 2 (-)
Except 0
1 (+) - 3 (-)
Except 0 or
2 (+) - 3 (-)
Except 0
MBIB1009E
EBS0121K

EC-1508
http://vnx.su


Description
PFP:23731
A
EBS0121L

EC
D
MBIB0618E

DTC No.
P0340
0340

circuit
EBS0121N
Possible cause
shorted.)
Camshaft position sensor signal is not detect by

the ECM when engine is running.
EBS0121O
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

for 5 seconds.
SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-1509
http://vnx.su

Wiring Diagram
EBS0121P
TBWA0571E
EC-1510
http://vnx.su

A
CAUTION:
EC
TERMINAL
NO.
45
WIRE
COLOR
ITEM
CONDITION
DATA
C
G/OR

power supply
[Engine is running]
Warm-up condition
Idle speed
Approximately 5.3V
0 - 6V
NOTE:
idle.
MBIB0877E
47
G/R
0 - 6V
[Engine is running]
Warm-up condition
H
MBIB0878E
66
G/Y

ground
67
Sensor ground
Approximately 0.3V
Approximately 0.3V
J
EBS0121Q

L

Yes or No
Yes
>> GO TO 2.
No
EC-1511
http://vnx.su


1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 3.
NG
EC-1512
http://vnx.su


1.
2.

EC
D
PBIB1890E
3.

OK or NG
OK
>> GO TO 4.
NG
MBIB1010E

1.
2.
3.


OK or NG
OK
>> GO TO 5.
NG
1.

OK or NG
OK
>> GO TO 6.
NG

OK or NG
OK
>> GO TO 7.
NG
EC-1513
http://vnx.su


>> INSPECTION END
EBS0121R

1.
2.
3.
4.

Remove the sensor.
MBIB0647E
5.

1 (+) - 2 (-)
Except 0
1 (+) - 3 (-)
2 (+) - 3 (-)
6.
Except 0 or
MBIB1009E
EBS0121S

EC-1514
http://vnx.su


Description
PFP:23731
A
EBS0121T

EC
D
MBIB0618E

DTC No.
P0341
0341

EBS0121V
Camshaft position sensor signal is not in the normal pattern when engine is running.
Possible cause
Harness connectors
(The sensor circuit is opener
shorted.)
Signal plate
EBS0121W
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

for 5 seconds.
SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-1515
http://vnx.su

Wiring Diagram
EBS0121X
TBWA0571E
EC-1516
http://vnx.su

A
CAUTION:
EC
TERMINAL
NO.
45
WIRE
COLOR
ITEM
CONDITION
DATA
C
G/OR

power supply
[Engine is running]
Warm-up condition
Idle speed
Approximately 5.3V
0 - 6V
NOTE:
idle.
MBIB0877E
47
G/R
0 - 6V
[Engine is running]
Warm-up condition
H
MBIB0878E
66
G/Y

ground
67
Sensor ground
Approximately 0.3V
Approximately 0.3V
J
EBS0121Y

L

Yes or No
Yes
>> GO TO 2.
No
EC-1517
http://vnx.su


1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 3.
NG
EC-1518
http://vnx.su


1.
2.

EC
D
PBIB1890E
3.

OK or NG
OK
>> GO TO 4.
NG
MBIB1010E

1.
2.
3.


OK or NG
OK
>> GO TO 5.
NG
1.

OK or NG
OK
>> GO TO 6.
NG

OK or NG
OK
>> GO TO 7.
NG
EC-1519
http://vnx.su

7. CHECK CAMSHAFT (EXHAUST)


OK or NG
OK
>> GO TO 8.
NG
MBIB0990E

>> INSPECTION END
EC-1520
http://vnx.su

EBS0121Z

1.
2.
3.
4.

Remove the sensor.
EC
E
MBIB0647E
5.

1 (+) - 2 (-)
Except 0
1 (+) - 3 (-)
2 (+) - 3 (-)
6.
Except 0 or

I
MBIB1009E
EBS01220

K
EC-1521
http://vnx.su


PFP:24810
EBS01FDA
meter. The ECM uses this signal for ASCD control. Refer to EC-1673, "AUTOMATIC SPEED CONTROL
EBS01FDB

NOTE:
DTC No.
P0501
0501
Trouble Diagnosis
Name
Vehicle speed sensor range/performance
A change of vehicle speed signal is excessively large during specified time.
Possible Cause
shorted.)
Combination meter

Wheel sensor
ECM
EBS01FDC
CAUTION:
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.

seconds.
MBIB1085E
SEF058Y
EC-1522
http://vnx.su

WITHOUT CONSULT-II
A
TESTING CONDITION:
EC
1. Start engine (ESP switch OFF).
2. Drive the vehicle at more than 10 km/h (6 MPH).
3. Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
C
4. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
EBS01FDD

without ESP).
OK or NG
OK
>> GO TO 2.
NG

>> INSPECTION END

I
EC-1523
http://vnx.su


PFP:24810
EBS01FDE
EBS01FDF

NOTE:
DTC No.
P0502
0502
Trouble Diagnosis
Name
Vehicle speed sensor circuit low input
Vehicle speed signal is excessively low compared with the driving condition.
Possible Cause
shorted.)
Combination meter

Wheel sensor
ECM
EBS01FDG
CAUTION:
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
Start engine and warm it up to normal operating temperature (ESP switch OFF).
Maintain the following condition for at least 5 seconds.
CKPSRPM (TDC)
More than 2,800 rpm
COOLAN TEMP/S
More than 60C (140 F)
Clutch pedal
Released
Shift lever
1st position
4.

MBIB1084E
EC-1524
http://vnx.su

WITHOUT CONSULT-II
A
TESTING CONDITION:
EC
1. Start engine and warm it up to normal operating temperature (ESP switch OFF).
2. Maintain the following condition for at least 5 seconds.
Engine speed
More than 2,800 rpm
Clutch pedal
Released
Shift lever
1st position
3.
4.
5.
E
EBS01FDH
without ESP).
OK or NG
OK
>> GO TO 2.
NG

>> INSPECTION END
EC-1525
http://vnx.su


PFP:24810
EBS01FDI
EBS01FDJ

NOTE:
DTC No.
P0503
0503
Trouble Diagnosis
Name
Vehicle speed sensor circuit high input
Vehicle speed signal is excessively high compared with the driving condition.
Possible Cause
shorted.)
Combination meter

Wheel sensor
ECM
EBS01FDK
CAUTION:
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
4.

seconds.
MBIB1085E
SEF058Y
EC-1526
http://vnx.su

WITHOUT CONSULT-II
A
TESTING CONDITION:
EC
1. Start engine.
2. Drive the vehicle at more than 10 km/h (6 MPH).
3. Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
C
4. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
EBS01FDL

Refer to BRC-58, "TROUBLE DIAGNOSIS" (models with ESP system) or BRC-11, "TROUBLE DIAGNOSIS"
(models without ESP system).
OK or NG
OK
>> GO TO 2.
NG

>> INSPECTION END

I
EC-1527
http://vnx.su


PFP:25320
EBS01FDM
When the brake pedal is depressed, ASCD brake switch (1) and
stop lamp switch (2) are turned ON. ECM detects the state of the
brake pedal by this input of two kinds (ON/OFF signal).
PBIB2882E
EBS01FDN

MONITOR ITEM
BRAKE SW
CONDITION
BRAKE SW2
Ignition switch: ON
Ignition switch: ON
SPECIFICATION
OFF

depressed
ON

Fully released
OFF

ON
EBS01FDO
MI will not light up for this diagnosis.

DTC No.
Trouble Diagnosis
Name
P0504
0504
ASCD brake switch
When the vehicle speed is above 5 km/h (3

MPH), ON signal from the stop lamp switch
and OFF signal from the ASCD brake
switch are sent to the ECM at the same
time.
EC-1528
http://vnx.su
Possible Cause
(The stop lamp switch circuit is open or
shorted.)
(The ASCD brake switch circuit is open or
shorted.)
(The ASCD clutch switch circuit is open or
shorted.)
Stop lamp switch
ASCD brake switch
ASCD clutch switch
ECM

DTC confirmation Procedure
EBS01FDP
A
CAUTION:
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at EC
TESTING CONDITION:
Steps 3 and 4 may be conducted with the drive wheels lifted in the shop or by driving the vehicle. If a C
WITH CONSULT-II
1.
2.
3.
VHCL SPEED SE
Selector lever
Suitable position
4.

If DTC is not detected, go to the following step.
VHCL SPEED SE
Selector lever
Suitable position
Driving location

the above-mentioned condition.
5.

G
MBIB1085E

J
EBS01FEH
Use this procedure to check the overall function of the ASCD brake switch circuit. During this check, a DTC
might not be confirmed.
WITHOUT CONSULT-II
1.
2.

Check voltage between ECM terminal 101 (ASCD brake switch
CONDITION
VOLTAGE

3.
Battery voltage
Approximately 0V

PBIB1677E
EC-1529
http://vnx.su

4.
Check voltage between ECM terminal 100 (Stop lamp switch

CONDITION

5.
VOLTAGE
Approximately 0V
Battery voltage
MBIB1097E
EC-1530
http://vnx.su

Wiring Diagram
EBS01FDQ
EC
TBWB0477E
EC-1531
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
100
Stop lamp switch
101
GY/L
ASCD brake switch
DATA (DC Voltage)
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
BATTERY VOLTAGE
(11 - 14V)

depressed
Approximately 0V
EBS01FDR

With CONSULT-II
1.
2.
CONDITION
INDICATION
ON
OFF
PBIB0472E
Without CONSULT-II
Condition
Voltage
battery voltage
Approximately 0V
OK or NG
OK
>> GO TO 2.
NG
>> GO TO 3.
MBIB1097E
EC-1532
http://vnx.su

With CONSULT-II
EC
CONDITION
INDICATION
ON
OFF
SEC013D
1.
2.
Without CONSULT-II
G
Condition
Voltage
Approximately 0V
Battery voltage
I
PBIB1677E
OK or NG
OK
>> GO TO 14.
NG
>> GO TO 7.
EC-1533
http://vnx.su


1.
2.

PBIB2878E
3.

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
PBIB0117E

15A fuse
1.
2.


OK or NG
OK
>> GO TO 6.
NG

OK or NG
OK
>> GO TO 14.
NG
EC-1534
http://vnx.su


1.
2.
3.

EC
D
PBIB2878E
4.

F

OK or NG
OK
>> GO TO 12.
NG
>> GO TO 8.
H
PBIB0857E
1.
2.

PBIB2878E
3.
4.

OK or NG
OK
>> GO TO 10.
NG
>> GO TO 9.
PBIB0799E
EC-1535
http://vnx.su


10A fuse
1.
2.


OK or NG
OK
>> GO TO 11.
NG

OK or NG
OK
>> GO TO 14.
NG
1.
2.
3.


OK or NG
OK
>> GO TO 13.
NG

OK or NG
OK
>> GO TO 14.
NG

>> INSPECTION END
EBS01FDS
ASCD BRAKE SWITCH

1.
EC-1536
http://vnx.su

2.
3.

Condition

Continuity
EC
Should exist.
Should not exist.

SEC023D
ASCD CLUTCH SWITCH

1.
2.
3.

Condition

Continuity
Should exist.
Should not exist.

H
SEC024D
STOP LAMP SWITCH

1.
2.
3.

Check harness continuity between stop lamp switch terminals 1
K
Condition
Continuity
Should not exist.
Should exist.

M
PBIB0118E
EC-1537
http://vnx.su


PFP:24410
EBS01221

DTC No.
P0563
0563
Battery voltage high

An excessively high voltage from the battery is
sent to ECM.
Possible cause
Battery
Battery terminal
Alternator
EBS01222
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EBS01223
1. INSPECTION START
Are jumper cables connected for the jump starting?
Yes or No
Yes
>> GO TO 3.
No
>> GO TO 2.
2. CHECK BATTERY AND ALTERNATOR

Check that the proper type of battery and alternator is installed.
Refer to SC-3, "BATTERY" and SC-12, "CHARGING SYSTEM" .
OK or NG
OK
>> GO TO 5.
NG
>> Replace with a proper one.
EC-1538
http://vnx.su

3. CHECK JUMPER CABLES INSTALLATION
Check that the jumper cables are connected in the correct sequence.
EC
D
SEF439Z
OK or NG
OK
>> GO TO 4.
NG
>> Reconnect jumper cables properly.
4. CHECK BATTERY FOR BOOSTER

Check that the battery for the booster is a 12V battery.
OK or NG
OK
>> GO TO 5.
NG
>> Change the vehicle for booster.
5. PERFORM DTC CONFIRMATION PROCEDURE AGAIN

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.
6. REPLACE ECM
1.
2.
3.
Replace ECM.
>> INSPECTION END
7. CHECK ELECTRICAL PARTS DAMAGE

Check the following for damage.
Wiring harness and harness connectors for burn
Fuses for short

OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace malfunctioning part.
EC-1539
http://vnx.su


PFP:25551
EBS01FDT
PBIB2877E
1.
2.
4.
SET/COAST switch
5.
MAIN switch
3.
CANCEL switch
EBS01FDU

MONITOR ITEM
MAIN SW
CANCEL SW
RESUME/ACC SW
SET SW
CONDITION
Ignition switch: ON
Ignition switch: ON
Ignition switch: ON
Ignition switch: ON
SPECIFICATION
OFF
ON
OFF
ON
Released
OFF
Pressed
ON
OFF
ON
EC-1540
http://vnx.su

EBS01FDV
A
MI will not light up for these diagnoses.
NOTE:
EC
DTC No.
Trouble Diagnosis
Name
P0580
0580
ASCD steering
switch circuit low
input
P0581
0581
ASCD steering
switch circuit high
input
Possible Cause

stuck ON.

ECM
EBS01FDW
NOTE:
WITH CONSULT-II
1.
2.
3.
4.
5.
6.
7.
8.

Press SET COAST switch for at least 10 seconds, then release it and wait at least 10 seconds.
WITHOUT CONSULT-II
1.
2.
3.
4.
5.
6.
7.
8.

Press CRUISE switch for at least 10 seconds, then release it and wait at least 10 seconds.
EC-1541
http://vnx.su

Wiring Diagram
EBS01FDX
LHD MODELS
TBWB0475E
EC-1542
http://vnx.su

RHD MODELS
A
EC
TBWB0476E
EC-1543
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
102
PU*1
W/R*2
103
B/OR

ground
*1: LHD models

*2: RHD models
EC-1544
http://vnx.su
DATA
(DC Voltage)
Approximately 4.3V
Approximately 0.3V
Approximately 1.3V
Approximately 3.3V
Approximately 2.3V
Approximately 0.3V

EBS01FDZ

1.
2.

EC
J
PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1545
http://vnx.su


With CONSULT-II
2. Select MAIN SW, RESUME/ACC SW, SET SW and CANCEL SW in DATA MONITOR mode with
CONSULT-II.
Switch
Monitor item
MAIN
MAIN SW
CANCEL
CANCEL SW
RESUME/ACCELERATE
RESUME/ACC SW
Condition
Indication
Pressed
ON
Released
OFF
Pressed
ON
Released
OFF
Pressed
ON
Released
OFF
Pressed
ON
Released
OFF
SEC006D
SET/COAST
SET SW
Without CONSULT-II
Switch
MAIN
CANCEL
RESUME/ACCELERATE
SET/COAST
Condition
Voltage (V)
Pressed
Approx. 0.3
Released
Approx. 4.3
Pressed
Approx. 1.3
Released
Approx. 4.3
Pressed
Approx. 3.3
Released
Approx. 4.3
Pressed
Approx. 2.3
Released
Approx. 4.3
MBIB0043E
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
1.
2.
3.
4.

Disconnect ASCD steering switch (1) harness connector.

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
EC-1546
http://vnx.su
PBIB2879E

EC
1.
E

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

OK or NG
OK
>> GO TO 8.
NG

>> INSPECTION END
EBS01FE0

1.
2.
Disconnect ASCD steering switch.

Switch
MAIN
CANCEL
RESUME/ACCELERATE
Condition
Resistance ()
Pressed
Approx. 0
Released
Approx. 4,000
Pressed
Approx. 250
Released
Approx. 4,000
Pressed
Approx. 1,480
Released
Approx. 4,000
EC-1547
http://vnx.su
PBIB2880E

Switch
SET/COAST
Condition
Resistance ()
Pressed
Approx. 660
Released
Approx. 4,000
EC-1548
http://vnx.su
DTC P0605 ECM

DTC P0605 ECM

Description
PFP:23710
A
EBS01224

EC
D
MBIB0625E

DTC No.
P0605
0605

(ROM)
EBS01225

ECM ROM is malfunctioning.
Possible cause
ECM
EBS01226
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-1549
http://vnx.su
DTC P0605 ECM

EBS01227
1. INSPECTION START
1.
2.
3.
4.
5.
With CONSULT-II
Touch ERASE.
Without CONSULT-II
Yes or No
Yes
>> GO TO 2.
No
>> INSPECTION END
2. REPLACE ECM
1.
2.
3.
Replace ECM.
>> INSPECTION END
EC-1550
http://vnx.su
DTC P0606 ECM

DTC P0606 ECM

Description
PFP:23710
A
EBS01228

EC
D
MBIB0625E

DTC No.
P0606
0606

(Processor)
EBS01229

Possible cause
ECM
EBS0122A
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-1551
http://vnx.su
DTC P0606 ECM

EBS0122B
1. INSPECTION START
1.
2.
3.
4.
5.
With CONSULT-II
Touch ERASE.
Without CONSULT-II
Yes or No
Yes
>> GO TO 2.
No
>> INSPECTION END
2. REPLACE ECM
1.
2.
3.
Replace ECM.
>> INSPECTION END
EC-1552
http://vnx.su


Description
PFP:16700
A
EBS0122C
EBS0122D

MONITOR ITEM
CONDITION
No-load
PUMP CURRENT
SPECIFICATION
Idle
1,700 - 1,900 mA
2,000 rpm
1,600 - 1,800 mA

DTC No.
EBS0122F
P0628
0628

low input

open or short to ground.
P0629
0629

high output

short to power.
Possible cause
shorted.)
Fuel pump
EBS0122G
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

M
SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.
5.

EC-1553
http://vnx.su

Wiring Diagram
EBS0122H
TBWA0574E
EC-1554
http://vnx.su

A
CAUTION:
EC
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA
C
[Engine is running]
Warm-up condition
Idle speed
0 - 12.5V
NOTE:
idle.
E
MBIB0885E
10
Y/L

0 - 12.5V
F
[Engine is running]
Warm-up condition
G
MBIB0886E
H
[Engine is running]
Warm-up condition
Idle speed
0.5 - 1.0V
NOTE:
idle.
J
MBIB0887E
29
Fuel pump
0.5 - 1.0V
K
[Engine is running]
Warm-up condition
L
MBIB0888E
EC-1555
http://vnx.su

EBS0122I

1.
2.

connector.
PBIB1943E
3.

OK or NG
OK
>> GO TO 2.
NG

1.

OK or NG
OK
>> GO TO 3.
NG
3. CHECK FUEL PUMP

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

1.
2.
Replace fuel pump.

>> INSPECTION END

>> INSPECTION END
EC-1556
http://vnx.su

EBS0122J
FUEL PUMP
1.

2.
EC
D
SEF807Z
EBS0122K
FUEL PUMP

F
EC-1557
http://vnx.su


PFP:18002
EBS01FE1

DTC No.
P0642
0642
Sensor power supply circuit low input
P0643
0643
Possible cause
(The APP sensor 1 power supply circuit is shorted.)

EBS01FE2
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-1558
http://vnx.su

Wiring Diagram
EBS01FE3
EC
TBWA0731E
EC-1559
http://vnx.su

CAUTION:
TERMINAL
NO.
82
WIRE
COLOR
B
ITEM
CONDITION
DATA
Approximately 5.3V
EBS01FE5

1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1560
http://vnx.su


1.
2.

connector.
EC
D
PBIB1893E
3.


F
OK or NG
OK
>> GO TO 3.
NG
PBIB0914E
3. CHECK APP SENSOR

I

OK or NG
OK
>> GO TO 4.
NG

>> INSPECTION END
EC-1561
http://vnx.su


PFP:18002
EBS01FE6

DTC No.
P0652
0652
Sensor power supply circuit low
P0653
0653
Possible cause
(APP sensor 2 power supply circuit is
shorted.)
(Crankshaft position sensor circuit is
shorted.)
(Camshaft position sensor circuit is
shorted.)
(Fuel rail pressure sensor circuit is
shorted.)
(Turbocharger boost sensor circuit is
shorted.)


EBS01FE7
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-1562
http://vnx.su

Wiring Diagram
EBS01FE8
EC
TBWB0645E
EC-1563
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
DATA
(DC Voltage)
CONDITION
44
L/W
Approximately 5.3V
45
G/OR
Camshaft position sensor power supply
Approximately 5.3V
63
Fuel rail pressure sensor power supply
Approximately 5.3V
64
Turbocharger boost sensor power supply
Approximately 5.3V
90

power supply
Approximately 5.3V
EBS01FEA

1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1564
http://vnx.su


1.
2.

connector.
EC
D
PBIB1893E
3.


F
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.
PBIB0915E
3. CHECK SENSOR POWER SUPPLY CIRCUITS

Harness for short to power and short to ground, between the following terminals.
ECM terminal
Sensor terminal
90
EC-1480
44
Crankshaft position sensor terminal 1
EC-1498
45
Camshaft position sensor terminal 3
EC-1514
63
Fuel rail pressure sensor terminal 1
EC-1510
64
Turbocharger boost sensor terminal 1
EC-1493
ECM pin terminal.

OK or NG
OK
>> GO TO 4.
NG
4. CHECK COMPONENTS
Crankshaft position sensor (Refer to EC-1502, "Component Inspection" .)
Camshaft position sensor (Refer to EC-1514, "Component Inspection" .)
Fuel rail pressure sensor (Refer to EC-1456, "Component Inspection" .)
Turbocharger boost sensor (Refer to EC-1496, "Component Inspection" .)

OK or NG
OK
>> GO TO 5.
NG
EC-1565
http://vnx.su

5. CHECK APP SENSOR

OK or NG
OK
>> GO TO 6.
NG

>> INSPECTION END
EC-1566
http://vnx.su
DTC P0686 ECM RELAY

DTC P0686 ECM RELAY

PFP:25230
A
EBS01234

DTC No.
P0686
0686

ECM relay circuit
(The ECM relay circuit is shorted.)
ECM relay
ECM detects ECM relay is stuck closed even if

ignition switch OFF.
EC
Possible cause
C
EBS01235
NOTE:
WITH CONSULT-II
1.
2.
3.
4.
5.

I
SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.
5.
6.

EC-1567
http://vnx.su
DTC P0686 ECM RELAY

Wiring Diagram
EBS01236
TBWA0576E
EC-1568
http://vnx.su
DTC P0686 ECM RELAY

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
105

switch OFF

113

switch OFF
119
120
Y
R
EC
DATA
(DC Voltage)
C
Approximately 1.2V
D
BATTERY VOLTAGE
(11 - 14V)
E
Approximately 1.2V
F
BATTERY VOLTAGE
(11 - 14V)
BATTERY VOLTAGE
(11 - 14V)
H
EBS01237
1. CHECK ECM OUTPUT SIGNAL CIRCUIT FOR SHORT TO GROUND

I
1.
2.
3.

Check harness continuity between ECM terminals 105, 113 and ground.

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


EC-1569
http://vnx.su
DTC P0686 ECM RELAY

3. CHECK ECM INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1.
2.

Check harness continuity between ECM terminal 119 and ECM
relay terminal 5, ECM terminals 120 and ECM relay terminal 7.

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
PBIB1899E


5. CHECK ECM RELAY

OK or NG
OK
>> GO TO 6.
NG

>> INSPECTION END
EBS01238
ECM RELAY
1.
2.

Condition
Continuity
Yes
OFF
No
3.

PBIB0077E
EC-1570
http://vnx.su


Description
PFP:47850
A
EBS01239
EC
EBS0123A

DTC No.
P1211
1211

TCS control unit

Possible cause
TCS related parts
EBS0123B
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

J
SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.

L
EBS0123C
EC-1571
http://vnx.su


Description
PFP:47850
EBS0123D
NOTE:
If DTC P1212 is displayed with DTC U1000, first perform the trouble diagnosis for DTC U1000.
Refer to EC-1411, "DTC U1000 CAN COMMUNICATION LINE" .
Be sure to erase the malfunction information such as DTC not only for ESP/TCS/ABS control unit
but also for ECM after TCS related repair.
EBS0123E

DTC No.
P1212
1212
TCS communication line
ECM can not receive the information from ESP/

TCS/ABS control unit continuously.
Possible cause
(The CAN communication line is
open or shorted.)
Dead (Weak) battery

EBS0123F
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EBS0123G
EC-1572
http://vnx.su


Description
PFP:16600
A
EBS0123H
The fuel injector adjustment resistor is built into the fuel injector. The resistance is constant and individual.
ECM uses the individual resistance to determine the fuel injection pulse.
EC
EBS0123J

DTC No.
Possible cause
P1260
1260

input
ECM.
P1261
1261

input
ECM.
P1262
1262

input
ECM.
P1263
1263

input
ECM.
P1264
1264

input
ECM.
P1265
1265

input
ECM.
P1266
1266

input
ECM.
P1267
1267

input
ECM.
F
(The fuel injector adjustment resistor
EC-1573
http://vnx.su

EBS0123K
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-1574
http://vnx.su

Wiring Diagram
EBS0123L
EC
TBWA0575E
EC-1575
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
59
W/B
60
Y/B
61
G/B
62
R/B
78
ITEM
DATA
(DC Voltage)
CONDITION

resistor No. 1
resistor No. 3
resistor No. 4
resistor No. 2
0.5 - 5.1V
resistors.)

resistor ground
Approximately 0.3V
EBS0123M

1.
2.

PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1576
http://vnx.su

2. CHECK FUEL INJECTOR ADJUSTMENT RESISTOR POWER SUPPLY CIRCUIT

1.
2.
Disconnect fuel injector harness connector of malfunctioning

cylinder.
EC
D
PBIB1896E
3.
Check voltage between fuel injector terminal 2 and ground with

OK or NG
OK
>> GO TO 3.
NG
MBIB0186E
3. CHECK FUEL INJECTOR ADJUSTMENT RESISTOR GROUND CIRCUIT

1.
2.
3.

Check harness continuity between fuel injector terminal 1 and ECM terminal 78.

OK or NG
OK
>> GO TO 4.
NG
4. CHECK FUEL INJECTOR ADJUSTMENT RESISTOR

M

OK or NG
OK
>> GO TO 5.
NG

>> INSPECTION END
EBS0123N
FUEL INJECTOR ADJUSTMENT RESISTOR

1.
EC-1577
http://vnx.su

2.

PBIB0415E
EBS0123O
FUEL INJECTOR
EC-1578
http://vnx.su


PFP:16600
A
EBS0126X
engine fuel needs.
EC
D
PBIB0465E
EBS0126Y

MONITOR ITEM
MAIN INJ WID
CONDITION
No-load
0.68 - 0.78 msec
Idle speed

0.78 - 0.88 msec
G
EBS01270

DTC No.
SPECIFICATION
P1268
1268

P1269
1269

P1270
1270

P1271
1271

Possible cause
Fuel injector
EC-1579
http://vnx.su

EBS01271
CAUTION:
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

with CONSULT-II.
Restart engine and let it idle for about 15 minutes.
Drive vehicle and maintain the following conditions for at least
60 seconds.
CKPSRPM
COOLAN TEMP/S
Less than 75C (167F)
Shift lever
Suitable position
Accelerator pedal
PBIB2156E
5.
WITHOUT CONSULT-II
1.
2.
3.
4.
5.
6.
Start engine and let it idle for about 15 minutes.

Set voltmeter probes between ECM terminal 70 (engine coolant temperature sensor signal) and ground.
Restart engine and drive vehicle and maintain the following conditions for at least 60 seconds.
Engine speed
Voltage between ECM

terminal 70 and ground
More than 0.6V
Shift lever
Suitable position
Accelerator pedal
7.
8.
9.
EC-1580
http://vnx.su

Wiring Diagram
EBS01272
EC
TBWA0569E
EC-1581
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
[Engine is running]
W/B
G/B

Warm-up condition
Idle speed
DATA
5 - 10V
NOTE:
idle.
MBIB0883E
5 - 10V
[Engine is running]
Warm-up condition
MBIB0884E
[Engine is running]
21
22
23
24
G/R
GY/L
G/R
GY/L
Fuel injector No. 2

Fuel injector No. 2
Fuel injector No. 3
Fuel injector No. 3
Warm-up condition
Idle speed
0 - 9V
NOTE:
idle.
MBIB0881E
0 - 9V
[Engine is running]
Warm-up condition
MBIB0882E
[Engine is running]
40
41
42
43
G/R
GY/L
G/R
GY/L
Fuel injector No. 4

Fuel injector No. 4
Fuel injector No. 1
Fuel injector No. 1
Warm-up condition
Idle speed
0 - 9V
NOTE:
idle.
MBIB0881E
0 - 9V
[Engine is running]
Warm-up condition
MBIB0882E
EC-1582
http://vnx.su

EBS01273
1. CHECK FUEL INJECOR POWER SUPPLY CIRCUIT FOR OPEN AND SHORT
1.
2.
3.
4.

Terminal
DTC
EC
Cylinder
ECM
Fuel injector
P1268
No.1
P1269
No.2
P1270
No.3
P1271
No.4
PBIB1896E

OK or NG
OK
>> GO TO 2.
NG

1.
Terminal
DTC
Cylinder
ECM
Fuel injector
P1268
42, 43
No.1
P1269
21, 22
No.2
P1270
23, 24
No.3
P1271
40, 41
No.4

OK or NG
OK
>> GO TO 3.
NG

OK or NG
OK
>> GO TO 4.
NG
EC-1583
http://vnx.su


1.
2.
3.
4.
5.
6.
7.
8.
With CONSULT-II
Touch ERASE.
Perform DTC Confirmation Procedure, EC-1580, "DTC Confirmation Procedure" .
Without CONSULT-II
6. Perform DTC Confirmation Procedure, EC-1580, "DTC Confirmation Procedure" .
Yes or No
OK
>> Replace fuel injector or malfunctioning cylinder.
NG
>> GO TO 5.

>> INSPECTION END
EBS01274
FUEL INJECTOR
1.
2.

3.
PBIB0406E
EBS01275
FUEL INJECTOR
EC-1584
http://vnx.su
DTC P1272 FUEL PUMP

DTC P1272 FUEL PUMP

Description
PFP:16700
A
EBS0123R
When the fuel pressure in fuel rail increases to excessively high, fuel
pressure relief valve opens to carry excess fuel to the return hose.
EC
D
PBIB1900E
EBS012AN

MONITOR ITEM
CONDITION
No-load
PUMP CURRENT
SPECIFICATION
Idle
1,700 - 1,900 mA
2,000 rpm
1,600 - 1,800 mA
EBS0123S

DTC No.
P1272
1272
Fuel rail pressure relief

valve open
Fuel rail pressure relief valve is open

because of fuel pressure control system malfunction.
Possible cause
(Fuel pump circuit is open or shorted.)
Fuel pump
Air mixed with fuel
Lack of fuel
EBS0123T
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

least 5 seconds, then release the accelerator pedal.
SEF817Y
WITHOUT CONSULT-II
1.
Start engine and keep engine speed more than 4,000 rpm for at least 5 seconds, then release the accelerator pedal.
EC-1585
http://vnx.su
DTC P1272 FUEL PUMP

2.
3.
4.
EC-1586
http://vnx.su
DTC P1272 FUEL PUMP

Wiring Diagram
EBS012AW
EC
TBWA0574E
EC-1587
http://vnx.su
DTC P1272 FUEL PUMP

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
DATA
CONDITION
[Engine is running]
Warm-up condition
Idle speed
0 - 12.5V
NOTE:
idle.
MBIB0885E
10
Y/L

0 - 12.5V
[Engine is running]
Warm-up condition
MBIB0886E
[Engine is running]
Warm-up condition
Idle speed
0.5 - 1.0V
NOTE:
idle.
MBIB0887E
29
Fuel pump
0.5 - 1.0V
[Engine is running]
Warm-up condition
MBIB0888E
EBS0123U

OK or NG
OK
>> GO TO 2.
NG
EC-1588
http://vnx.su
DTC P1272 FUEL PUMP

A
NOTE:
EC
With CONSULT-II
C
D
5. Touch ERASE.
E
Without CONSULT-II
F
G
Yes or No
H
Yes
>> GO TO 3.
No
>> INSPECTION END
1.
2.

connectors.
PBIB1943E
3.

OK or NG
OK
>> GO TO 4.
NG
EC-1589
http://vnx.su
DTC P1272 FUEL PUMP


1.

OK or NG
OK
>> GO TO 5.
NG
5. CHECK FUEL PUMP

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 8.

OK or NG
OK
>> GO TO 7.
NG

OK or NG
OK
>> GO TO 8.
NG

1.
2.
Replace fuel pump.

>> INSPECTION END
EBS012AP
FUEL PUMP
1.

2.
SEF807Z
EBS0123W
FUEL RAIL
EC-1590
http://vnx.su
DTC P1272 FUEL PUMP

FUEL PUMP
A
EC
EC-1591
http://vnx.su
DTC P1273 FUEL PUMP

DTC P1273 FUEL PUMP

Description
PFP:16700
EBS0123X
amount of the fuel inhalation of fuel pump increases, the fuel raises the fuel exhalation pressure. As a result,
EBS0123Y

MONITOR ITEM
CONDITION
No-load
PUMP CURRENT
SPECIFICATION
Idle
1,700 - 1,900 mA
2,000 rpm
1,600 - 1,800 mA
EBS01240

DTC No.
P1273
1273
Fuel pump insufficient flow
ECM detects the abnormal pulse of fuel pressure.
Possible cause
Fuel pump
Air mixed with fuel
Lack of fuel

EBS01241
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.
5.

EC-1592
http://vnx.su
DTC P1273 FUEL PUMP

Wiring Diagram
EBS01242
EC
TBWA0574E
EC-1593
http://vnx.su
DTC P1273 FUEL PUMP

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
DATA
CONDITION
[Engine is running]
Warm-up condition
Idle speed
0 - 12.5V
NOTE:
idle.
MBIB0885E
10
Y/L

0 - 12.5V
[Engine is running]
Warm-up condition
MBIB0886E
[Engine is running]
Warm-up condition
Idle speed
0.5 - 1.0V
NOTE:
idle.
MBIB0887E
29
Fuel pump
0.5 - 1.0V
[Engine is running]
Warm-up condition
MBIB0888E
EBS01243

OK or NG
OK
>> GO TO 2.
NG
EC-1594
http://vnx.su
DTC P1273 FUEL PUMP

A
NOTE:
EC
With CONSULT-II
2. Clear fuel pump learning value. Refer to EC-1357, "Fuel Pump Learning Value Clearing" .
C
D
5. Touch ERASE.
E
Without CONSULT-II
2. Clear fuel pump learning value. Refer to EC-1357, "Fuel Pump Learning Value Clearing" .
F
G
6. Is DTC displayed again?
Yes or No
H
Yes
>> GO TO 3.
No
>> INSPECTION END
1.
2.
3.

connectors.
pump terminal 2.

OK or NG
OK
>> GO TO 4.
NG

1.

OK or NG
OK
>> GO TO 5.
NG
EC-1595
http://vnx.su
PBIB1943E
DTC P1273 FUEL PUMP


OK or NG
OK
>> GO TO 6.
NG
6. CHECK FUEL PUMP

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.

1.
2.
Replace fuel pump.

>> INSPECTION END

>> INSPECTION END
EBS01244
FUEL PUMP
1.

2.
SEF807Z
EBS01245
FUEL PUMP
EC-1596
http://vnx.su
DTC P1274 FUEL PUMP

DTC P1274 FUEL PUMP

Description
PFP:16700
A
EBS01246
EBS01247

MONITOR ITEM
CONDITION
No-load
PUMP CURRENT
SPECIFICATION
Idle
1,700 - 1,900 mA
2,000 rpm
1,600 - 1,800 mA

DTC No.
Fuel pump protection
EBS01249

value.
shorted.)
Fuel pump
H
EBS0124A
NOTE:
WITH CONSULT-II
1.
2.
3.
4.
Possible cause
P1274
1274
Tuning ignition switch ON.

SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-1597
http://vnx.su
DTC P1274 FUEL PUMP

Wiring Diagram
EBS0124B
TBWA0574E
EC-1598
http://vnx.su
DTC P1274 FUEL PUMP

A
CAUTION:
EC
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
DATA
C
[Engine is running]
Warm-up condition
Idle speed
0 - 12.5V
NOTE:
idle.
E
MBIB0885E
10
Y/L

0 - 12.5V
F
[Engine is running]
Warm-up condition
G
MBIB0886E
H
[Engine is running]
Warm-up condition
Idle speed
0.5 - 1.0V
NOTE:
idle.
J
MBIB0887E
29
Fuel pump
0.5 - 1.0V
K
[Engine is running]
Warm-up condition
L
MBIB0888E
EC-1599
http://vnx.su
DTC P1274 FUEL PUMP

EBS0124C

1.
2.
3.

connectors.
pump terminal 2.

OK or NG
OK
>> GO TO 2.
NG
PBIB1943E

1.

OK or NG
OK
>> GO TO 3.
NG

OK or NG
OK
>> GO TO 4.
NG
4. CHECK FUEL PUMP

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

1.
2.
Replace fuel pump.

>> INSPECTION END

>> INSPECTION END
EC-1600
http://vnx.su
DTC P1274 FUEL PUMP

EBS0124D
FUEL PUMP
1.

2.
EC
D
SEF807Z
EBS0124E
FUEL PUMP

F
EC-1601
http://vnx.su
DTC P1275 FUEL PUMP

DTC P1275 FUEL PUMP

Description
PFP:16700
EBS0124F
amount of the fuel inhalation of fuel increases, the fuel pump raises the fuel exhalation pressure. As a result,
the fuel injection pressure is raised. When the load of the engine increases, the ECM sends a signal to fuel
EBS0124G

MONITOR ITEM
CONDITION
No-load
PUMP CURRENT
SPECIFICATION
Idle
1,700 - 1,900 mA
2,000 rpm
1,600 - 1,800 mA

DTC No.
P1275
1275
Fuel pump exchange
EBS0124I

value.
Possible cause
shorted.)
Fuel pump

EBS0124J
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.
5.

EC-1602
http://vnx.su
DTC P1275 FUEL PUMP

Wiring Diagram
EBS0124K
EC
TBWA0574E
EC-1603
http://vnx.su
DTC P1275 FUEL PUMP

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
[Engine is running]
Warm-up condition
Idle speed
DATA
0 - 12.5V
NOTE:
idle.
MBIB0885E
10
Y/L

0 - 12.5V
[Engine is running]
Warm-up condition
MBIB0886E
[Engine is running]
Warm-up condition
Idle speed
0.5 - 1.0V
NOTE:
idle.
MBIB0887E
29
Fuel pump
0.5 - 1.0V
[Engine is running]
Warm-up condition
MBIB0888E
EC-1604
http://vnx.su
DTC P1275 FUEL PUMP

EBS0124L

1.
2.
3.

connectors.
pump terminal 2.
EC

OK or NG
OK
>> GO TO 2.
NG
PBIB1943E

1.

OK or NG
OK
>> GO TO 3.
NG

J

OK or NG
OK
>> GO TO 4.
NG
4. CHECK FUEL PUMP

L

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

1.
2.
Replace fuel pump.

>> INSPECTION END

>> INSPECTION END
EC-1605
http://vnx.su
DTC P1275 FUEL PUMP

EBS0124M
FUEL PUMP
1.

2.
SEF807Z
EBS0124N
FUEL PUMP
EC-1606
http://vnx.su


Description
PFP:18002
A
EBS0124O

EC
D
PBIB1741E
EBS0124P

MONITOR ITEM
ACCEL POS SEN*
ACCEL SEN 2*
CONDITION
SPECIFICATION
Ignition switch: ON
(Engine stopped)
0.2 - 0.7V
3.9 - 4.9V
Ignition switch: ON
(Engine stopped)
0.1 - 0.4V
1.9 - 2.4V
EBS0124R

DTC No.
Possible cause
P2135
2135

sensor 1, 2 signal correlation
The correlation between APP sensor 1 signal

and APP sensor 2 signal is out of the normal
range.
(The APP sensor circuit is open or
shorted.)
EBS0124S
NOTE:
WITH CONSULT-II
1.
2.
3.
4.
5.

Depress accelerator pedal slowly spending 5 seconds, and then
release it slowly spending 5 seconds.
SEF817Y
WITHOUT CONSULT-II
1.
2.
3.

Depress accelerator pedal slowly spending 5 seconds, and then release it slowly spending 5 seconds.
EC-1607
http://vnx.su

4.
5.

EC-1608
http://vnx.su

Wiring Diagram
EBS0124T
EC
TBWA0730E
EC-1609
http://vnx.su

CAUTION:
TERMINAL
NO.
82
WIRE
COLOR
B
ITEM
CONDITION
DATA
Approximately 5.3V
83

sensor 1
Engine stopped
0.5 - 1.0V
Engine stopped
4.2 - 5.2V
84

sensor 1 ground
Approximately 0.3V
85
Sensor ground
Approximately 0.3V
90

Approximately 5.3V
91
92

sensor 2

sensor 2 ground
Engine stopped
0.4 - 0.7V
Engine stopped
EC-1610
http://vnx.su
2.2 - 2.7V
Approximately 0.3V

EBS0124U

1.
2.

EC
J
PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1611
http://vnx.su

2. CHECK APP SENSOR POWER SUPPLY CIRCUIT

1.
2.

connector.
PBIB1893E
3.
Check voltage between APP sensor terminals 4, 6 and ground

OK or NG
OK
>> GO TO 3.
NG
PBIB0560E

1.
2.
3.

Check harness continuity between APP sensor terminals 3 and ECM terminal 84, APP sensor terminal 1

OK or NG
OK
>> GO TO 4.
NG
1.
Check harness continuity between ECM terminal 83 and APP sensor terminal 5, ECM terminal 91 and
APP sensor terminal 2.

OK or NG
OK
>> GO TO 5.
NG
5. CHECK APP SENSOR

OK or NG
OK
>> GO TO 6.
NG
EC-1612
http://vnx.su


EC
>> INSPECTION END
EBS0124V

1.
2.
3.
Terminal
Accelerator pedal
Voltage
83
sensor 1)
Fully released
0.5 - 1.0V
Fully depressed
4.2 - 5.2V
Fully released
0.4 - 0.7V
Fully depressed
2.2 - 2.7V
91
sensor 2)
4.

conditions.
MBIB0615E
EBS0124W
ACCELERATOR PEDAL

I
EC-1613
http://vnx.su


PFP:16600
EBS0124X
needs.
PBIB0465E
EBS0124Y

MONITOR ITEM
MAIN INJ WID
CONDITION
SPECIFICATION
No-load
0.68 - 0.78 msec
Idle speed

0.78 - 0.88 msec

DTC No.
EBS01250
P2146
2146


P2149
2149


Possible cause
EBS01251
NOTE:
TESTING CONDITION
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-1614
http://vnx.su

Wiring Diagram
EBS01252
EC
TBWA0733E
EC-1615
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
[Engine is running]
W/B
G/B

Warm-up condition
Idle speed
DATA
5 - 10V
NOTE:
idle.
MBIB0883E
5 - 10V
[Engine is running]
Warm-up condition
MBIB0884E
[Engine is running]
21
22
23
24
G/R
GY/L
G/R
GY/L
Fuel injector No. 2

Fuel injector No. 2
Fuel injector No. 3
Fuel injector No. 3
Warm-up condition
Idle speed
0 - 9V
NOTE:
idle.
MBIB0881E
0 - 9V
[Engine is running]
Warm-up condition
MBIB0882E
[Engine is running]
40
41
42
43
G/R
GY/L
G/R
GY/L
Fuel injector No. 4

Fuel injector No. 4
Fuel injector No. 1
Fuel injector No. 1
Warm-up condition
Idle speed
0 - 9V
NOTE:
idle.
MBIB0881E
0 - 9V
[Engine is running]
Warm-up condition
MBIB0882E
EC-1616
http://vnx.su

EBS01253
1. CHECK FUEL INJECOR POWER CIRCUIT FOR OPEN AND SHORT

1.
2.
3.
4.

Terminal
EC
Cylinder
ECM
Fuel injector
No.1
No.2
No.3
No.4
E
PBIB1896E

OK or NG
OK
>> GO TO 2.
NG

>> INSPECTION END
EC-1617
http://vnx.su


PFP:16600
EBS01254
engine fuel needs.
PBIB0465E
EBS01255

MONITOR ITEM
MAIN INJ WID
CONDITION
SPECIFICATION
No-load
0.68 - 0.78 msec
Idle speed

0.78 - 0.88 msec

DTC No.
EBS01257
P2147
2147
Fuel injector circuit low

input

ground.
P2148
2148
Fuel injector circuit high

input

power.
Possible cause
(The fuel injector circuit is shorted.)
EBS01258
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF817Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-1618
http://vnx.su

Wiring Diagram
EBS01259
EC
TBWA0569E
EC-1619
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
[Engine is running]
W/B
G/B

Warm-up condition
Idle speed
DATA
5 - 10V
NOTE:
idle.
MBIB0883E
5 - 10V
[Engine is running]
Warm-up condition
MBIB0884E
[Engine is running]
21
22
23
24
G/R
GY/L
G/R
GY/L
Fuel injector No. 2

Fuel injector No. 2
Fuel injector No. 3
Fuel injector No. 3
Warm-up condition
Idle speed
0 - 9V
NOTE:
idle.
MBIB0881E
0 - 9V
[Engine is running]
Warm-up condition
MBIB0882E
[Engine is running]
40
41
42
43
G/R
GY/L
G/R
GY/L
Fuel injector No. 4

Fuel injector No. 4
Fuel injector No. 1
Fuel injector No. 1
Warm-up condition
Idle speed
0 - 9V
NOTE:
idle.
MBIB0881E
0 - 9V
[Engine is running]
Warm-up condition
MBIB0882E
EC-1620
http://vnx.su

EBS0125A

1.
2.

EC
J
PBIB2020E
OK or NG
OK
>> GO TO 2.
NG
EC-1621
http://vnx.su

2. CHECK ECM OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT

1.
2.
3.

Terminal
Cylinder
Fuel injector
42, 43
3
No.1
4
3
No.2
4
3
No.3
4
3
No.4
4
Continuity
ECM
Should not exist
Should exist
42,43
Should exist
PBIB1896E
Should not exist
21, 22
Should not exist
Should exist
21, 22
Should exist
Should not exist
23, 24
Should not exist
Should exist
23, 24
Should exist
Should not exist
40, 41
Should not exist
Should exist
40, 41
Should exist
Should not exist

OK or NG
OK
>> GO TO 3.
NG

OK or NG
OK
>> GO TO 4.
NG

>> INSPECTION END
EC-1622
http://vnx.su

EBS0125B
FUEL INJECTOR
1.
2.

EC

3.

C
PBIB0406E
EBS0125C
FUEL INJECTOR
EC-1623
http://vnx.su


Description
PFP:23731
EBS0125D
The barometric pressure sensor is built into ECM. The sensor

detects ambient barometric pressure and sends the voltage signal to
the microcomputer.
MBIB0625E
EBS0125E

DTC No.
P2228
2228
Barometric pressure sensor circuit low input
An excessively low voltage from the barometric

P2229
2229
Barometric pressure sensor circuit high input
An excessively high voltage from the barometric

Possible cause
ECM
EBS0125F
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

SEF058Y
WITHOUT CONSULT-II
1.
2.
3.
4.

EC-1624
http://vnx.su

EBS0125G
1. INSPECTION START
1.
2.
3.
4.
5.
With CONSULT-II
Touch ERASE.
Is 1st trip DTC P2228 or P2229 displayed again?
EC
Without CONSULT-II
4. Is DTC 2228 or 2229 displayed again?
Yes or No
Yes
>> GO TO 2.
No
>> INSPECTION END
2. REPLACE ECM
1.
2.
3.
Replace ECM.
>> INSPECTION END

J
EC-1625
http://vnx.su
GLOW CONTROL SYSTEM

GLOW CONTROL SYSTEM

Description
PFP:25230
EBS0125H
SYSTEM DESCRIPTION
Sensor
Input Signal to ECM
ECM Function
Engine speed
Glow control
Actuator
Glow lamp
Glow relay
Glow plugs
When engine coolant temperature is more than approximately 80C (176F), the glow relay turns off.
When coolant temperature is lower than approximately 80C (176F):
Ignition switch ON
After ignition switch has turned to ON, the glow relay turns ON for a certain period of time in relation to
engine coolant temperature, allowing current to flow through glow plug.
Cranking
The glow relay turns ON, allowing current to flow through glow plug.
Starting
After engine has started, current continues to flow through glow plug (after-glow mode) for a certain period
in relation to engine coolant temperature.
The glow indicator lamp turns ON for a certain period of time in relation to engine coolant temperature at the
time glow relay is turned ON.
Glow Plug
The glow plug is provided with a ceramic heating element to obtain a
high-temperature resistance. It glows in response to a signal sent
from the ECM, allowing current to flow through the glow plug via the
glow relay.
SEF376Y
EC-1626
http://vnx.su
GLOW CONTROL SYSTEM

Wiring Diagram
EBS0125I
LHD MODELS
EC
TBWA0577E
EC-1627
http://vnx.su
GLOW CONTROL SYSTEM

RHD MODELS
TBWA0578E
EC-1628
http://vnx.su
GLOW CONTROL SYSTEM

EBS0125J
1. INSPECTION START
Check fuel level, fuel supplying system, starter motor, etc.

OK or NG
OK
>> GO TO 2.
NG
>> Correct.
EC
2. CHECK INSTALLATION
Check that glow plug nut and all glow plug connecting plate nuts are
installed properly.
OK or NG
OK
>> GO TO 3.
NG
>> Install properly.
SEF392YA
3. CHECK GLOW INDICATOR LAMP OPERATION

1.
2.
3.
4.
5.
With CONSULT-II
CONSULT-II.
Confirm that COOLAN TEMP/S indicates below 80C (176F).
If it indicates above 80C (176F), cool down engine.
ON.
lamp turned OFF.
SEF013Y
1.
2.
3.
4.
Without CONSULT-II
Set the tester probe between ECM terminal 51 (engine coolant
temperature sensor signal) and ground.
Confirm that the voltage indicates above 1.53V. If it indicates
below 1.53V, cool down engine.
ON.
lamp turned OFF.
PBIB2216E
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 5.
EC-1629
http://vnx.su
GLOW CONTROL SYSTEM

4. CHECK GLOW CONTROL SYSTEM OVERALL FUNCTION

1.
2.
3.
4.
5.
With CONSULT-ll
CONSULT-II.
Confirm that COOLAN TEMP/S indicates approximately 25C
(77F). If NG, cool down engine.
SEF013Y
6.
Conditions
Voltage
Battery voltage

switch ON
Approx. 0V
PBIB0425E
1.
2.
3.
4.
5.
Without CONSULT-II
Set the tester probe between ECM terminal 51 (engine coolant
temperature sensor signal) and ground.
Confirm that the voltage indicates approximately 3.62V. If NG,
cool down engine.
PBIB2216E
6.
Conditions
Voltage
Battery voltage

switch ON
Approx. 0V
PBIB0425E
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 7.
EC-1630
http://vnx.su
GLOW CONTROL SYSTEM

5. CHECK DTC
A
Yes or No
Yes
>> Perform trouble diagnoses for DTC U1000, refer to EC-1411, "DTC U1000 CAN COMMUNICA- EC
TION LINE" .
No
>> GO TO 6.
C
CHECK COMBINATON METER OPERATION
6.

Yes or No
Yes
>> GO TO 14.
No

1.
2.

I
MBIB0078E
3.
Check voltage between glow relay terminals 1, 3 and ground


K
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.
PBIB1413E

60A fusible link
Harness for open or short between glow relay and battery

EC-1631
http://vnx.su
GLOW CONTROL SYSTEM

9. CHECK GLOW RELAY OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.


OK or NG
OK
>> GO TO 11.
NG
>> GO TO 10.

Harness for open or short between glow relay and ECM

11. CHECK HARNESS CONTINUITY BETWEEN GLOW RELAY AND GLOW PLUG FOR OPEN AND
SHORT
1.
2.
Disconnect glow plug harness connector.

Check harness continuity between glow relay terminal 5 and glow plug harness connector.

OK or NG
OK
>> GO TO 12.
NG
12. CHECK GLOW RELAY

OK or NG
OK
>> GO TO 13.
NG
13. CHECK GLOW PLUG

OK or NG
OK
>> GO TO 14.
NG
>> Replace glow plug.

>> INSPECTION END
EC-1632
http://vnx.su
GLOW CONTROL SYSTEM

EBS0125K
GLOW RELAY
Conditions
EC
Continuity
Yes
No current supply
No
D
PBIB0428E
GLOW PLUG
1.
2.
Remove glow plug connecting plate.

Check glow plug resistance.
Resistance: Approximately 0.8 [at 25C (77F)]
NOTE:
Do not bump glow plug heating element. If it is bumped,
replace glow plug with a new one.
If glow plug is dropped from a height of 10 cm (3.94 in) or
higher, replace with a new one.
If glow plug installation hole is contaminated with carbon, remove it with a reamer or suitable tool.
Hand-tighten glow plug by turning it two or three times,
then tighten using a tool to specified torque.
H
PBIB0429E
: 20.1 N-m (2.1 kg-m, 15 ft-lb)

J
EBS0125L
GLOW PLUG
Refer to EM-159, "GLOW PLUG" .
EC-1633
http://vnx.su
EGR VOLUME CONTROL SYSTEM


Description
PFP:14710
EBS0125M
SYSTEM DESCRIPTION
Sensor
Input Signal to ECM
Engine speed
Vehicle speed
Ignition switch
Start signal
ECM Function
EGR volume control
Actuator
EGR volume control

valve
Engine stopped
Engine starting
High engine speed
SEF908Y
SEF411Y
EC-1634
http://vnx.su

EBS0125N

MONITOR ITEM
CONDITION
No-load
EGR VOL CON/V
SPECIFICATION
More than 10 steps

rpm
0 step
EC
EC-1635
http://vnx.su

Wiring Diagram
EBS0125P
TBWB0009E
EC-1636
http://vnx.su

CAUTION:
TERMINAL
NO.
25
26
27
28
WIRE
COLOR
GY
W/L
OR/B
GY/B
ITEM
CONDITION
[Engine is running]
Warm-up condition
Idle speed
DATA
0.1 - 14V
control valve.)
EC
EC-1637
http://vnx.su

EBS0125Q
1. CHECK EGR VOLUME CONTROL SYSTEM OVERALL FUNCTION

1.
2.
3.
4.

Set the oscilloscope probe between ECM terminals 25, 26, 27, 28 and ground.
Check the oscilloscope screen when revving engine up to 3,200 rpm and return to idle.
MBIB0617E
The pulse signal as shown in the figure should appear.

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
2. CHECK EGR VOLUME CONTROL VALVE POWER SUPPLY CIRCUIT-I

1.
2.
3.

PBIB1901E
4.

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.
PBIB2013E
EC-1638
http://vnx.su

EC
1.
2.
3.

ECM terminal
25
26
27
28

OK or NG
OK
>> GO TO 5.
NG

OK or NG
OK
>> GO TO 6.
NG
6. CHECK EGR PASSAGE

Check the following for clogging and cracks.
EGR tube
EGR hose
EGR cooler
OK or NG
OK
>> GO TO 7.
NG
>> Repair or replace EGR passage.

>> INSPECTION END
EBS0125R

With CONSULT-II
1.
EC-1639
http://vnx.su

2.
3.
4.
5.

Temperature C (F)
Resistance
20 (68)
13 - 17

PBIB2014E
6.
SEF819Y

NOTE:
checking.
Without CONSULT-II
1.
EC-1640
http://vnx.su

2.

3.
4.
5.
Temperature C (F)
Resistance
20 (68)
13 - 17
EC

G
PBIB2014E
6.
NOTE:
SEF560W
EBS0125S

L
EC-1641
http://vnx.su
TC BOOST CONTROL SOLENOID VALVE


Description
PFP:14956
EBS0125T
The turbocharger boost control solenoid valve controls vacuum signal to the turbocharger boost control actuator. By changing the variable nozzle vane opening through the rods, the intake air volume is
adjusted.
MBIB0626E

PBIB1897E
EC-1642
http://vnx.su

Wiring Diagram
EBS0125V
EC
TBWB0010E
EC-1643
http://vnx.su

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
Warm-up condition
Idle speed
DATA
0 - 12.5V
NOTE:
idle.
6
MBIB0889E

solenoid valve
0 - 12.5V
Warm-up condition
MBIB0890E
EBS0125W

1.
2.

Make sure that turbocharger control actuator rod moves slightly
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
PBIB1936E
EC-1644
http://vnx.su


1.
2.

connector.
EC
D
PBIB1897E
3.

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.
PBIB1945E

Harness for open and short between turbocharger boost control solenoid valve and ECM relay
Harness for open and short between turbocharger boost control solenoid valve and ECM
OPEN AND SHORT
1.
2.
3.

Check harness continuity between ECM terminal 6 and turbocharger boost control solenoid valve terminal

OK or NG
OK
>> GO TO 5.
NG
5. CHECK TURBOCHARGER BOOST CONTROL SOLENOID VALVE

OK or NG
OK
>> GO TO 6.
NG
EC-1645
http://vnx.su


>> INSPECTION END
EBS0125X

1.
2.

connector.
PBIB1897E
3.
CONDITIONS

between A and B

between A and C

Yes
No
No supply
No
Yes
EC-1646
http://vnx.su
MBIB0996E
BRAKE SWITCH
BRAKE SWITCH
Description
PFP:25230
A
EBS0125Z
STOP LAMP SWITCH

The stop lamp switch (1) is installed to brake pedal bracket. The
switch senses brake pedal position and sends an ON-OFF signal to
the ECM. The ECM uses the signal to control the fuel injection control system.
EC
PBIB2883E
ASCD BRAKE SWITCH (MODELS WITH ASCD)

When depress on the brake pedal, ASCD brake switch is turned OFF and stop lamp switch is turned ON. ECM
detects the state of the brake pedal by this input of two kinds (ON/OFF signal).
EBS01260

MONITOR ITEM
BRAKE SW
BRAKE SW2
CONDITION
Ignition switch: ON
Ignition switch: ON
SPECIFICATION
OFF

depressed
ON

Fully released
OFF

ON
EC-1647
http://vnx.su
BRAKE SWITCH
Wiring Diagram
EBS01FH0
MODELS WITHOUT ASCD
TBWA0580E
EC-1648
http://vnx.su
BRAKE SWITCH
MODELS WITH ASCD
A
EC
TBWB0685E
EC-1649
http://vnx.su
BRAKE SWITCH
CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
100
Stop lamp switch
101
GY/L
ASCD brake switch
DATA (DC Voltage)
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
BATTERY VOLTAGE
(11 - 14V)

depressed
Approximately 0V
EBS01263

With CONSULT-II
1.
2.
CONDITION
INDICATION
ON
OFF
PBIB0472E
Without CONSULT-II
Condition
Voltage
battery voltage
Approximately 0V
OK or NG
OK (Models with ASCD)>>GO TO 2.
OK (Models without ASCD)>>INSPECTION END
NG
>> GO TO 3.
EC-1650
http://vnx.su
MBIB1097E
BRAKE SWITCH
With CONSULT-II
EC
CONDITION
INDICATION
ON
OFF
SEC013D
1.
2.
Without CONSULT-II
G
Condition
Voltage
Approximately 0V
Battery voltage
I
PBIB1677E
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 7.
EC-1651
http://vnx.su
BRAKE SWITCH

1.
2.

PBIB2878E
3.

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
PBIB0117E

15A fuse
1.
2.


OK or NG
OK
>> GO TO 6.
NG

OK or NG
OK
>> GO TO 14.
NG
EC-1652
http://vnx.su
BRAKE SWITCH

1.
2.
3.

EC
D
PBIB2878E
4.

F

OK or NG
OK
>> GO TO 12.
NG
>> GO TO 8.
H
PBIB0857E
1.
2.

PBIB2878E
3.
4.

OK or NG
OK
>> GO TO 10.
NG
>> GO TO 9.
PBIB0799E
EC-1653
http://vnx.su
BRAKE SWITCH

10A fuse
1.
2.


OK or NG
OK
>> GO TO 11.
NG

OK or NG
OK
>> GO TO 14.
NG
1.
2.
3.


OK or NG
OK
>> GO TO 13.
NG

OK or NG
OK
>> GO TO 14.
NG

>> INSPECTION END
EBS01264
ASCD BRAKE SWITCH

1.
EC-1654
http://vnx.su
BRAKE SWITCH
2.
3.

Condition

Continuity
EC
Should exist.
Should not exist.

SEC023D
ASCD CLUTCH SWITCH

1.
2.
3.

Condition

Continuity
Should exist.
Should not exist.

H
SEC024D
STOP LAMP SWITCH

1.
2.

Check continuity between stop lamp switch terminals 1 and 2
Conditions

When Brake pedal is slightly depressed.
Continuity
Should not exist.
Should exist.

PBIB0118E
EC-1655
http://vnx.su
PNP SWITCH
PNP SWITCH
Description
PFP:32006
EBS01265
When the gear position is in Neutral, park/neutral position is ON. ECM detects the position because the continuity of the line (the ON signal) exists.
EBS01266

MONITOR ITEM
P/N POSI SW
CONDITION
Ignition switch: ON
SPECIFICATION
ON
Except above
OFF
EC-1656
http://vnx.su
PNP SWITCH
Wiring Diagram
EBS01268
EC
TBWA0581E
EC-1657
http://vnx.su
PNP SWITCH
CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
110
G/OR
switch
DATA
(DC Voltage)
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
EBS01269

With CONSULT-II
Select P/N POSI SW in DATA MONITOR mode with CONSULT-II.
3. Check P/N POSI SW signal under the following conditions.
1.
2.
P/N POSI SW
Neutral position
ON
OFF
SEF212Y
Without CONSULT-II
Neutral position
Voltage
Approximately 0V
Battery voltage
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
PBIB1947E
EC-1658
http://vnx.su
PNP SWITCH

1.
2.
3.

Disconnect park/neutral position (PNP) switch harness connector.
Check harness continuity between PNP switch terminal 2 and
ground.
EC

OK or NG
OK
>> GO TO 3.
NG
1.
2.

Check harness continuity between ECM terminal 110 and PNP switch terminal 1.
D
PBIB1903E

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

5. CHECK PARK/NEUTRAL POSITION SWITCH

Refer to MT-13, "POSITION SWITCH" .
OK or NG
OK
>> GO TO 6.
NG
>> Replace park/neutral position switch.

>> INSPECTION END
EC-1659
http://vnx.su
PSP SWITCH
PSP SWITCH
PFP:49761
EBS0126A
The power steering pressure switch is attached to the power steering high-pressure tube and detects a power steering load.
When a power steering load is detected, it signals the ECM. The
ECM adjusts the fuel injector pulse width to increase the idle speed
and adjust for the increased load.
PBIB1904E
EBS0126B

MONITOR ITEM
PW/ST SIGNAL
CONDITION

engine
SPECIFICATION

(Forward direction)
OFF
ON
EC-1660
http://vnx.su
PSP SWITCH
Wiring Diagram
EBS0126D
EC
TBWA0583E
EC-1661
http://vnx.su
PSP SWITCH
CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
CONDITION
[Engine is running]
111
P/B

switch
[Engine is running]
DATA
(DC Voltage)
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
EBS0126E

1.
2.
With CONSULT-II
Start engine.
Check PW/ST SIGNAL in DATA MONITOR mode with CONSULT-II under the following conditions.
Conditions
PW/ST SIGNAL
Steering wheel is in neutral position
OFF
Steering wheel is turned
ON
PBIB0434E
Without CONSULT-II
1. Start engine.
Conditions
Steering wheel is in neutral position
Steering wheel is turned
Voltage
Battery voltage
Approximately 0V
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
PBIB1948E
EC-1662
http://vnx.su
PSP SWITCH
2. CHECK POWER STEERING PRESSURE SWITCH GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Disconnect power steering pressure switch harness connector.
Check harness continuity between power steering pressure
switch terminal 2 and ground. Refer to Wiring Diagram.
EC

OK or NG
OK
>> GO TO 3.
NG
D
PBIB1904E
3. CHECK POWER STEERING PRESSURE SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.

Check harness continuity between ECM terminal 111 and power steering pressure switch terminal 1.

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
Harness for open and short between power steering pressure switch and ECM
5. CHECK POWER STEERING PRESSURE SWITCH

L

OK or NG
OK
>> GO TO 6.
NG
>> Replace power steering pressure switch.

>> INSPECTION END
EBS0126F
POWER STEERING PRESSURE SWITCH

1.
Disconnect power steering pressure switch harness connector and then start engine.
EC-1663
http://vnx.su
PSP SWITCH
2.
Check continuity between power steering pressure switch terminal 1 and 2 under the following conditions.
Conditions
Continuity
Steering wheel is being fully turned.
Yes
No
MBIB0624E
EBS0128A
EC-1664
http://vnx.su
FUEL TRANSPORT PUMP

FUEL TRANSPORT PUMP

Description
PFP:17020
A
EBS0126G
SYSTEM DESCRIPTION
Sensor
Input Signal to ECM
Engine speed
Fuel level switch
Fuel level
ECM function
Actuator
EC
C
Condition
Engine is running.
Operates
Engine is stopped.
Stops
The remainder of the fuel in the fuel tank is less than specified value.
Stops
Fuel supply entrance of fuel tank is at the left side of fuel tank. The duel at the right side of the fuel tank is sent
to the left side of the fuel tank by fuel transport pump.
When the ECM receives engine revolution signal from the crankshaft position sensor, it knows that the engine
is rotating, and causes the pump operate. If the remainder of the fuel at the right side of the fuel tank
decreases, fuel level switch sends a signal to the ECM. When the ECM receives a signal from the fuel level
switch, the ECM stops the operation of the pump.
The ECM does not directly drive the fuel transport pump. It controls the ON/OFF fuel transport pump relay,
which in turn controls the fuel transport pump.
J
PBIB1887E
Fuel Transport Pump
Fuel transport pump sends the fuel from right side of fuel tank to left
side.
PBIB0469E
Fuel Level Switch

Fuel level switch is assembled in sub fuel level sensor unit. When the remainder of the fuel at the right side of
the fuel tank is less than specified value, the switch is turned OFF.
EC-1665
http://vnx.su
FUEL TRANSPORT PUMP

Wiring Diagram
EBS0126I
LHD MODELS
TBWA0590E
EC-1666
http://vnx.su
FUEL TRANSPORT PUMP

RHD MODELS
A
EC
TBWA0591E
EC-1667
http://vnx.su
FUEL TRANSPORT PUMP

CAUTION:
TERMINAL
NO.
WIRE
COLOR
ITEM
14
W/PU
Fuel level switch
[Engine is running]
39
B/OR
DATA
(DC Voltage)
CONDITION
[Engine is running]
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
Approximately 0V
BATTERY VOLTAGE
(11 - 14V)
EBS0126J

1.
2.
3.
4.
5.

Remove sub fuel level sensor unit.
Reconnect sub fuel level sensor unit harness connector.
PBIB1944E
6.
Soak fuel level switch in fuel and check operating sound of fuel
transport pump.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
PBIB2015E
EC-1668
http://vnx.su
FUEL TRANSPORT PUMP

2. CHECK FUEL TRASPORT PUMP FUNCTION

1.
2.
3.
4.
5.

Install suitable harness between ECM harness connector terminal 39 and ground.
Listen the fuel transport pump operating sound.
EC

D
OK or NG
OK
>> GO TO 11.
NG
>> GO TO 3.
PBIB2016E
3. CHECK FUEL TRASPORT PUMP RELAY POWER SUPPLY CIRCUIT

1.
2.
3.
4.

Disconnect fuel transport pump relay.
J
PBIB1933E
5.
Check voltage between fuel transport pump relay terminals 1, 5


L
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
PBIB0471E
4. DETECT MALFUNCTIONING PERT

Fuse block (J/B) connectors M1
15A fuse
Harness for open or short between fuse and fuel transport pump relay
EC-1669
http://vnx.su
FUEL TRANSPORT PUMP

5. CHECK FUEL TRANSPORT PUMP POWER SUPPLY AND GROUND CIRCUIT FOR OPEN AND
SHORT
1.
2.
3.

Disconnect fuel transport pump harness connector.
Check harness continuity between fuel transport pump relay terminal 3 and fuel transport pump terminal 1 and between fuel
transport pump terminal 2 and ground. Refer to Wiring Diagram.

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.
PBIB1931E

Harness connector B22, B128
Harness for open or short between fuel transport pump relay and fuel transport pump
Harness for open or short between fuel transport pump and ground
7. CHECK FUEL TRANSPORT PUMP RELAY OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.

Check harness continuity between ECM terminal 39 and fuel transport pump relay terminal 2. Refer to
Wiring Diagram.

OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.
8. DETECT MALFUNSTIONING PART

Harness connector M18, B2 (RHD models)
Harness connector M63, F30
Harness for open or short between ECM and fuel transport pump relay
9. CHECK FUEL TRANSPORT PUMP RELAY

OK or NG
OK
>> GO TO 10.
NG
>> Replace fuel transport pump relay.
EC-1670
http://vnx.su
FUEL TRANSPORT PUMP

10. CHECK TRANSPORT PUMP

OK or NG
OK
>> GO TO 14.
NG
>> Replace fuel transport pump.
EC
11. CHECK FUEL LEVEL SWITCH POWER SUPPLY AND GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.
4.

Check harness continuity between ECM terminal 14 and sub
fuel level sensor unit terminal 2, between sub fuel level sensor
unit terminal 4 and ground. Refer to Wiring Diagram.

OK or NG
OK
>> GO TO 13.
NG
>> GO TO 12.
G
PBIB1944E
Harness connector F30, M63
Harness connectors M18, B2 (RHD models)
Harness for open or short between ECM and sub fuel level sensor unit
Harness for open or short between sub fuel level sensor unit and ground.
13. CHECK FUEL LEVEL SWITCH

L

OK or NG
OK
>> GO TO 14.
NG
>> Replace sub fuel level sensor unit.

Refer to EC-1401, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT"
>> INSPECTION END
EC-1671
http://vnx.su
FUEL TRANSPORT PUMP

EBS0126K
FUEL TRANSPORT PUMP RELAY

Check continuity between terminals 3 and 5 under the following conitions.
Conditions
Continuity
Yes
No current supply
No
PBIB0098E
FUEL TRANSPORT PUMP

1.
2.
3.
Remove fuel transport pump.

Apply battery voltage between fuel transport pump terminal 1 and 2.
Check operating sound of fuel transport pump under the following conditions.
Conditions
Operating sound
12V direct current supply between fuel transport pump

terminals 1 and 2
Yes
No current supply
No
4.
Listen fuel transport pump operating sound.
FUEL LEVEL SWITCH

1.
2.
Check continuity between sub fuel level sensor unit terminal 2
Conditions
Continuity
Fuel level switch is soaked in fuel.
Yes
Fuel level switch is not soaked in fuel.
No
PBIB2015E
EBS0126L
FUEL TRANSPORT PUMP

Refer to FL-23, "FUEL TANK" .
SUB FUEL LEVEL SENSOR UNIT

Refer to FL-19, "FUEL LEVEL SENSOR UNIT" .
EC-1672
http://vnx.su


System Description
PFP:18930
A
EBS01FEB

Sensor
Input signal to ECM
ASCD brake switch
Stop lamp switch
ASCD clutch switch
Combination meter
Vehicle speed
ECM function
Actuator
EC
BASIC ASCD SYSTEM

h (25 MPH) and 185 km/h (115 MPH).
ECM controls fuel injection value to regulate engine speed.
SET OPERATION
MPH), press SET switch. (Then SET indicator in combination meter illuminates.)
ACCEL OPERATION
If the RESUME/ACCELERATE switch is depressed during cruise control driving, increase the vehicle speed
until the switch is released or vehicle speed reaches maximum speed controlled by the system.
CANCEL OPERATION
CANCEL switch is depressed
More than 2 switches at ASCD steering switch are depressed at the same time (Set speed will be
cleared.).
Vehicle speed increased to 13 km/h higher than the set speed
Vehicle speed decreased to 13 km/h lower than the set speed
ESP system is operated

COAST OPERATION
When the SET/COAST switch is depressed during cruise control driving, decrease vehicle set speed until the
RESUME OPERATION
When the RESUME/ACCELERATE switch is depressed after cancel operation other than depressing MAIN
switch is performed, vehicle speed will return to last set speed. To resume vehicle set speed, vehicle condition
must meet following conditions.
Brake pedal is released
Clutch pedal is released
EC-1673
http://vnx.su

EBS01FEC

Refer to EC-1540 .
ASCD BRAKE SWITCH

ASCD CLUTCH SWITCH

Refer to EC-1528 .
STOP LAMP SWITCH

ASCD INDICATOR
Refer to EC-1675 .
EC-1674
http://vnx.su
ASCD INDICATOR
ASCD INDICATOR
PFP:24814
A
EBS01FED
ASCD indicator lamp illuminates to indicate ASCD operation status. The Lamp has two indicators, CRUISE
and SET, and is integrated in combination meter.
EC
SET indicator illuminates when the following conditions are met.
C
ASCD setting.
D
E
EC-1675
http://vnx.su
ASCD INDICATOR
Wiring DiagramLHD Models
EBS01FEE
TBWB0478E
EC-1676
http://vnx.su
ASCD INDICATOR
Wiring DiagramRHD Models
EBS01FEF
EC
TBWB0479E
EC-1677
http://vnx.su
ASCD INDICATOR
EBS01FEG

ASCD INDICATOR
CRUISE LAMP
SET LAMP
CONDITION
SPECIFICATION
MAIN switch: Pressed at the

first timeat the 2nd time
ONOFF
MAIN switch: ON
COAST/SET switch pressed
ON
When vehicle speed is

between 40 km/h (25 MPH)
and 185 km/h (115 MPH)
COAST/SET switch released
OFF
Ignition switch: ON
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
2. CHECK DTC
OK or NG
OK
>> Perform trouble diagnoses for DTC U1000. Refer to EC-1411, "DTC U1000 CAN COMMUNICATION LINE" .
NG
>> GO TO 3.
3. CHECK COMBINATION METER OPERATION

Yes or No
Yes
>> GO TO 4.
No

>> INSPECTION END
EC-1678
http://vnx.su
START SIGNAL
START SIGNAL
Wiring Diagram
PFP:48750
A
EBS0126M
EC
TBWA0582E
EC-1679
http://vnx.su
START SIGNAL
EBS0126N
1. CHECK START SIGNAL OVERALL FUNCTION

1.
2.
With CONSULT-II
Check START SIGNAL in DATA MONITOR mode with CONSULT-II under the following conditions.
Condition
START SIGNAL
Ignition switch ON
OFF
ON
PBIB0433E
Without CONSULT-II
Condition
Ignition switch ON
Voltage
Approximately 0V
Battery voltage
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
PBIB1949E
2. CHECK START SIGNAL INPUT SIGNAL CIRCUIT

1.
2.
3.

Disconnect ECM harness connector and ignition switch harness connector.
Check harness continuity between ECM terminal 99 and ignition switch terminal 6.

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

10A fuse
Fuse block (J/B) connectors M1, E102
Harness for open or short between ECM and ignition switch

EC-1680
http://vnx.su
START SIGNAL

EC
>> INSPECTION END
EC-1681
http://vnx.su


Wiring Diagram
PFP:24814
EBS0126O
LHD MODELS
TBWA0585E
EC-1682
http://vnx.su

RHD MODELS
A
EC
TBWA0586E
EC-1683
http://vnx.su


Engine
PFP:00100
EBS0126P
YD22DDTi
725 25 rpm
Idle speed
Maximum engine speed
4,900 rpm
EBS0126Q
Supply voltage
Approx. 0.4V
1.5 - 2.0V
2.2 - 2.7V

Temperature C (F)
EBS0126R
Resistance k
20 (68)
2.1 - 2.9
50 (122)
0.68 - 1.00
90 (194)
0.236 - 0.260
Fuel Rail Pressure Sensor
EBS0126S
Supply voltage
Approximately 5V
1.7 - 2.0V
2.0 - 2.3V
Glow Plug
EBS0126T
Approximately 0.8
EBS0126U
13 - 17
Crankshaft Position Sensor
EBS0126V
Camshaft Position Sensor
EBS0126W
EC-1684
http://vnx.su
FUEL SYSTEM
B ENGINE
SECTION
FL
FUEL SYSTEM
FL
CONTENTS
QR
YD22DDTi
PREPARATION ........................................................... 2
FUEL SYSTEM ........................................................... 3
Checking Fuel Lines ................................................. 3
General Precautions ................................................ 3
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND
FUEL PUMP ASSEMBLY ........................................... 4
Removal and Installation .......................................... 4
REMOVAL ............................................................. 4
INSPECTION AFTER REMOVAL ......................... 7
INSTALLATION ..................................................... 7
INSPECTION AFTER INSTALLATION ................. 8
Disassembly and Assembly ..................................... 8
DISASSEMBLY ..................................................... 8
ASSEMBLY ........................................................... 9
FUEL TANK ...............................................................11
REMOVAL ............................................................11
INSTALLATION ................................................... 12
Standard and Limit ................................................. 14
FUEL TANK ......................................................... 14
PREPARATION ......................................................... 15
FUEL SYSTEM ......................................................... 16
Checking Fuel Lines ............................................... 16
General Precautions ............................................... 16
FUEL FILTER ............................................................ 17
REMOVAL ........................................................... 17
INSTALLATION ................................................... 17
Air Bleeding ............................................................ 18
Draining Water from Fuel Filter .............................. 18
FUEL LEVEL SENSOR UNIT ................................... 19
REMOVAL ........................................................... 19
INSTALLATION ................................................... 22
FUEL TANK .............................................................. 23
REMOVAL ........................................................... 23
INSTALLATION ................................................... 24
Standard and Limit .................................................. 26
FL-1
http://vnx.su
PREPARATION
[QR]
PREPARATION
[QR]
PFP:00002
EBS00KOR
Tool name
Description
Fuel tank lock ring wrench
Removing and installing fuel tank lock ring
ZZA0122D
FL-2
http://vnx.su
FUEL SYSTEM
[QR]
FUEL SYSTEM
Checking Fuel Lines
PFP:17503
A
EBS00KOS
Inspect fuel lines, filler cap and tank for improper attachment, leaks,
cracks, damage, loose connections, chafing or deterioration.
If necessary, repair or replace damaged parts.
FL
D
SMA803A
General Precautions
EBS011T7
WARNING:
When replacing fuel line parts, be sure to observe the following.
Put a CAUTION: INFLAMMABLE sign in the workshop.
Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.
CAUTION:
Use gasoline required by the regulations for octane number. Refer to GI-5, "Precautions for Fuel" .
Before removing fuel line parts, perform the following procedures:
Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in
safe area.
Release fuel pressure from the fuel lines. Refer to EC-48, "FUEL PRESSURE RELEASE" (WITH
EURO-OBD) or EC-559, "FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).
Always replace O-rings and clamps with new ones.
Do not kink or twist tubes when they are being installed.
Do not tighten hose clamps excessively to avoid damaging hoses.
After connecting fuel tube quick connectors, make sure

quick connectors are secure.
Ensure that connector and resin tube do not contact any
adjacent parts.
After installing tubes, check if there are no fuel leaks at connections in the following steps.
Apply fuel pressure to fuel lines with turning ignition switch

ON (with engine stopped). Then check for fuel leaks at
connections.
Start engine and rev it up and check for fuel leaks at connections.
For servicing Evaporative Emission System parts, refer to

EC-520, "EVAPORATIVE EMISSION SYSTEM" (WITH EUROODB) or EC-958, "EVAPORATIVE EMISSION SYSTEM"
(WITHOUT EURO-OBD).
SBIA0504E
FL-3
http://vnx.su
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
[QR]
PFP:17042
EBS00KOU
PBIC2257E
1.
Lock ring
2.
Main fuel level sensor unit, fuel filter

and fuel pump assembly
4.
Chamber
5.
Seal packing
3.
Jet pump, fuel hose and jet pump

inlet assembly
6.
Sub fuel level sensor unit
REMOVAL
WARNING:
Be sure to read General Precautions when working on the fuel system. Refer to FL-3, "General Precautions" .
1. Check fuel level on fuel gauge. If gauge indicates more than the
level as shown in the figure (full or almost full), drain fuel from
fuel tank until gauge indicates level as shown in the figure or
below.
NOTE:
Fuel will be spilled when removing main and sub fuel level sensor units for the top of the fuel is above the main and sub fuel
level sensor units installation surface.
As a guide, fuel level becomes the position as shown in the
figure or below when approximately 15
(13-1/4 Imp qt) of
PBIC3641E
fuel are drained from fuel tank.
In case fuel pump does not operate, perform the following
procedure.
a. Insert fuel tube of less than 25 mm (0.98 in) in diameter into fuel filler tube through fuel filler opening to
draw fuel from fuel filler tube.
b. Disconnect fuel filler hose from fuel filler tube. Refer to FL-11, "FUEL TANK" .
c. Insert fuel tube into fuel tank through fuel filler hose to draw fuel from fuel tank.
2. Release the fuel pressure from the fuel lines. Refer to EC-48, "FUEL PRESSURE RELEASE" (WITH
EURO-OBD) or EC-559, "FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).
3. Open fuel filler lid.
4. Open fuel filler cap and release the pressure inside fuel tank.
5. Lift to hold rear seat cushion up. Refer to SE-31, "REAR SEAT" .
FL-4
http://vnx.su
[QR]
6.
Remove inspection hole cover for main and sub fuel level sensor units by turning clips clockwise by 90 degrees.
Remove cover by pushing it, then by turning clips clockwise
by 90 degrees and by matching both cover hole and clip
shape.
FL
C
PBIC2258E
7.
Disconnect harness connector and fuel feed hose.

E
G
KBIA0280E
Disconnect quick connector as follows:

Hold the sides of connector, push in tabs and pull out fuel feed
hose.
If quick connector sticks to tube of fuel level sensor unit, push
and pull quick connector several times until it starts to move.
Then disconnect quick connector by pulling.
SFE562A
FL-5
http://vnx.su
[QR]
CAUTION:
Quick connector can be disconnected when the tabs
are completely depressed. Do not twist it more than
necessary.
Do not use any tools to disconnect quick connector.
Keep resin tube away from heat. Be especially careful
when welding near the resin tube.
Prevent acid liquid such as battery electrolyte, etc.
from getting on resin tube.
Do not bend or twist resin tube during installation and
disconnection.
Do not remove the remaining retainer on hard tube (or
the equivalent) except when resin tube or retainer is
replaced.
When resin tube or hard tube (or the equivalent) is
replaced, also replace retainer with a new one.
Replace same color retainer as before replacing.
Retainer color: Green
SBIA0504E
To keep the connecting portion clean and to avoid

damage and foreign materials, cover them completely
with plastic bags or something similar.
PBIC0163E
8.
Using a fuel tank lock ring wrench (commercial service tool),

remove lock ring.
PBIC0240E
9.
Remove main fuel level sensor unit, fuel filter and fuel pump assembly, and sub fuel level sensor unit as
follows.
CAUTION:
Do not bend float arm during removal.
Avoid polluting the inside by residue fuel. Draw out with avoiding inclination by supporting with
a cloth.
Avoid impacts such as falling when handling components.
FL-6
http://vnx.su
[QR]
a.
Removal of main fuel level sensor unit, fuel filter and fuel pump
assembly:
i. Raise main fuel level sensor unit, fuel filter and fuel pump
assembly, and disconnect jet pump.
ii. Leave jet pump on fuel tank with fuel hose.
CAUTION:
Do not disconnect jet pump and fuel hose.
iii. If necessary, remove chamber from the bottom of fuel tank by
sliding toward the rear of the vehicle.
FL
C
KBIA0281E
b.
i.
ii.
Removal of sub fuel level sensor unit:

Raise and release sub fuel level sensor unit to remove.
If necessary, remove jet pump inlet from the bottom of fuel tank by pinching tabs.
CAUTION:
Do not separate jet pump inlet and fuel hose.

Make sure that fuel pump strainer is free from foreign materials. If any are found, remove them.
INSTALLATION
Chamber and Jet Pump
When installing chamber and jet pump, insert them fully until a click
sound of full stopper engagement is heard (Ditto for jet pump inlet).
K
KBIA0302E
Main and Sub Fuel Level Sensor Unit

1.
2.
Install seal packing to fuel tank without any twist.

Face fuel level sensor unit, fuel filter and fuel pump assembly as
shown in the figure, and install it to fuel tank. (Figure shows left
side of fuel tank.)
CAUTION:
Do not bend float arm during installing.
NOTE:
On right side of fuel tank, there are three carved lines on fuel
tank. Set mating mark between two outer carved lines.
KBIA0282E
3.
Tighten rock ring with rock ring wrench (commercial service tool).
CAUTION:
Install rock ring horizontally.
Quick Connector
Connect quick connector as follows:
1. Check the connection for damage and foreign materials.
FL-7
http://vnx.su
[QR]
2.
3.
Align the connector with the tube, then insert the connector straight into the tube until a click sound is
heard.
After connecting, make sure that the connection is secure by following method.
Visually confirm that the two tabs are connected to the connector.
Pull the tube and the connector to make sure they are
securely connected.
PBIC1653E
Inspection Hole Cover

1.
2.
Install inspection hole covers with the front mark (arrow) facing front of the vehicle.
Lock clips by turning counterclockwise by 90 degrees.

Use the following procedure to check for fuel leaks.
1. Turn ignition switch ON (with engine stopped), then check connections for leaks by applying fuel pressure to fuel piping.
2. Start engine and let it idle and make sure there are no fuel leaks at the fuel system connections.
EBS00KOV
PBIC2259E
1.
Fuel filter
2.
O-ring
3.
Clip
4.
Pressure regulator
5.
O-ring
6.
Fuel level sensor unit
7.
Bracket
8.
Rubber
9.
Fuel pump
10. Packing
CAUTION:
Sub fuel level sensor unit cannot be disassembled and should be replaced as a unit.
DISASSEMBLY
1.
Separate fuel pump and bracket from fuel filter as follows:
FL-8
http://vnx.su
[QR]
a.
Using a screwdriver, separate the snap fit portion of bracket in

numerical order as shown in the figure.
CAUTION:
Put cloth or similar one on the edge of screwdriver not to
damage the inserted portion.
FL
C
PBIC0242E
b.
Pull out fuel pump, and disconnect harness connector.

E
G
PBIC0243E
2.
a.
b.
3.
a.
b.
Separate fuel filter and fuel level sensor unit as follows:

Fit a used O-ring into space between fuel level sensor unit and
fuel filter to release tabs.
NOTE:
For reference when reassembling, put a mating mark on outer
edges of fuel level sensor unit and fuel filter with some means
which cannot be erased by fuel.
Insert screwdriver to the gap between fuel filter and fuel level
sensor unit to separate them.
CAUTION:
Put cloth or similar one on the edge of screwdriver not to
damage the inserted portion.
Remove pressure regulator from fuel filter as follows:
Open and remove the clip.
Pull pressure regulator straight out during removal.
CAUTION:
Avoid impacts such as falling during removal.
Do not disassemble or adjust.
PBIC0244E
ASSEMBLY
Note the following, and assemble in the reverse order of disassembly.
Fuel Filter and Fuel Pump
Install fuel filter and fuel pump with the tabs aligned, make sure a click sound of secure engagement is
heard.
Securely connect harness connector of fuel pump.
Pressure Regulator
Install pressure regulator as follows:
1. Install O-ring.
CAUTION:
Do not reuse O-ring. Replace it with a new one.
FL-9
http://vnx.su
[QR]
Visually check O-ring, mounting parts and mating parts for foreign materials and flaws.
Before installing, lubricate new engine oil.
To avoid damage, do not apply an excessive force (pulling or stretching).
Insert the clip to the groove of pressure regulator.
2.
PBIC2494E
3.
4.
With the clip installed, insert pressure regulator straight by matching the fuel filter lug and the clip notch.
Make sure that the fuel filter lug and clip notch are securely engaged.
FL-10
http://vnx.su
FUEL TANK
[QR]
FUEL TANK
PFP:17202
A
EBS00KOW
FL
I
PBIC0246E
1.
Fuel filler cap
2.
Grommet
3.
Fuel filler tube
4.
Vent hose
5.
Vent tube
6.
Fuel tank
7.
Fuel filler hose
8.
Fuel tank band
9.
Fuel tank protector
REMOVAL
WARNING:
Be sure to read General Precautions when working on the fuel system. Refer to FL-3, "General Precautions" .
1. Perform the steps 1 to 7 of REMOVAL in FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL
PUMP ASSEMBLY. Refer to FL-4, "REMOVAL" .
2. Drain fuel more from fuel tank if necessary.
CAUTION:
Because fuel tank forwardly inclines and becomes unstable when installing/removing, fuel should
be drained if found the remaining quantity.
3. Remove exhaust center tube and insulator. Refer to EX-2, "EXHAUST SYSTEM" .
4. Remove propeller shaft. Refer to PR-3, "REAR PROPELLER SHAFT" .
FL-11
http://vnx.su
FUEL TANK
[QR]
5.
6.
Using a transmission jack, support the bottom of final drive

assembly.
Remove mounting nuts on rear suspension member, and lower
the transmission jack carefully until just before rear suspension
member is removed from stud bolts on the vehicle. Refer to
RSU-5, "REAR SUSPENSION ASSEMBLY" .
KBIA0285E
7.
Disconnect fuel filler hose, EVAP hose and vent hose at fuel
tank side.
For disconnection procedure of quick connector on EVAP
hose, refer to FL-4, "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY" .
KBIA0286E
8.
Remove fuel tank protector.
9.
Remove fuel tank band mounting bolts while supporting fuel

tank.
CAUTION:
Sustain the bottom of fuel tank by using plate or anything
same.
10. Remove fuel tank.
After lifting down the front portion of fuel tank, remove fuel
tank by pulling it from the upper front of final drive assembly,
so that fuel tank can move forwardly.
CAUTION:
Pay attention not to fall fuel tank because it forwardly
inclines and becomes unstable.
NOTE:
It is desirable that more than two technicians work together.
INSTALLATION
Surely clamp fuel hoses and insert hose to the length below.
Fuel filler hose
The other hoses
Be sure hose clamp is not placed on swelled area of fuel tube.

Tighten fuel hose clamp so that the remaining length of screw thread becomes to the following.
Fuel tank side
Fuel filler tube side
: 35mm (1.38 in)

: 25mm (0.98 in)
: 5 - 9 mm (0.20 - 0.35 in)

: 7 - 11 mm (0.28 - 0.43 in)
Fit fuel tank band pin to the vehicle side securely.

Before fixing fuel tank, temporarily install fuel filler tube.
FL-12
http://vnx.su
KBIA0290E
FUEL TANK
[QR]
CAUTION:
Use genuine fuel filler tube mounting bolts or equivalent. Make sure to tighten them to the specified torque.
To connect quick connector, refer to FL-7, "Quick Connector" .
FL

Use the following procedure to check for fuel leaks.
1. Turn ignition switch ON (with engine stopped), and check connections for leaks by applying fuel pressure to fuel piping.
2. Start engine and let it idle and make sure there are no fuel leaks at the fuel system tube and hose connections.
FL-13
http://vnx.su

[QR]

Standard and Limit
PFP:00030
EBS00KOX
FUEL TANK
Fuel tank capacity
Approx. 60
Fuel recommendation
(13-1/4 Imp gal)
Refer to GI-5
Tightening Torque
EBS00KOY

Lock ring
32.9 (3.4, 24)
Fuel tank band
27.4 - 35.3 (2.8 - 3.6, 21 - 26)
Fuel tank protector
4.3 - 5.8 (0.43 - 0.59, 38 - 51)*
Fuel filler tube
7.8 - 10.4 (0.80 - 1.0, 69 - 92)*
Vent tube
7.8 - 10.4 (0.80 - 1.0, 69 - 92)*
FL-14
http://vnx.su
PREPARATION
[YD22DDTi]
PREPARATION
[YD22DDTi]
PFP:00002
A
EBS00BKG
Tool name
Description
Fuel filter wrench
Removing fuel filter
FL
PBIC0519E
Fuel tank lock ring wrench
Removing and installing fuel tank lock ring
F
ZZA0122D
FL-15
http://vnx.su
FUEL SYSTEM
[YD22DDTi]
FUEL SYSTEM
Checking Fuel Lines
PFP:17503
EBS00BKH
Inspect fuel lines, filler cap and tank for improper attachment, leaks,
cracks, damage, loose connections, chafing or deterioration.
If necessary, repair or replace damaged parts.
SMA803A
General Precautions
EBS00BKI
WARNING:
When replacing fuel line parts, be sure to observe the following.
Put a CAUTION: INFLAMMABLE sign in workshop.
Be sure to work in a well-ventilated area and furnish workshop with a CO2 fire extinguisher.
Do not smoke while servicing fuel system. Keep open flames and spark away from work area.
CAUTION:
Use diesel fuel required by the regulations for cetane number. Refer to GI-5, "Precautions for Fuel"
.
Before removing fuel line parts, perform the following procedures:
Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in
safe area.
Always replace O-ring and clamps with new ones.
Do not kink or twist tubes when they are being installed.
Do not tighten hose clamps excessively to avoid damaging hoses.
After connecting fuel tube quick connectors, make sure

quick connectors are secure.
Ensure that connector and resin tube do not contact any
adjacent parts.
After installing tubes, make sure there is no fuel leakage at

connections in the following steps.
Start the engine and rev it up and check for fuel leaks at
connections.
SBIA0504E
FL-16
http://vnx.su
FUEL FILTER
[YD22DDTi]
FUEL FILTER
PFP:16400
A
EBS00BLA
FL
D
PBIC2501E
REMOVAL
1.
2.
3.
4.
Remove air duct, air cleaner case and mass air flow sensor assembly. Refer to EM-139, "AIR CLEANER
AND AIR DUCT" .
Remove fuel filter protector.
Disconnect fuel hoses at fuel filter bracket.
CAUTION:
Plug the pipe to prevent fuel from draining.
Remove fuel filter with fuel filter bracket.
CAUTION:
Do not splash fuel during removal. If fuel is splashed,
immediately wipe it off.
I
SBIA0135E
5.
6.
7.
Using band-type fuel filter wrench (commercial service tool),

remove fuel filter.
Turn fuel filter upside down to drain fuel.
Remove drain plug from fuel filter.
SBIA0136E
INSTALLATION
Replace O-ring on drain plug with new one.

Drain plug
: 4.9 Nm (0.5 kg-m, 43 in-lb)
Screw the fuel filter by hand until packing contacts sealing surface of bracket. Then tighten it by turning
approximately 2/3 turn.
After installation, bleed air from fuel line. Refer to FL-18, "Air Bleeding" .

Make sure there is no fuel leakage at connections in the following steps.
Start the engine and rev it up and make sure there is no fuel leakage at connections.
FL-17
http://vnx.su
FUEL FILTER
[YD22DDTi]
Air Bleeding
EBS00BLB
After fuel filter is replaced and after fuel system components are
removed/installed, bleed air from fuel line as follows:
Move priming pump up and down to bleed air from fuel path.
When air is bled, pumping of priming pump becomes heavy stop

operation at that time.
Crank engine until it starts. Do not crank engine for more than
30 seconds.
If engine does not start, stop cranking and repeat step 1 above.
If engine does not operate smoothly after it has started, race it

two or three times.
SBIA0137E
If air cannot be bled easily (pumping of priming pump does not

become heavy), disconnect feed-side of hose between fuel filter and electronically controlled fuel pump.
After that, operate priming pump and confirm that fuel comes out.
CAUTION:
Prepare a tray to collect fuel. Prevent fuel from adhering to rubber parts, especially the engine
mounting insulator.
Draining Water from Fuel Filter

1.
2.
3.
4.
5.
EBS00MRU
Prepare a tray at the drain hose open end.

Loosen drain cock, and operate priming pump to drain water
from fuel filter.
CAUTION:
Water in filter is drained with fuel. Prepare larger capacity
pan than fuel filter volume.
Drained water is mixed with fuel. Prevent fuel from adhering to rubber parts such as engine mounting insulator.
After draining, close drain cock by hand.
CAUTION:
If drain cock is tightened excessively, it may be damaged
and fuel will leak. Do not use tools to tighten drain cock.
Bleed air in fuel piping. Refer to FL-18, "Air Bleeding" .
Start engine and make sure there is no fuel leakage.
FL-18
http://vnx.su
SBIA0138E
FUEL LEVEL SENSOR UNIT

[YD22DDTi]

PFP:17042
A
EBS00BLD
FL
G
PBIC2031E
1.
Lock ring
2.
Main fuel level sensor unit
4.
Chamber
5.
Sub fuel level sensor unit
3.
Seal packing
REMOVAL
WARNING:
Be sure to read General Precautions When working on fuel system. Refer to FL-16, "General Precautions" .
1. Open fuel filler lid.
2. Open the fuel filler cap and release the pressure inside fuel tank.
3. Check fuel level on level place. If gauge indicates more than the
level shown in figure (full or almost full), drain fuel from fuel tank
until gauge indicates level shown in figure or below.
Refer to the following for draining fuel.
a. Insert fuel tube of less than 25 mm (0.98 in) in diameter into fuel
filler tube through fuel filler opening to draw fuel from fuel filler
tube.
b. Disconnect fuel filler hose from fuel filler tube.
c. Insert fuel tube into fuel tank through fuel filler hose to draw fuel
from fuel tank.
PBIC3641E
As a guide, fuel level becomes the position shown in figure or
below when approximately 15 liter (13-1/4 lmp qt) of fuel are drained from full tank.
NOTE:
Adjusting fuel level is to prevent fuel from spilling, when fuel level sensor unit is removed.
4. Disconnect the battery cable from the negative terminal.
5. Lift to fold rear seat cushion up. Refer to SE-31, "REAR SEAT" .
6. Peel off floor carpet, then remove inspection hole cover.
FL-19
http://vnx.su

[YD22DDTi]
Remove clip by turning it about 90 degrees clockwise.

Left hand
Right hand
: Main fuel level sensor unit

: Sub fuel level sensor unit
SBIA0140E
7.
Disconnect harness connector, fuel feed tube, fuel return tube

and fuel hose. (Figure shows left side of fuel tank.)
For the right, disconnect harness connector and fuel hose.
PBIC2034E
Disconnect quick connector of fuel feed tube and fuel return

tube as follows.
NOTE:
Hold the sides of the connector, push in tubs and pull out the
tube.
If the connector and the tube are stuck together, push and pull
several times until they start to move. Then disconnect them
by pulling.
SFE562A
FL-20
http://vnx.su

[YD22DDTi]
CAUTION:
The quick connector can be removed when the tabs are
completely depressed. Do not twist it more than necessary.
Do not use any tools to disconnect quick connector.
Keep the resin tube away from heat. Be especially careful
when welding near the tube.
Prevent acid liquid such as battery electrolyte etc. from
getting on resin tube.
Do not bend or twist the tube during installation and
removal.
Do not remove the remaining retainer on hard tube (or
equivalent) except when resin tube or retainer is
replaced.
When resin tube or fuel level sensor unit is replaced, also
replace retainer with a new one.
Retainer color
FL
: Green (Fuel feed tube)

: Gray
(Fuel return tube)
G
SBIA0504E
K
PBIC0163E
8.
Using a fuel tank lock ring wrench (commercial service tool),

remove the lock ring.
PBIC0240E
9.
Remove main fuel level sensor unit (Left hand) and sub fuel level sensor unit (Right hand).
CAUTION:
Do not bend the float arm during removal.
Avoid impacts such as falling when handling components.
Left hand (main fuel level sensor unit):
If necessary, remove the chamber from the bottom of the fuel tank.
Remove the chamber by sliding toward the rear of the vehicle.
FL-21
http://vnx.su

[YD22DDTi]
Make sure fuel pump strainer is free from foreign materials. If any are found, remove them.
INSTALLATION
Connect quick connector as follows.

1. Check connection for damage and foreign materials.
2. Align the connector with the tube, then insert connector straight into tube until a click is heard.
3. After connecting, make sure that the connection is secure by following the steps below.
Visually confirm that the two tabs are connected to connector.
Pull the tube and connector to make sure they are securely
connected.
PBIC1653E
Install fuel level sensor unit with mating mark (triangular protrusion) facing between two carved lines on fuel tank. (Figure
shows left side of fuel tank.)
NOTE:
On right side of fuel tank, there are three carved lines on fuel
tank. Set mating mark between two outer carved lines.
PBIC2032E
Install inspection hole cover with the front mark (arrow) facing front of vehicle (both for RH and LH).

Start engine and rev it up and make sure there is no fuel leakage at connections.
FL-22
http://vnx.su
FUEL TANK
[YD22DDTi]
FUEL TANK
PFP:17202
A
EBS00BL3
FL
I
PBIC2033E
1.
Fuel filler cap
2.
Grommet
3.
Fuel filler tube
4.
Vent hose
5.
Vent tube
6.
EVAP hose
7.
Fuel filler hose
8.
Fuel transport pump
9.
Fuel hose
10. Fuel tube
11. Fuel tank protector
12. Fuel tank band
13. Fuel tank
REMOVAL
WARNING:
Be sure to read General Precautions when working on fuel system. Refer to FL-16, "General Precautions" .
1. Perform the procedure from 1 to 7 in removal of FL-19, "FUEL LEVEL SENSOR UNIT" .
2. Drain fuel more from fuel tank if necessary.
CAUTION:
Because fuel tank forwardly inclines and becomes unstable when installing/removing, fuel should
be drained if found the remaining quantity.
3. Remove exhaust center tube and insulator. Refer to EX-2, "EXHAUST SYSTEM" .
4. Remove propeller shaft, Refer to PR-3, "REAR PROPELLER SHAFT" .
FL-23
http://vnx.su
FUEL TANK
[YD22DDTi]
5.
6.
Using a transmission jack, support the bottom of final drive

assembly.
Remove the mounting nuts on the rear suspension member, and
lower the transmission jack carefully until just before the rear
suspension member is removed from the stud bolts on the vehicle.
KBIA0285E
7.
8.
Disconnect fuel filler hose, EVAP hose and vent hose at fuel
tank side.
Instruction for quick connector of EVAP hose. Refer to FL-19,
"FUEL LEVEL SENSOR UNIT" .
Disconnect connector of fuel transport pump and remove bolts
for bracket.
PBIC2035E
9.
Remove fuel tank protector.
10. Remove fuel tank band mounting bolts while supporting fuel
tank.
CAUTION:
Sustain the bottom of the tank by using plate or anything
same.
11. Remove fuel tank.
CAUTION:
Pay attention not to fall fuel tank because it forwardly
inclines and becomes unstable.
NOTE:
KBIA0290E
It is desirable that more than two technicians work together.
After lifting down the front portion of fuel tank, remove the fuel tank by pulling it from the upper front of
final drive assembly, so that the fuel tank can move forwardly.
INSTALLATION

Surely clamp fuel hoses and insert hose to the length below.
Fuel filler hose
The other hose
Be sure hose clamp is not positioned on swelled area of fuel tube.

Tighten fuel hose clamp so that the distance between its lugs becomes to the following.
Fuel tank side
Fuel filler tube side
: 35 mm (1.38 in)
: 25 mm (0.98 in)
: 5 - 9 mm (0.20 - 0.35 in)

: 7 - 11 mm (0.28 - 0.43 in)
Fit mounting band pin to the vehicle side securely.

Before fixing the fuel tank, temporarily install the fuel filler tube.
CAUTION:
Use genuine fuel filler tube mounting bolts or equivalent. Make sure to tighten them to the specified torque.
To connect quick connector. Refer to FL-19, "FUEL LEVEL SENSOR UNIT" .
FL-24
http://vnx.su
FUEL TANK
[YD22DDTi]
Start engine and rev it up and make sure there is no fuel leakage at connections.
FL
FL-25
http://vnx.su

[YD22DDTi]

Standard and Limit
Fuel tank capacity
PFP:00030
EBS00BL5
Approx. 60
Fuel recommendation
(13-1/4 Imp gal)
Refer to GI-5
Tightening Torque
EBS00BL6

Fuel filter drain plug
4.9 (0.50, 43)*
Fuel tank band
31.4 (3.2, 23)
Fuel filler tube
9.1 (0.93, 81)*
Vent tube
9.1 (0.93, 81)*
Lock ring
32.9 (3.4, 24)
Fuel transport pump
4.8 (0.49, 42)*
FL-26
http://vnx.su
EXHAUST SYSTEM
B ENGINE
SECTION
EX
EXHAUST SYSTEM
EX
CONTENTS
EXHAUST SYSTEM ................................................... 2
Checking Exhaust System ....................................... 2
REMOVAL ............................................................. 3
INSTALLATION ..................................................... 3
SERVICE DATA AND SPECIFICATIONS (SDS) ........ 5

Tightening Torque ..................................................... 5
QR20DE AND QR25DE ........................................ 5
YD22DDTI ............................................................. 5
EX-1
http://vnx.su
EXHAUST SYSTEM
EXHAUST SYSTEM
Checking Exhaust System
PFP:20100
EBS00AZ6
Check exhaust pipes, muffler and mounting for improper attachment,

leaks, cracks, damage or deterioration.
SMA211A
EBS003DN
CAUTION:
Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat
resistance, corrosion resistance and shape.
Perform the operation with the exhaust system fully cooled down because the system will be hot
just after engine stops.
Be careful not to cut your hand on the insulator edge.
QR20DE and QR25DE
PBIC3627E
EX-2
http://vnx.su
EXHAUST SYSTEM
*: In regard to the notation of torque in the figure, NEW shows an ISO standard, OLD shows a conventional standard, and the measurements of hexagonal width across flats are in parentheses.
1.
Main muffler
2.
Mounting rubber
3.
Spring
4.
Gasket
5.
Three way catalyst
6.
Exhaust front tube
7.
Seal bearing
8.
Mounting rubber bracket
9.
Mounting bracket
EX
10. Exhaust center tube
YD22DDTi
K
PBIC3628E
*: In regard to the notation of torque in the figure, NEW shows an ISO standard, OLD shows a conventional standard, and the measurements of hexagonal width across flats are in parentheses.
1.
Main muffler
2.
Mounting rubber
3.
Spring
4.
Ring gasket
5.
Exhaust tube
6.
Exhaust front tube
7.
Mounting bracket
8.
Mounting rubber bracket
9.
Mounting bracket
12.
Seal bearing
10. Exhaust center tube
11. Gasket
REMOVAL
Separate each connection as necessity.
INSTALLATION
CAUTION:
Always replace exhaust gaskets and seal bearings with new ones when reassembling.
If insulator is badly deformed, repair or replace it. If deposits such as mud pile up on insulator,
remove them.
When installing insulator avoid large gaps or interference between insulator and each exhaust
pipe.
Remove deposits from the sealing surface of each connection. Connect them securely to avoid
gas leakage.
EX-3
http://vnx.su
EXHAUST SYSTEM
Temporarily tighten mounting nuts on the exhaust manifold side and mounting bolts on the vehicle side. Check each part for unusual interference, and then tighten them to the specified torque.
When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/
left directions.
Install seal bearings at exhaust front tube and main muffler as follows.
CAUTION:
Do not mix the bolt and spring for seal bearing as the dimension is different for each seal bearing.
Exhaust Front Tube Side (QR20DE and QR25DE)

Insert seal bearing in the direction shown in the figure.
CAUTION:
Tighten mounting bolt without causing interference with
exhaust front tube flange.
PBIC2274E
Main Muffler Side (QR20DE, QR25DE and YD22DDTi)

Insert seal bearing in the direction shown in the figure.
CAUTION:
Tighten mounting bolt without causing interference with main
muffler flange.
PBIC2275E
With the engine running, check exhaust tube joints for gas leakage and unusual noises.
Check to ensure that mounting brackets and mounting rubbers are installed properly and free from undue
stress. Improper installation could result in excessive noise and vibration.
EX-4
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Tightening Torque
PFP:00030
A
EBS00KP4
QR20DE AND QR25DE

Exhaust system connections
Exhaust manifold three way catalyst assembly to exhaust
front tube
Conventional bolt
49.0 (5.0, 36)
Exhaust front tube to three way catalyst
Conventional nut
57.9 (5.9, 43)
ISO nut
45.0 (4.6, 33)
Three way catalyst to exhaust center tube
Conventional nut
57.9 (5.9, 43)
ISO nut
45.0 (4.6, 33)
Exhaust center tube to main muffler
Conventional bolt
49.0 (5.0, 36)
EX
Mounting bolts and nuts
14.2 (1.4, 10)
YD22DDTI
Exhaust system connections

Catalyst rear diffuser to exhaust front tube
Exhaust front tube to exhaust tube
Exhaust tube to exhaust center tube
Exhaust center tube to main muffler
64.7 (6.6, 48)

Conventional nut
57.9 (5.9, 43)
ISO nut
45.0 (4.6, 33)
Conventional nut
57.9 (5.9, 43)
ISO nut
45.0 (4.6 ,33)
Conventional bolt
49.0 (5.0, 36)
Mounting bolts and nuts
14.2 (1.4, 10)
EX-5
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EX-6
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ACCELERATOR CONTROL SYSTEM
B ENGINE
SECTION
ACC
ACC
CONTENTS
ACCELERATOR CONTROL SYSTEM ...................... 2
REMOVAL ............................................................. 2
INSTALLATION ..................................................... 2
SERVICE DATA AND SPECIFICATIONS (SDS) ........ 3

Tightening Torque ..................................................... 3
ACC-1
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PFP:18005
EBS00KP5
PBIC2412E
1.
Accelerator pedal assembly
REMOVAL
1.
2.
Disconnect accelerator pedal position sensor harness connector.

Loosen nuts, and remove accelerator pedal assembly.
CAUTION:
Do not disassemble accelerator pedal assembly. Do not remove accelerator pedal position sensor from accelerator pedal assembly.
Avoid impact from dropping etc. during handling.
Be careful to keep accelerator pedal assembly away from water.
Do not adjust adjusting screw (painted white).
INSTALLATION
Make sure that accelerator pedal moves smoothly within the whole operation range.
Make sure that accelerator pedal securely returns to the original position.
For the electrical inspection of accelerator pedal position sensor, refer to EC-408, "DTC P2122, P2123
APP SENSOR" (QR20DE and QR25DE) or EC-1093, "DTC P0122, P0123 APP SENSOR" (YD22DDTi).
CAUTION:
When the harness connector of the accelerator pedal position sensor is disconnected, perform
Accelerator Pedal Released Position Learning. (QR20DE and QR25DE) Refer to EC-45, "Accelerator Pedal Released Position Learning" (WITH EURO-OBD) or EC-556, "Accelerator Pedal
Released Position Learning" (WITHOUT EURO-OBD).
NOTE:
In the case of YD22DDTi, it is unnecessary to perform Accelerator Pedal Released Position Learning
even when disconnecting the harness connector of the accelerator pedal position sensor.
ACC-2
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Tightening Torque
PFP:00030
A
EBS00KP6
Unit: Nm (kg-m, in-lb)

Accelerator pedal assembly
5.1 (0.52, 45)
ACC
ACC-3
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ACC-4
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CLUTCH
C TRANSMISSION/TRANSAXLE
SECTION
CL
CLUTCH
CL
CONTENTS
PRECAUTIONS .......................................................... 2
Service Notice or Precautions .................................. 2
PREPARATION ........................................................... 3
TROUBLESHOOTING ................................................ 4
NVH Troubleshooting Chart ..................................... 4
CLUTCH PEDAL ........................................................ 5
On-Vehicle Inspection and Adjustment .................... 5
COMPONENTS .................................................... 6
REMOVAL ............................................................. 6
INSPECTION AFTER REMOVAL ......................... 7
INSTALLATION ..................................................... 7
CLUTCH FLUID .......................................................... 8
Air Bleeding Procedure ............................................ 8
CLUTCH MASTER CYLINDER .................................. 9
Components ............................................................. 9
REMOVAL ........................................................... 10
INSTALLATION ................................................... 10
DISASSEMBLY ................................................... 10
INSPECTION AFTER DISASSEMBLY ............... 10
ASSEMBLY ..........................................................11
OPERATING CYLINDER .......................................... 12
Components ........................................................... 12

REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
DISASSEMBLY ................................................... 12
ASSEMBLY ......................................................... 12
CLUTCH PIPING ....................................................... 13
CLUTCH RELEASE MECHANISM ........................... 14
COMPONENTS ................................................... 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 15
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL... 16
COMPONENTS ................................................... 16
REMOVAL ........................................................... 16
INSPECTION AND ADJUSTMENT AFTER
REMOVAL ........................................................... 17
INSTALLATION ................................................... 18
Clutch Control System ............................................ 19
Clutch Master Cylinder ........................................... 19
Clutch Operating Cylinder ...................................... 19
Clutch Disc ............................................................. 19
Clutch Cover ........................................................... 19
CL-1
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PRECAUTIONS
PRECAUTIONS
Service Notice or Precautions
PFP:00001
ECS004JW
Recommended clutch fluid is brake fluid DOT 3" or DOT 4". Refer to MA-17, "Fluids and Lubricants" .
Do not reuse drained clutch fluid.
Be careful not to splash clutch fluid on painted areas.
When removing and installing clutch piping, use Tool.
Tool number
: GG94310000 or Commercial equivalent
Use new clutch fluid to clean or wash all parts of master cylinder
and operating cylinder.
Do not use mineral oils such as gasoline or kerosene. It will corrode the rubber parts of the hydraulic system.
WARNING:
After cleaning clutch disc, clean it with a dust collector. Do not
use compressed air.
PCIB0272E
CL-2
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PREPARATION
PREPARATION
PFP:00002
A
ECS008B7
Tool number
Tool name
Description
ST20050240
Diaphragm adjusting wrench
Adjusting unevenness of diaphragm spring of

clutch cover
CL
D
ZZA0508D
KV30101600
Clutch aligning bar
a: 15.9 mm (0.626 in) dia.
b: 17.9 mm (0.705 in) dia.
c: 40 mm (1.57 in) dia.
Installing clutch cover and clutch disc

(For QR engine models)
F
S-NT405
KV30100100
Clutch aligning bar
a: 15.7 mm (0.618 in) dia.
b: 22.8 mm (0.898 in) dia.
Installing clutch cover and clutch disc

(For YD engine models)
H
ZZA1178D
ECS00CRA
Tool name
Description
Pin punch
Tip diameter: 4.5 mm (0.177 in) dia.
Removing and installing master cylinder

spring pin
L
ZZA0515D
GG94310000
Flare nut torque wrench
a: 10 mm (0.39 in)
Removing and installing clutch piping
S-NT406
CL-3
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Symptom
Clutch grabs/chatters
Clutch pedal spongy
1
1
Clutch noisy
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CL-4
CL-12
OPERATING CYLINDER PISTON CUP (Damaged)
CLUTCH DISC (Dirty or burned)
CLUTCH DISC (Lining broken)
CLUTCH DISC (Runout is excessive)
CLUTCH DISC (Out of true)
RELEASE BEARING (Worn, dirty or damaged)
2
2
2
6
2
FLYWHEEL (Distortion)
EM-113 (QR engine models),EM-248 (YD engine models)

NVH Troubleshooting Chart
PRESSURE PLATE (Distortion)
DIAPHRAGM SPRING (Out of tip alignment)
DIAPHRAGM SPRING (Damaged)
CLUTCH DISC (Lack of spline grease)
CL-16
CL-14
EM-82 (QR engine models), EM-219 (YD engine models)
CL-9
MASTER CYLINDER PISTON CUP (Damaged)
CLUTCH DISC (Hardened)
Clutch does not disengage
2
CLUTCH DISC (Worn out)
1
2
CLUTCH DISC (Oily)
Clutch slips
2
ENGINE MOUNTING (Loose)
CL-8
CLUTCH LINE (Air in line)
SUSPECTED PARTS (Possible cause)

CL-5
Reference page
CLUTCH PEDAL (Inspection and adjustment)

PFP:00003
ECS008B8
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspection. If necessary, repair or replace these parts.
CLUTCH PEDAL
CLUTCH PEDAL
On-Vehicle Inspection and Adjustment
1.
a.
b.
c.
d.
2.
a.
b.
3.
a.
b.
PFP:46540
A
ECS001WB
Make sure that clevis pin floats freely in bore of clutch pedal. It
should not be bound by clevis or clutch pedal.
B
If clevis pin is not free, make sure that pedal stopper bolt or
ASCD clutch switch is not applying pressure to clutch pedal
causing clevis pin to bind. To adjust, loosen lock nut and turn
CL
pedal stopper bolt or ASCD clutch switch.
Tighten lock not.
Make sure that clevis pin floats in bore of clutch pedal. It should
D
not be bound by clutch pedal.
If clevis pin is still not free, remove clevis pin and check for
deformation or damage. Replace clevis pin if necessary. Leave
E
clevis pin removed for step 2.
Check clutch pedal stroke for free range of movement.
With clevis pin removed, manually move clutch pedal up and
F
down to determine if it moves freely.
If any sticking is found, replace related parts (clutch pedal
bracket, assist spring, bushing etc.). Reassemble clutch pedal
G
and again make sure that clevis pin floats freely in bore of clutch
pedal.
Check clutch hydraulic and system components (clutch master
H
cylinder, clutch operating cylinder, clutch withdrawal lever, clutch
PCIB0876E
release bearing, etc.) for sticking or binding.
If any sticking or binding is found, repair or replace related parts as necessary.
I
If hydraulic system repair was necessary, bleed the clutch hydraulic system. Refer to CL-8, "Air Bleeding
Procedure" .
NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or J
power bleeder will not purge all the air from the system.
K
CL-5
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CLUTCH PEDAL
ECS001WC
COMPONENTS
RHD models
PCIB0877E
1.
Clutch pedal assembly
2.
Assist spring
3.
Bushing
4.
Stopper rubber
5.
Clevis pin
6.
Bushing
7.
Stopper rubber
8.
Pedal stopper bolt (Without ASCD)
9.
ASCD clutch switch (With ASCD)
10. Snap pin
LHD models
PCIB1452E
1.
Clutch pedal assembly
2.
Assist spring
3.
Bushing
4.
Clevis pin
5.
Bushing
6.
Stopper rubber
7.
Pedal stopper bolt (Without ASCD)
8.
ASCD clutch switch (With ASCD)
9.
Stopper rubber
10. Snap pin
11. Bracket
REMOVAL
1.
2.
3.
Remove instrument driver lower panel. Refer to IP-10, "INSTRUMENT PANEL ASSEMBLY" .
Disconnect ASCD clutch switch harness connector. (With ASCD)
Remove snap pin and clevis pin from clevis of clutch master cylinder.
CL-6
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CLUTCH PEDAL
4.
Remove clutch pedal assembly mounting nuts and bolt, and then remove clutch pedal assembly from the
vehicle.
Check clutch pedal for bend, damage or a cracked weld. If bend, damage or a cracked weld is found,
replace clutch pedal.
Check assist spring for settling. If settling is found, replace assist spring.
INSTALLATION
CL

NOTE:
Tighten pedal stopper bolt lock nut or ASCD clutch switch lock nut to the specified torque after installing clutch
pedal assembly in vehicle and adjusting the pedal free play.
CL-7
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CLUTCH FLUID
CLUTCH FLUID
Air Bleeding Procedure
PFP:00017
ECS008B9
NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or
power bleeder will not purge all the air from the system.
CAUTION:
Monitor clutch fluid level in reservoir tank to make sure it

does not empty.
Keep painted surface on the body or other parts free of

clutch fluid. If it spills, wipe up immediately and wash the
affected area with water.
Bleed the air of operating cylinder.

1. Fill master cylinder reservoir tank with new clutch fluid.
2. Connect a transparent vinyl hose to air bleeder valve.
3. Depress clutch pedal slowly and fully several times at an interval
of 2 to 3 seconds and hold it.
SCIA1098E
4. With clutch pedal depressed, open air bleeder valve to release
air.
5. Close air bleeder valve.
6. Release clutch pedal and wait for 5 seconds.
7. Repeat steps 3 to 6 until no bubbles can be observed in clutch
fluid.
8. Tighten air bleeder valve to the specified torque. Refer to CL-12,
"Components" .
SCL839
CL-8
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CLUTCH MASTER CYLINDER

Components
PFP:30610
A
ECS00G83
RHD models
B
CL
G
PCIB0763E
1.
Nipple
2.
Clamp
3.
Hose
4.
Cylinder body
5.
Seat
6.
Clevis
7.
Clevis pin
8.
Snap pin
9.
Stopper ring
10.
Stopper
11. Push rod
12. Piston assembly
13.
Return spring
14. Seal
15. Spring pin
LHD models
J
PCIB0764E
1.
Nipple
2.
Clamp
3.
Hose
4.
Cylinder body
5.
Seat
6.
Clevis
7.
Clevis pin
Stopper ring
8.
Snap pin
9.
10. Stopper
11.
Push rod
12.
Piston assembly
13. Return spring
14. Seal
15.
Spring pin
CL-9
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ECS008BA
REMOVAL
1.
2.
3.
4.
Using one of the following methods, remove hose from nipple.

Drain clutch fluid from reservoir tank and remove hose.
Remove hose from nipple. Immediately plug hose and reservoir tank to prevent clutch fluid from dripping.
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
Remove clutch tube using a flare nut torque wrench.
Remove snap pin and clevis pin on clevis in passenger compartment to separate clutch pedal.
Remove mounting nuts on master cylinder assembly, and then master cylinder assembly from vehicle.
INSTALLATION
1.
Check position of clevis and push rod. If measurement is outside

the standard length, adjust position of clevis and push rod.
Length L
RHD models
LHD models
2.
3.
4.
5.
6.
7.
8.
: 125.5 mm (4.80 in)

: 122.0 mm (4.94 in)
Connect clutch tube to master cylinder assembly and temporarily tighten flare nut.
Install master cylinder assembly and tighten mounting nuts to
the specified torque. Refer to CL-9, "Components" .
SCIA5158E
Tighten clutch tube flare nut to the specified torque using a flare
nut torque wrench. Refer to CL-13, "Removal and Installation" .
Set clevis to clutch pedal and insert clevis pin.
Attach snap pin to clevis pin.
Install hose to nipple.
After completing this procedure, inspect and adjust for clutch pedal and then bleed the air from the clutch
hydraulic system. Refer to CL-5, "On-Vehicle Inspection and Adjustment" and CL-8, "Air Bleeding Procedure" .
ECS008BB
DISASSEMBLY
1.
2.
3.
4.
5.
6.
Remove spring pin using a pin punch.

Remove nipple and seal from cylinder body.
Loosen push rod lock nut then remove clevis and lock nut, if
necessary.
NOTE:
Clutch pedal height is controlled with position of clevis and push
rod.
Remove seat from cylinder body.
Remove stopper ring and stopper. Remove push rod from cylinder body while holding it securely to prevent piston assembly
popping out.
Remove piston assembly and return spring.

Check for any of the conditions shown below. If any malfunction is found, replace the part concerned.
Damaged cylinder internal wall, foreign matter, wear, corrosion, or pinhole
Damaged or deformed nipple or reservoir tank
Settling of return spring
Cracked or deformed seat
CL-10
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PCIB0274E

ASSEMBLY
1.
2.
3.
4.
5.
6.
Apply rubber lubricant to the internal surface of cylinder body, the sliding surface of piston assembly, and A
piston cup. Insert return spring and piston assembly to cylinder body.
Apply silicon grease to push rod and install stopper. Install stopper ring while holding down push rod by
hand to prevent piston assembly from popping out.
B
Install seat to cylinder body.
Install seal and nipple to cylinder body. Install spring pin using a pin punch.
CL
Install clevis to push rod.
Check and adjust the positions of clevis and push rod. After
adjusting L, tighten lock nut to the specified torque. Refer to
D
CL-9, "Components" .
Length L
RHD models
LHD models
: 125.5 mm (4.80 in)

: 122.0 mm (4.94 in)
F
SCIA5158E
CL-11
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OPERATING CYLINDER
OPERATING CYLINDER
Components
PFP:30620
ECS00G84
PCIB0765E
1.
Air bleeder valve
2.
Copper washer
3.
Union bolt
4.
Clutch hose
5.
Cylinder body
6.
Dust cover
7.
Push rod
8.
Piston assembly
9.
Piston cup
10. Piston spring
ECS008BC
REMOVAL
1.
2.
3.
Drain clutch fluid.

CAUTION:
Remove clutch hose from operating cylinder.
Remove operating cylinder mounting bolts and remove operating cylinder from the vehicle.
INSTALLATION
Install hose with care so that it will not be bent or twisted.
After completing the procedure, bleed the air from the clutch hydraulic system. Refer to CL-8, "Air Bleeding Procedure" .
ECS008BD
DISASSEMBLY
Remove dust cover and push rod. Then remove piston, piston cup, and piston spring from inside cylinder
body.

Check for any of the conditions shown below. If any malfunction is found, replace the part concerned.
Damage to cylinder internal surface or piston sliding surface. Foreign matter, wear, corrosion, or pinhole
Settling of piston spring
Cracked or deformed dust cover
ASSEMBLY
1.
2.
Apply rubber lubricant to cylinder body internal surface and rubber grease to piston cup and piston. Insert
piston assembly and piston spring into cylinder body.
Apply rubber grease to dust cover and install push rod and dust cover.
CL-12
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CLUTCH PIPING
CLUTCH PIPING
PFP:30650
A
ECS008BE
CL
D
PCIB0813E
1.
Clutch tube
2.
Lock plate
3.
Clutch hose
4.
Operating cylinder
5.
Clutch pedal
6.
Master cylinder
Carefully observe the following steps during clutch tube removal and installation.
CAUTION:
To fix clutch hose on bracket, position clutch hose clasp on the

emboss of bracket and drive lock plate vertically from above. Be
careful not to bend or twist clutch hose. Do not scratch or damage clutch hose.
Tighten clutch tube flare nut to the specified torque.
Tighten clutch hose union bolt to the specified torque.

CAUTION:
Do not reuse copper washer.
After installation, bleed the air from the clutch hydraulic system.
Refer to CL-8, "Air Bleeding Procedure" .
PCIB0681E
CL-13
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CLUTCH RELEASE MECHANISM

PFP:30502
ECS008BF
COMPONENTS
QR engine models
PCIB0767E
1.
Dust cover
4.
Release bearing
2.
Withdrawal lever
3.
Retainer spring
3.
Snap spring
YD engine models
PCIB1453E
1.
Dust cover
4.
Release bearing
2.
Withdrawal lever
REMOVAL
1.
2.
3.
4.
Remove manual transaxle from the vehicle. Refer to MT-17, "Removal and Installation" .
Remove release bearing and withdrawal lever from inside clutch housing.
Remove dust cover.
Remove retainer spring (QR engine models) or snap spring (YD engine models) from withdrawal lever.
CL-14
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If release bearing is seized, damaged, not properly centered or

does not rotate smoothly, replace it.
If contact surface of withdrawal lever is excessively worn,
replace it.
If dust cover is cracked, replace it.
CL
SCL733
INSTALLATION
CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or judder. Wipe off any grease oozing
from the parts.
Be careful not to bring any grease to the clutch disk facing, pressure plate surface and flywheel
surface.
1. Following the instructions below, apply grease to the specified points.
J
SCL815
2.
CAUTION:
Wipe off any old grease, debris, or powdery residue left on the grease applying surfaces.
Evenly apply approximately 1 mm (0.04 in) thick coating of recommended grease to withdrawal lever
and release bearing sliding surface.
Apply recommended grease to withdrawal lever ball pin contact surface and inner slots of release bearing. The grease surface should be level with the surrounding area.
Apply a thin coat of recommended grease evenly to release bearing sliding surface. Install release
bearing. Wipe off any excess grease that oozes from the parts and then remove release bearing.
CAUTION:
Before installing manual transaxle to the vehicle, make sure that each sliding surface slides
smoothly by operating withdrawal lever.
When assembling, make sure that both ends of snap
spring touch the end face of withdrawal lever. (For YD
engine models)
Be careful with the orientation snap spring. (For YD
engine models)
SCIA6903E
CL-15
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CLUTCH DISC, CLUTCH COVER AND FLYWHEEL

PFP:30100
ECS008BG
COMPONENTS
QR engine models
PCIB0768E
1.
Flywheel
2.
Clutch disc
3.
Clutch cover
YD engine models
PCIB0769E
1.
Flywheel
2.
Clutch disc
3.
Clutch cover
CAUTION:
Be careful not to bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.
REMOVAL
1.
2.
Remove manual transaxle from the vehicle. Refer to MT-17, "Removal and Installation"
Loosen clutch cover mounting bolts evenly. Then remove clutch cover and clutch disc.
CL-16
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INSPECTION AND ADJUSTMENT AFTER REMOVAL
Clutch Disc
Measure circumferential runout relative to clutch disc center

spline. If it is outside the specification, replace clutch disc.
B
Runout limit/diameter of the area to be measured

: 1.0 mm (0.039 in) /230 mm (9.06 in) dia.
Maximum allowable spline backlash

: 1.0 mm (0.039 in)
CL
Measure clutch disc spline and input shaft spline backlash at the
circumference of clutch disc. If outside the specification, replace
clutch disc.
SCL221
Using calipers, measure the depth to clutch disc facing rivet

heads. If it exceeds the allowable wear limit, replace clutch disc.
Facing wear limit (depth to the rivet head)

: 0.3 mm (0.012 in)
SCL229
Clutch Cover
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
using the diaphragm adjusting wrench.
Tolerance for diaphragm spring lever unevenness

: 0.7 mm (0.028 in) or less
Tool number
: ST20050240
Check clutch cover thrust ring for wear or breakage. If wear or

breakage is found, replace clutch cover assembly.
NOTE:
PCIB0276E
Worn thrust ring will generate a beating noise when tapped at
the rivet with a hammer.
Broken thrust ring will make a clinking sound when cover is shaken up and down.
If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace the assembly.
Flywheel Runout
Using a dial indicator, measure runout at the flywheel clutch contact
surface. If runout is outside the specification, replace flywheel. If a
trace of burn or discoloration is found on the surface, repair it with
sandpaper.
Allowable flywheel runout
QR engine models
: Refer to EM-113, "FLYWHEEL DEFLECTION (M/T
MODELS)" .
YD engine models
: Refer to EM-248, "FLYWHEEL DEFLECTION" .
CAUTION:
Measure it at flywheel outer face (not on knock pin and clutch cover mounting hole).
CL-17
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PBIC2168E

INSTALLATION
1.
2.
Apply recommended grease to clutch disc and input shaft splines.

CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or judder. Wipe off any grease oozing
from the parts.
Install clutch disc and clutch cover. Pre-tighten mounting bolts
and install clutch aligning bar.
Tool number
QR engine models
YD engine models
3.
4.
: KV30101600
: KV30100100
Tighten clutch cover mounting bolts evenly in two steps in the

order shown in the figure. Refer to CL-16, "COMPONENTS" .
Install manual transaxle. Refer to MT-17, "Removal and Installation" .
CL-18
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SCIA0909E

Clutch Control System
PFP:00030
A
ECS008BH
Type of clutch control
Hydraulic
Clutch Master Cylinder
ECS008BI
Inner diameter
15.87 mm (5/8 in)
CL
Clutch Operating Cylinder
ECS008BJ
Inner diameter
19.05 mm (3/4 in)
Clutch Disc
Engine model
ECS008BK
QR20DE
QR25DE
Model
YD22DDTi
240
Facing size
(outer dia. x inner dia. x thickness)
240 mm x 160 mm x 3.5 mm (9.45 in x 6.30 in x 0.138 in)
240 mm x 170 mm x 3.5 mm

(9.45 in x 6.69 in x 0.138 in)
Thickness of disc assembly with load
7.90 - 8.30 mm (0.3110 - 0.3268 in) with 5,688 N (580 kg,

1,279 lb)
7.70 - 8.10 mm (0.303 0.319 in) with 7,845N (800

kg, 1,764 lb)
Wear limit of facing surface to rivet head
0.3 mm (0.012 in)
Runout limit/diameter of the area to be

measured
1.0 mm (0.039 in) / 230 mm (9.06 in) dia.
Maximum spline backlash

(at outer edge of disc)
1.0 mm (0.039 in)
Clutch Cover
Engine model
ECS008BL
QR20DE
Model
Set-load
QR25DE
240
4,903 N (500 kg, 1,103 lb)
Diaphragm spring lever height
YD22DDTi
250
5,884 N (600 kg, 1,323 lb)
7,600 N (775 kg, 1,708 lb)
37.0 - 39.0 mm (1.457 - 1.535 in)
Uneven limit diaphragm spring toe height
0.7 mm (0.028 in) or less
CL-19
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CL-20
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MANUAL TRANSAXLE
SECTION
MT
MANUAL TRANSAXLE
MT
CONTENTS
PRECAUTIONS .......................................................... 3
Service Notice or Precautions .................................. 3
PREPARATION ........................................................... 4
TROUBLESHOOTING ................................................ 8
NVH Troubleshooting Chart ..................................... 8
DESCRIPTION ............................................................ 9
Cross-Sectional View ............................................... 9
DOUBLE-CONE SYNCHRONIZER .................... 10
TRIPLE-CONE SYNCHRONIZER ...................... 10
REVERSE GEAR NOISE PREVENTION FUNCTION (SYNCHRONIZING METHOD) ................. 10
M/T OIL ......................................................................11
Changing M/T Oil ....................................................11
DRAINING ............................................................11
FILLING ................................................................11
Checking M/T Oil .....................................................11
OIL LEAKAGE AND OIL LEVEL ..........................11
SIDE OIL SEAL ........................................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
POSITION SWITCH .................................................. 13
Checking ................................................................ 13
BACK-UP LAMP SWITCH .................................. 13
PARK/NEUTRAL POSITION SWITCH ............... 13
CONTROL LINKAGE ............................................... 14
Components of Control Device and Cable ............. 14
AIR BREATHER HOSE ............................................ 16
TRANSAXLE ASSEMBLY ........................................ 17
COMPONENTS .................................................. 17
REMOVAL ........................................................... 17
INSTALLATION ................................................... 18
Disassembly and Assembly (RS5F51A) ................ 19
COMPONENTS .................................................. 19
DISASSEMBLY ................................................... 23
ASSEMBLY ......................................................... 27
ADJUSTMENT .................................................... 33
Disassembly and Assembly (RS6F51A) ................. 37
COMPONENTS ................................................... 37
DISASSEMBLY ................................................... 41
ASSEMBLY ......................................................... 45
ADJUSTMENT .................................................... 51
INPUT SHAFT AND GEARS .................................... 55
DISASSEMBLY ................................................... 55
ASSEMBLY ......................................................... 59
DISASSEMBLY ................................................... 63
ASSEMBLY ......................................................... 67
MAINSHAFT AND GEARS ....................................... 71
DISASSEMBLY ................................................... 71
ASSEMBLY ......................................................... 74
DISASSEMBLY ................................................... 78
ASSEMBLY ......................................................... 81
REVERSE IDLER SHAFT AND GEARS .................. 87
DISASSEMBLY ................................................... 87
ASSEMBLY ......................................................... 88
DISASSEMBLY ................................................... 88
ASSEMBLY ......................................................... 89
FINAL DRIVE ............................................................ 91
PRE-INSPECTION .............................................. 91
DISASSEMBLY ................................................... 91
MT-1
http://vnx.su
ASSEMBLY ......................................................... 92
PRE-INSPECTION .............................................. 94
DISASSEMBLY ................................................... 94
ASSEMBLY ......................................................... 96
SHIFT CONTROL ...................................................... 98
Inspection (RS5F51A) ............................................ 98
SHIFT FORK ....................................................... 98
Inspection (RS6F51A) ............................................ 99
SHIFT FORK ....................................................... 99
General Specifications .......................................... 100
TRANSAXLE ..................................................... 100
FINAL GEAR ..................................................... 101
Gear End Play ...................................................... 101
Baulk Ring Clearance ........................................... 101
Available Snap Rings ............................................ 102
INPUT SHAFT BEARING SPACER .................. 102
6TH INPUT GEAR BUSHING ........................... 102
5TH MAIN GEAR ............................................... 102

Available C-Rings ................................................. 102
MAINSHAFT C-RING ........................................ 102
Available Thrust Washer ....................................... 103
INPUT SHAFT THRUST WASHER ................... 103
DIFFERENTIAL SIDE GEAR THRUST WASHER
.103
Available Adjusting Shims ..................................... 103
4TH MAIN GEAR ADJUSTING SHIM ................ 103
INPUT SHAFT REAR BEARING ADJUSTING
SHIM .................................................................. 104
MAINSHAFT REAR BEARING ADJUSTING
SHIM .................................................................. 104
REVERSE IDLER GEAR ADJUSTING SHIM .... 104
6TH MAIN GEAR ADJUSTING SHIM ................ 104
Available Shims .................................................... 105
BEARING PRELOAD ......................................... 105
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIM(S) ............................................................. 105
MT-2
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PRECAUTIONS
PRECAUTIONS
PFP:00001
A
ECS008BM
Do not reuse transaxle oil, once it has been drained.

B
Check oil level or replace oil with vehicle on level surface.
During removal or installation, keep inside of transaxle clear of dust or dirt.
Check for the correct installation status prior to removal or disassembly. If matching mark are required, be
MT
certain they do not interfere with the function of the parts they are applied.
In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, use it.
D
Be careful not to damage sliding surfaces and mating surfaces.
MT-3
http://vnx.su
PREPARATION
PREPARATION
PFP:00002
ECS008BN
Tool number
Tool name
Description
KV381054S0
Puller
Removing differential side bearing outer

race
Removing mainshaft front bearing
Installing input shaft oil seal
Installing reverse main gear
Installing 1st main gear bushing
Installing 1st-2nd synchronizer hub

assembly
Installing 2nd main gear bushing
Installing 3rd main gear
Removing differential side bearing (clutch

housing side)
Installing differential oil seal
Installing differential side bearing outer race
Installing mainshaft rear bearing
Installing differential side bearing
Installing mainshaft front bearing
Installing 6th input gear bushing

(RS6F51A)
Installing 4th main gear
Installing 6th main gear (RS6F51A)
ZZA0601D
ST35321000
Drift
a: 49 mm (1.93 in) dia.
b: 41 mm (1.61 in) dia.
ZZA1000D
ST30720000
Drift
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
ZZA0811D
ST33200000
Drift
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.
ZZA1002D
KV40105320
Drift
a: 88 mm (3.46 in) dia.
Installing differential side bearing outer race
ZZA0898D
ST33061000
Drift
a: 38 mm (1.50 in) dia.
b: 28.5 mm (1.122 in) dia.
ZZA1000D
MT-4
http://vnx.su
Installing bore plug
Removing differential side bearing

(transaxle case side)
PREPARATION
Tool number
Tool name
Description
ST33052000
Drift
a: 22 mm (0.87 in) dia.
b: 28 mm (1.10 in) dia.
Installing welch plug
Removing input shaft rear bearing
Removing input shaft bearing spacer and

5th stopper (RS5F51A)
Removing 5th input gear bushing, thrust

washer, 4th input gear, 4th input gear
bushing, 3rd-4th synchronizer hub
assembly and 3rd input gear
Installing input shaft front bearing
Removing 6th input gear and 6th input gear

bushing (RS6F51A)
Removing mainshaft rear bearing
Removing 4th main gear and 5th main gear
Removing 6th main gear (RS6F51A)
Removing 5th input gear, 5th synchronizer

hub assembly (RS5F51A) and 5th-6th
synchronizer hub assembly (RS6F51A)
Removing 3rd main gear, 2nd main gear,

2nd main gear bushing, 1st-2nd
synchronizer hub assembly, 1st main gear,
reverse main gear and 1st main gear
bushing
ZZA1023D
KV40105020
Drift
a: 39.7 mm (1.563 in) dia.
b: 35 mm (1.38 in) dia.
c: 15 mm (0.59 in)
ZZA1133D
KV40105710
Press stand
a: 46 mm (1.81 in) dia.
b: 41 mm (1.61 in)
Installing 3rd-4th synchronizer hub

assembly
Installing 5th synchronizer hub assembly

(RS5F51A)
Installing 5th-6th synchronizer hub

assembly (RS6F51A)
Installing 2nd main gear bushing
Installing 3rd main gear

assembly
ZZA1058D
ST38220000
Press stand
a: 63 mm (2.48 in) dia.
b: 65 mm (2.56 in)
ZZA1058D
ST30032000
Drift
a: 80 mm (3.15 in) dia.
b: 38 mm (1.50 in) dia.
c: 31 mm (1.22 in) dia.
Installing 5th stopper and input shaft

bearing spacer (RS5F51A)
Installing input shaft front bearing
Installing input shaft rear bearing
Installing 6th main gear (RS6F51A)
Installing mainshaft rear bearing
ZZA0978D
ST30901000
Drift
a: 79 mm (3.11 in) dia.
b: 45 mm (1.77 in) dia.
c: 35.2 mm (1.386 in) dia.
ZZA0978D
MT-5
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MT
PREPARATION
Tool number
Tool name
Description
ST30031000
Puller
Measuring wear of inner baulk ring
ZZA0537D
KV40101630
Drift
a: 68 mm (2.68 in) dia.
b: 60 mm (2.36 in) dia.
ZZA1003D
KV38102510
Drift
a: 71 mm (2.80 in) dia.
b: 65 mm (2.56 in) dia.

assembly
Installing differential side bearing (transaxle

case side)
ZZA0838D
Installing differential side bearing (clutch

housing side)
KV40104830
Drift
a: 70 mm (2.76 in) dia.
b: 63.5 mm (2.500 in) dia.
ZZA0936D
ST15243000
Drift
a: 30 mm (1.18 in) dia.
Measuring end play of side gear
SCIA1088J
ECS008BO
Tool name
Description
Puller
Removing each bearing, gear and bushing
ZZA0537D
MT-6
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PREPARATION
Tool name
Description
Puller
Removing each bearing, gear and bushing
MT
NT077
Pin punch
Tip diameter: 4.5 mm (0.177 in) dia.
Removing and installing each retaining pin
E
ZZA0815D
MT-7
http://vnx.su

NVH Troubleshooting Chart
PFP:00003
ECS008BP
Hard to shift or will not shift
Jumps out of gear
MT-8
BEARING (Worn or damaged)
MT-20 (RS5F51A), MT-38 (RS6F51A)

GEAR (Worn or damaged)
MT-22 (RS5F51A), MT-40 (RS6F51A)
2
2
1
http://vnx.su
SHIFT FORK (Worn)
O-RING (Worn or damaged)
OIL SEAL (Worn or damaged)

2
INSERT SPRING (Damaged)
Oil leakage
GASKET (Damaged)
OIL (Oil level is high.)
BAULK RING (Worn or damaged)
Symptoms
OIL (Wrong oil.)
Noise
OIL (Oil level is low.)
SUSPECTED PARTS
(Possible cause)
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)
MT-14
Reference page
SHIFT CONTROL LINKAGE (Worn)
MA-39
MT-19 (RS5F51A), MT-37 (RS6F51A)
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspection. If necessary, repair or replace these parts.
DESCRIPTION
DESCRIPTION
Cross-Sectional View
PFP:00000
A
ECS008BQ
MT
PCIB0773E
1.
3rd input gear
2.
3rd-4th synchronizer hub
3.
3rd-4th coupling sleeve
4.
4th input gear
5.
5th input gear
6.
5th synchronizer hub
7.
5th coupling sleeve
8.
Input shaft rear bearing
9.
Mainshaft rear bearing
10. 5th main gear
11. 4th main gear
12. 3rd main gear
13. 2nd main gear
14. 1st-2nd coupling sleeve
15. 1st-2nd synchronizer hub
16. 1st main gear
17. Reverse main gear
18. Differential side bearing
19. Differential case
20. Final gear
22. Mainshaft front bearing
23. Mainshaft
24. Input shaft
25. Input shaft front bearing
26. Clutch housing
27. Reverse idler shaft
28. Reverse idler gear (Front)
29. Reverse coupling sleeve
30. Reverse synchronizer hub
31. Reverse idler gear (Rear)
32. 5th input gear
33. 5th-6th synchronizer hub
34. 5th-6th coupling sleeve
35. 6th input gear
36. Input shaft rear bearing
37. Mainshaft rear bearing
38. 5th main gear
39. 6th main gear
MT-9
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DESCRIPTION
DOUBLE-CONE SYNCHRONIZER
Double-cone synchronizer is adopted for 3rd gear to reduce operating force of the shift lever.
TRIPLE-CONE SYNCHRONIZER
Triple-cone synchronizer is adopted for 1st and 2nd gears to reduce operating force of the shift lever.
PCIB1454E
REVERSE GEAR NOISE PREVENTION FUNCTION (SYNCHRONIZING METHOD)

Reverse gear can be matched smoothly in a structure by setting synchronizer hub, coupling sleeve, baulk ring and insert spring to
reverse gear, and letting reverse gear be synchronized.
PCIB0775E
MT-10
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M/T OIL
M/T OIL
Changing M/T Oil
PFP:KLD20
A
ECS008BR
DRAINING
1.
2.
3.
Start engine and let it run to warm up transaxle.

B
Stop engine. Remove drain plug and then drain oil.
Set a gasket on drain plug and install it to transaxle case. Tighten drain plug to the specified torque. Refer
to MT-19, "Case and Housing Components" (RS5F51A) or MT-37, "Case and Housing Components" MT
(RS6F51A).
CAUTION:
Do not reuse gasket.
D
FILLING
1.
Remove filler plug. Fill with new oil to transaxle.

Oil grade and viscosity
Oil capacity (reference)
2.
3.
: Refer to MA-17, "Fluids and Lubricants"

: Approx. 2.2
(3-7/8 lmp pt)
After refilling oil, check oil level.

Set a gasket on filler plug and then install it to clutch housing. Tighten filler plug to the specified torque.
Refer to MT-19, "Case and Housing Components" (RS5F51A) or MT-37, "Case and Housing Components" (RS6F51A).
CAUTION:
Checking M/T Oil
ECS008BS
OIL LEAKAGE AND OIL LEVEL
Make sure that oil is not leaking from transaxle or around it.
Measure oil level using a suitable gauge as shown in the figure,
and then check if it is within the specifications.
Oil level L
: 165.0 - 171.0 mm (6.50 - 6.73 in)
CAUTION:
Do not start engine while checking oil level.
Set a gasket on filler plug and then install it to clutch housing.
Tighten filler plug to the specified torque. Refer to MT-19, "Case
and Housing Components" (RS5F51A) or MT-37, "Case and
Housing Components" (RS6F51A).
CAUTION:
PCIB1478E
MT-11
http://vnx.su
SIDE OIL SEAL

SIDE OIL SEAL
PFP:32113
ECS008BT
REMOVAL
1.
2.
Clutch housing side oil seal used on 4WD vehicles is attached to transfer. Be sure to replace it
when transfer is removed.
Remove drive shaft from transaxle. Refer to FAX-11, "Removal and Installation" .
Remove oil seal with a flat-bladed screwdriver.
CAUTION:
Be careful not to damage the case surface when removing
oil seal.
SCIA0824E
INSTALLATION
1.
Using the drift, drive the oil seal straight until it protrudes from
the case end equal to dimension A shown in the figure.
Dimension A
: Within 0.5 mm (0.020 in) of flush with the case.
Drift to be used:
Transaxle case side
Clutch housing side
: ST30720000
: ST30720000
CAUTION:
SCIA0352E
Apply multi-purpose grease onto oil seal lip. (For clutch
housing side)
Do not reuse oil seal.
Install all parts in the reverse order of removal and check oil level after installation. Refer to MT-11,
"Checking M/T Oil" .
2.
MT-12
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POSITION SWITCH
POSITION SWITCH
Checking
PFP:32005
A
ECS008BU
BACK-UP LAMP SWITCH
Check continuity.
Gear position
B
Continuity
Reverse
Yes
Except reverse
No
MT
SCIA5644E
PARK/NEUTRAL POSITION SWITCH
Check continuity.
F
Gear position
Continuity
Neutral
Yes
Except neutral
No
MT-13
http://vnx.su
CONTROL LINKAGE
CONTROL LINKAGE
Components of Control Device and Cable
PFP:34103
ECS008BV
PCIB0777E
1.
Control lever knob
2.
Select cable
3.
Shift cable
4.
Lock plate (shift side)
5.
Lock plate (select side)
6.
Clutch housing
7.
Cable mounting bracket
8.
Control device assembly
9.
Control lever
10. Lock plate
11. Washer
12. Snap pin
13. Washer
MT-14
http://vnx.su
CONTROL LINKAGE
ECS00CY6
A
Note the following, when removal and installation.
Shift the control lever to the neutral position for removal.
Keep in mind that the select side lock plate for securing control cable is different from the shift side lock B
plate.
After assembly, make sure selector lever automatically returns to Neutral when it is moved to 1st, 2nd, or
Reverse.
MT
Install select cable according to the following procedure.
1. Install select cable of transaxle side to control assembly.
2. Install select cable to pin on select lever part of control device
D
assembly.
E
PCIB0815E
3.
4.
Push lock part (A) of select cable all the way to the direction of
the arrow. (For 6 M/T models)
Slide stopper part (B) all the way to lock part (A) as shown by
the arrow. (For 6 M/T models)
CAUTION:
Make sure that select cable and select lever are installed
securely.
J
PCIB0817E
MT-15
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AIR BREATHER HOSE

AIR BREATHER HOSE
PFP:31098
ECS008BW
Refer to the figure for air breather hose removal and installation information.
QR engine models
PCIB0778E
1.
Air cleaner case
2.
Transaxle
3.
Clip
4.
Air breather hose
5.
Clip
6.
PCV hose
7.
Resonator
YD engine models
PCIB0779E
1.
Air cleaner case
2.
Transaxle
3.
Clip
4.
Clip
5.
Air breather hose
6.
Clip
7.
Bracket
8.
CAUTION:
Make sure there are no pinched or restricted areas on air breather hose caused by bending or
winding when installing it.
Be sure to insert air breather hose into air breather tube until overlap area reaches the spool.
MT-16
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TRANSAXLE ASSEMBLY
TRANSAXLE ASSEMBLY
PFP:32010
A
ECS008BX
COMPONENTS
B
MT
PCIB1476E
1.
Center member
2.
3.
4.
Transaxle assembly
5.
6.
7.
LH engine mounting insulator
8.
Stopper
9.
LH engine mounting bracket
Grommet
REMOVAL
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Remove air cleaner, air duct and battery. Refer to EM-16, "Removal and Installation" (QR engine models)
or EM-139, "Removal and Installation" (YD engine models).
Remove air breather hose. Refer to MT-16, "Removal and Installation" .
Remove clutch operating cylinder. Refer to CL-12, "Removal and Installation" .
CAUTION:
Do not depress clutch pedal during removal procedure.
Disconnect control cable from transaxle assembly. Refer to MT-15, "Removal and Installation" .
Drain gear oil. Refer to MT-11, "DRAINING" .
Disconnect PNP switch, back-up lamp switch and ground harness connectors.
Remove exhaust front tube. Refer to EX-2, "Removal and Installation" .
Remove drive shaft. Refer to FAX-11, "FRONT DRIVE SHAFT" .
Remove transfer. Refer to TF-57, "Removal and Installation" .
Remove starter motor. Refer to SC-26, "Removal and Installation" .
Support transaxle assembly with a jack.
CAUTION:
When setting a jack, be careful not to bring it into contact with switches.
Remove center member, engine insulator and engine mount bracket. Refer to EM-82, "ENGINE ASSEMBLY" (QR engine models) or EM-219, "ENGINE ASSEMBLY" (YD engine models).
MT-17
http://vnx.su
TRANSAXLE ASSEMBLY
14.
15.
16.
17.
Remove suspension members. Refer to FSU-12, "FRONT SUSPENSION MEMBER" .

Support engine with a jack under oil pan.
Remove transaxle assembly mounting bolts.
Remove transaxle assembly from the vehicle.
CAUTION:
Secure transaxle assembly to a jack while removing it.
MTD0062D
INSTALLATION
When installing the transaxle assembly to the engine, install the mounting bolts following the standard
below.
CAUTION:
When installing transaxle assembly, be careful not to bring transaxle input shaft into contact with
clutch cover.
QR engine models
Bolt No.
Quantity
40
(1.57)
75
(2.95)
45
(1.77)
40
(1.57)
30
(1.18)
40
(1.57)
Bolt length
mm (in)
Tightening torque
Nm (kg - m, ft- lb)
74.5
(7.6, 55)
42.7
(4.4, 31)
35.3
(3.6, 26)
SCIA0353E
YD engine models
Bolt No.
Quantity
55
(2.17)
50
(2.76)
120
(4.72)
45
(1.77)
40
(1.57)
35
(1.38)
Bolt length
mm (in)
Tightening torque
Nm (kg - m, ft- lb)
44
(4.5, 32)
33.5
(3.4, 25)
After installation, check oil level, and check for leaks and loose
mechanisms. Refer to MT-11, "Checking M/T Oil" .
MT-18
http://vnx.su
SCIA0748E
TRANSAXLE ASSEMBLY
Disassembly and Assembly (RS5F51A)
ECS008C0
COMPONENTS
Case and Housing Components
MT
PCIB1471E
1.
Clutch housing
2.
Differential oil seal
3.
Ball pin
4.
Washer
5.
Input shaft oil seal
6.
Oil channel
7.
Magnet
8.
Gasket
9.
Filler plug
10. Back-up lamp switch
11. Oil gutter
12. Baffle plate
13. Transaxle case
14. Plug
15. Welch plug
16. Bore plug
17. Drain plug
18. Differential oil seal
19. Park/Neutral position (PNP) switch
20. Air breather tube
MT-19
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TRANSAXLE ASSEMBLY
Gear Components
PCIB1458E
1.
Input shaft front bearing
2.
Input shaft
3.
3rd needle bearing
4.
3rd input gear
5.
3rd inner baulk ring
6.
3rd synchronizer cone
7.
3rd outer baulk ring
8.
3rd-4th spread spring
9.
3rd-4th shifting insert
10. 3rd-4th synchronizer hub
11. 4th baulk ring
12. 3rd-4th coupling sleeve
13. 4th input gear bushing
14. 4th needle bearing
15. 4th input gear
16. Thrust washer
19. 5th input gear
20. 5th baulk ring
21. 5th spread spring
22. 5th shifting insert
23. 5th synchronizer hub
24. 5th coupling sleeve
25. 5th stopper
26. Input shaft bearing spacer
27. Snap ring
29. Oil channel
30. Input shaft rear bearing adjusting

shim
31. Retaining pin
33. Thrust needle bearing
34. Reverse idler gear needle bearing
35. Reverse insert spring
37. Reverse baulk ring
40
Reverse idler gear adjusting shim
MT-20
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TRANSAXLE ASSEMBLY
A
MT
PCIB0783E
1.
Mainshaft front bearing
4.
Reverse main gear
5.
1st main gear
6.
1st main gear bushing
7.
1st needle bearing
8.
1st inner baulk ring
9.
1st synchronizer cone
10. 1st outer baulk ring
2.
Mainshaft bearing retainer
11. 1st-2nd spread spring
3.
14. 2nd outer baulk ring
15. 2nd synchronizer cone
16. 2nd inner baulk ring
18. 2nd main gear bushing

21. 3rd main gear
19. 2nd needle bearing
20. 2nd main gear
22. 3rd-4th mainshaft spacer
23. 4th main gear adjusting shim
24. 4th main gear
25. 5th main gear
26. Snap ring
28. Mainshaft C-ring
29. C-ring holder
30. Snap ring
31. Snap ring
32. Mainshaft rear bearing adjusting shim
MT-21
12. 1st-2nd shifting insert
http://vnx.su
Mainshaft
TRANSAXLE ASSEMBLY
Shift Control Components
PCIB0868E
1.
3rd-4th bracket
2.
Retaining pin
3.
Stopper ring
4.
5th-reverse bracket
5.
Reverse lever assembly
6.
Shifter cap
7.
Reverse shift fork
8.
Reverse fork rod
9.
Check plug
10. Check spring
11. Shift check sleeve
12. Check ball
13. 5th-reverse fork rod
14. 5th shift fork
15. Check spring
16. 3rd-4th fork rod
17. Interlock pin
19. 1st-2nd fork rod
20. 1st-2nd bracket
21. 1st-2nd shift fork
22. 3rd-4th shift fork
23. Control assembly
24. Transaxle case
25. Stopper bolt
26. Shift check
27. O-ring
MT-22
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TRANSAXLE ASSEMBLY
Final Drive Components
A
MT
PCIB0872E
1.
Differential side bearing outer race

(clutch housing side)
2.
Differential side bearing (clutch

housing side)
3.
Differential case
4.
Final gear
5.
Differential side bearing (transaxle

case side)
6.

7.
Differential side bearing adjusting

shim
8.
Pinion mate shaft
9.
Side gear
10. Side gear thrust washer
K
11. Pinion mate gear
12. Pinion mate thrust washer
13. Retaining pin
DISASSEMBLY
1.
2.
3.
4.
Remove filler plug from clutch housing.

Remove drain plug and plug from transaxle case.
Remove park/neutral position switch and back-up lamp switch
from transaxle case.
Remove shift check and stopper bolt from transaxle case, and
then remove control assembly from transaxle case.
SCIA0389E
MT-23
http://vnx.su
TRANSAXLE ASSEMBLY
5.
Remove check plugs (3 pieces), check springs (3 pieces), check

balls (3 pieces) and shift check sleeve (1 piece).
SCIA0396E
6.
7.
Remove transaxle case mounting bolts.

Remove bore plug from transaxle case.
CAUTION:
Be careful not to damage transaxle case.
8. While spreading the snap ring of mainshaft rear bearing located
at bore plug hole, remove transaxle case from clutch housing.
9. Remove oil gutter, baffle plate from transaxle case.
10. Remove snap ring, mainshaft rear bearing adjusting shim from
transaxle case.
11. Remove input shaft rear bearing adjusting shim and reverse
idler gear adjusting shim.
SCIA0983E
12. Remove differential side bearing outer race from transaxle case
using the puller, and then remove differential side bearing
adjusting shim from transaxle case.
SCIA0897E
13. Remove welch plug from transaxle case.
SCIA0402E
MT-24
http://vnx.su
TRANSAXLE ASSEMBLY
14. Remove differential oil seal from transaxle case.
CAUTION:
15. Remove magnet from clutch housing.
MT
SCIA0397E
16. With shift lever in 5th position, remove mounting bolts from
reverse lever assembly. Lift reverse lever assembly to remove.
CAUTION:
Be careful not to lose shifter cap.
17. Pull out reverse fork rod then remove reverse shift fork.
G
SCIA0390E
18. Shift 3rd-4th fork rod to 3rd position. Remove retaining pin of 5th
shift fork using a pin punch.
SCIA0391E
19. Remove stopper rings for 5th-reverse bracket.

20. Pull out 5th-reverse fork rod and remove 5th shift fork and 5threverse bracket.
21. Remove check balls (2 pieces) from clutch housing.
SCIA0392E
22. Remove retaining pin of 3rd-4th bracket using a pin punch.

23. Remove stopper rings for 3rd-4th shift fork.
24. Pull out 3rd-4th fork rod and remove 3rd-4th shift fork and 3rd4th bracket.
25. Remove interlock pin and shift check sleeve from clutch housing.
SCIA0393E
MT-25
http://vnx.su
TRANSAXLE ASSEMBLY
26.
27.
28.
29.
Remove retaining pin of 1st-2nd shift fork using a pin punch.

Pull out 1st-2nd fork rod with 1st-2nd bracket.
Remove 1st-2nd shift fork.
Remove retaining pin of 1st-2nd bracket using a pin punch and
separate 1st-2nd fork rod and 1st-2nd bracket.
SCIA0394E
30. Remove gear components from clutch housing in the following

procedure.
a. Remove input shaft assembly, mainshaft assembly and reverse
idler gear assembly as a set, tapping input shaft with plastic
hammer.
CAUTION:
Always withdraw mainshaft straight out. Failure to do so
can damage resin oil channel on clutch housing side.
b. Remove final drive assembly.
SCIA0395E
31. Remove mainshaft bearing retainer and then mainshaft front

bearing from clutch housing using the puller.
32. Remove oil channel from clutch housing.
SCIA1077J
33. Remove differential oil seal from clutch housing.

CAUTION:
Be careful not to damage clutch housing.
SCIA1068J
34. Remove differential side bearing outer race from clutch housing
using the puller.
SCIA1069J
MT-26
http://vnx.su
TRANSAXLE ASSEMBLY
35. Remove input shaft oil seal from clutch housing.
CAUTION:
MT
SCIA0398E
ASSEMBLY
1.
Install input shaft oil seal to clutch housing using the drift.
Dimension
A: 1.8 - 2.8 mm (0.071 - 0.110 in)
CAUTION:
F
PCIB0873E
2.
Apply multi-purpose grease to differential oil seal lip, and then

install oil seal to clutch housing using the drift.
CAUTION:
SCIA1070J
3.
Install oil channel on mainshaft side.

CAUTION:
Be careful with the orientation of installation.
SCIA0986E
MT-27
http://vnx.su
TRANSAXLE ASSEMBLY
4.
Install mainshaft front bearing to clutch housing using the drift.

CAUTION:
SCIA0401E
5.
Install mainshaft bearing retainer to clutch housing and tighten

mounting bolt to the specified torque. Refer to MT-20, "Gear
Components" .
CAUTION:
Install with punched surface facing up.
PCIB0789E
6.
Install differential side bearing outer race to clutch housing using

the drifts.
SCIA0987E
7.
Install final drive assembly into clutch housing.
SCIA0888E
8.
Install input shaft assembly, mainshaft assembly, and reverse

idler gear assembly into clutch housing.
CAUTION:
Be sure not to damage input shaft oil seal.
SCIA0395E
MT-28
http://vnx.su
TRANSAXLE ASSEMBLY
9.
Install 1st-2nd bracket onto 1st-2nd fork rod, and then install
retaining pin to 1st-2nd bracket.
CAUTION:
Do not reuse retaining pin.
MT
SCIA0889E
10. Install 1st-2nd fork rod and 1st-2nd shift fork, and then install
retaining pin to1st-2nd shift fork.
CAUTION:
11. Install shift check sleeve to clutch housing.
G
SCIA0394E
12. Install interlock pin to 3rd-4th fork rod.

13. Install 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod.
14. Install stopper rings onto 3rd-4th shift fork.
CAUTION:
Do not reuse stopper ring.
15. Install retaining pin onto 3rd-4th bracket.
CAUTION:
16. Install 2 check balls to clutch housing.
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17. Install 5th-reverse bracket, 5th shift fork, and 5th-reverse fork
rod.
18. Install stopper rings onto 5th-reverse bracket.
CAUTION:
SCIA0392E
19. Install retaining pin onto 5th shift fork.

CAUTION:
20. Install reverse shift fork and reverse fork rod.
21. Install reverse lever assembly following the procedures below.
a. Install shifter cap onto reverse lever assembly cam, and then
install them onto reverse shift fork.
CAUTION:
Do not drop shifter cap.
SCIA0391E
MT-29
http://vnx.su
TRANSAXLE ASSEMBLY
b.
While lifting reverse shift fork, align cam with 5th-reverse

bracket.
PCIB0929E
c.
Install reverse lever assembly to clutch housing, and then

tighten mounting bolts to the specified torque. Refer to MT-22,
"Shift Control Components" .
22. Install check ball, shift check sleeve, check spring and check
plug to clutch housing.
CAUTION:
Do not reuse check plug.
Do not drop check ball.
23. Install the magnet onto clutch housing.
SCIA0390E
24. Install differential oil seal until it is flush with end face of transaxle case using the drift.
CAUTION:
Do not reuse differential oil seal.
25. Install selected differential side bearing adjusting shim and differential side bearing outer race.
For selection of adjusting shim, refer to MT-33, "Differential
Side Bearing Preload" .
26. Install selected reverse idler gear adjusting shim onto reverse
idler gear assembly.
For selection of adjusting shims, refer to MT-34, "Reverse
Idler Gear End Play" .
27. Install selected input shaft rear bearing adjusting shim onto input shaft.
For selection of adjusting shims, refer to MT-34, "Input Shaft End Play" .
28. Install baffle plate and oil gutter to transaxle case.
29. Install transaxle case following the procedures below.
a. Install selected mainshaft rear bearing adjusting shim into transaxle case.
For selection of adjusting shims, refer to MT-35, "Mainshaft End Play" .
b. Temporarily install snap ring of mainshaft rear bearing into transaxle case.
CAUTION:
Do not reuse snap ring.
c. Apply recommended sealant to mating surfaces of transaxle
case and clutch housing.
CAUTION:
Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.
SCIA0887E
PCIB0816E
MT-30
http://vnx.su
TRANSAXLE ASSEMBLY
d.
With snap ring of mainshaft rear bearing temporarily installed,

place transaxle case over clutch housing.
MT
SCIA0892E
e.
f.
Through bore plug mounting hole, with snap ring stretched, and
lift up mainshaft assembly from the control assembly mounting
hole.
Securely install snap ring onto mainshaft rear bearing.
SCIA0893E
g.
Tighten mounting bolts to the specified torque.

Bolt A:
: 52 Nm (5.3 kg-m, 38 ft-lb)

Bolt B:
M
: 65 Nm (6.6 kg-m, 48 ft-lb)
h.
i.
j.
CAUTION:
Always replace bolts B as they are self-sealing bolts.
Apply gear oil to O-ring and install it to control assembly. Then
SCIA1064E
install control assembly to transaxle case. Tighten bolts to the
specified torque. Refer to MT-22, "Shift Control Components" .
CAUTION:
Do not reuse O-ring.
Install shift check to transaxle case, and then tighten shift check to the specified torque. Refer to MT-22,
CAUTION:
Do not reuse shift check.
Install stopper bolt to transaxle case, and then tighten stopper bolt to the specified torque. Refer to MT-22,
CAUTION:
Do not reuse stopper bolt.
MT-31
http://vnx.su
TRANSAXLE ASSEMBLY
30. Install bore plug to transaxle case using the drift.
CAUTION:
Do not reuse bore plug.
SCIA0894E
31. Install welch plug to transaxle case using the drift.

CAUTION:
Do not reuse welch plug.
SCIA0403E
32. Install 2 check balls, 2 check springs and 2 check plugs to transaxle case, and then tighten check plug to the specified torque.
Refer to MT-22, "Shift Control Components" .
CAUTION:
SCIA1668J
33. Apply recommended sealant to threads of park/neutral position

switch and back-up lamp switch. Then install them to transaxle
case and tighten to the specified torque. Refer to MT-19, "Case
and Housing Components" .
34. Install gaskets onto drain plug and plug, and then install them
into transaxle case. Tighten drain plug and plug to the specified
torque. Refer to MT-19, "Case and Housing Components" .
CAUTION:
35. Install gasket onto filler plug, and then install it into clutch housing. Tighten filler plug to the specified torque. Refer to MT-19,
"Case and Housing Components" .
CAUTION:
After oil is filled, tighten filler plug to specified torque.
MT-32
http://vnx.su
SCIA0895E
TRANSAXLE ASSEMBLY
ADJUSTMENT
Differential Side Bearing Preload
When adjusting differential side bearing preload, select adjusting shim for differential side bearing. To select adjusting shim,
measure clearance L between transaxle case and differential
side bearing outer race. Refer to MT-105, "DIFFERENTIAL
SIDE BEARING ADJUSTING SHIM(S)" .
CAUTION:
Up to 2 adjusting shims can be selected.
Calculate dimension L (thickness of adjusting shim) using the
following procedure to satisfy specification of preload for differential side bearing.
Preload: 0.15 - 0.21 mm (0.0059 - 0.0083 in)
DimensionL = (L1 - L2 ) + Preload
L:
Thickness of adjusting shim
L1 : Distance between transaxle case end face and
mounting face of adjusting shim
L2 : Distance between differential side bearing
outer race and clutch housing end face
1.
2.
MT
D
PCIB0795E
Using depth micrometer and straightedge, measure dimension

L1 between transaxle case end face and mounting face of
adjusting shim.
Install differential side bering outer race onto differential side
bearing on final gear side. Holding lightly differential side bearing outer race horizontally by hand, rotate final gear five times or
more (for smooth movement of bearing roller).
J
SCIA1078E
3.
Using depth micrometer and straightedge as shown in the figure, measure dimension L2 between differential side bearing
outer race and clutch housing end face.
SCIA1079E
4.
Install selected differential side bearing adjusting shim, and then

install differential side bearing outer race using the drift.
SCIA0898E
MT-33
http://vnx.su
TRANSAXLE ASSEMBLY
Reverse Idler Gear End Play
When adjusting reverse idler gear end play, select adjusting

shim for reverse idler gear. To select adjusting shim, measure
clearance between transaxle case and reverse idler gear. Refer
to MT-104, "REVERSE IDLER GEAR ADJUSTING SHIM" .
CAUTION:
Only 1 adjusting shim can be selected.
Calculate dimension Q (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for
reverse idler gear.
End play: 0.04 - 0.10 mm (0.0016 - 0.0039 in)
DimensionQ = (Q1 - Q2 ) - End play
Q:
Q1 : Distance between transaxle case end face and
Q2 : Distance between clutch housing end face
and end face of reverse idler gear (Rear)
1.
PCIB0796E

Q1 between transaxle case end face and mounting face of
adjusting shim.
SCIA1003E
2.
3.
Using depth micrometer and straightedge as shown in the figure, measure dimension Q2 between clutch housing end face
and end face of reverse idler gear (Rear).
Install selected reverse idler gear adjusting shim onto reverse
PCIB0797E
Input Shaft End Play
When adjusting input shaft end play, select adjusting shim for
input shaft rear bearing. To select adjusting shim, measure
clearance between transaxle case and input shaft rear bearing.
Refer to MT-104, "INPUT SHAFT REAR BEARING ADJUSTING
SHIM" .
CAUTION:
Calculate dimension O (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for input
shaft rear bearing.
SCIA1006E
End play: 0 - 0.06 mm (0 - 0.0024 in)

DimensionO = (O1 - O2 ) - End play
MT-34
http://vnx.su
TRANSAXLE ASSEMBLY
O:
O1 :
O2 :
1.

Distance between transaxle case end face and
Distance between clutch housing end face
and end face of input shaft rear bearing

O1 between transaxle case end face and mounting face of
adjusting shim.
MT
E
SCIA1002E
2.
3.
Using depth micrometer and straightedge as shown in the figure, measure dimension O2 between clutch housing end face
and end face of input shaft rear bearing.
Install selected input shaft rear bearing adjusting shim onto input
shaft.
I
PCIB0792E
Mainshaft End Play
When adjusting mainshaft end play, select adjusting shim for

mainshaft rear bearing. To select adjusting shim, measure clearance M between transaxle case and mainshaft rear bearing.
Refer to MT-104, "MAINSHAFT REAR BEARING ADJUSTING
SHIM" .
CAUTION:
Calculate dimension P (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for mainshaft rear bearing.
End play: 0 - 0.06 mm (0 - 0.0024 in)
DimensionP = M - End play
P:
M:
Distance between mainshaft rear bearing end
face and transaxle case end face
1.
2.
3.
M
PCIB0793E
Install mainshaft assembly to clutch housing.

Install snap ring to transaxle case.
Install transaxle case to clutch housing, and temporarily assemble them with fixing bolts. Install temporarily snap ring to mainshaft rear bearing.
MT-35
http://vnx.su
TRANSAXLE ASSEMBLY
4.
Install dial indicator to bore plug mounting hole, and expand

snap ring. Lift mainshaft assembly through control assembly
installation hole, and push it against transaxle case. This state
shall be defined as base. Moving distance of mainshaft assembly, with snap ring fit on main rear bearing, becomes M.
PCIB0874E
MT-36
http://vnx.su
TRANSAXLE ASSEMBLY
ECS008C1
COMPONENTS
Case and Housing Components
MT
PCIB1472E
1.
Clutch housing
2.
Differential oil seal
3.
Ball pin
4.
Washer
5.
Input shaft oil seal
6.
Oil channel
7.
Magnet
8.
Gasket
9.
Filler plug
10. Back-up lamp switch
11. Oil gutter
12. Baffle plate
13. Transaxle case
14. Plug
15. Welch plug
16. Bore plug
17. Drain plug
18. Differential oil seal
19. Park/Neutral position (PNP) switch
20. Air breather tube
MT-37
http://vnx.su
TRANSAXLE ASSEMBLY
Gear Components
PCIB1460E
1.
Input shaft front bearing
2.
Input shaft
3.
3rd needle bearing
4.
3rd input gear
5.
3rd inner baulk ring
6.
3rd synchronizer cone
7.
3rd outer baulk ring
8.
3rd-4th spread spring
9.
3rd-4th shifting insert
10. 3rd-4th synchronizer hub
11. 4th baulk ring
12. 3rd-4th coupling sleeve
15. 4th input gear
16. Thrust washer
19. 5th input gear
20. 5th baulk ring
21. 5th-6th spread spring
22. 5th-6th shifting insert
23. 5th-6th synchronizer hub
24. 5th-6th coupling sleeve
25. 6th baulk ring
26. 6th input gear
29. Snap ring
31. Oil channel
32. Input shaft rear bearing adjusting

shim
33. Retaining pin
35. Thrust needle bearing
36. Reverse idler gear needle bearing
37. Reverse insert spring
39. Reverse balk ring
42. Reverse idler gear adjusting shim
MT-38
http://vnx.su
TRANSAXLE ASSEMBLY
A
MT
PCIB0787E
1.
Mainshaft front bearing
4.
Reverse main gear
5.
1st main gear
6.
1st main gear bushing
7.
1st needle bearing
8.
1st inner baulk ring
9.
1st synchronizer cone
10. 1st outer baulk ring
2.
Mainshaft bearing retainer
3.
11. 1st-2nd spread spring
12. 1st-2nd shifting insert
14. 2nd outer baulk ring
15. 2nd synchronizer cone
16. 2nd inner baulk ring
18. 2nd main gear bushing
19. 2nd needle bearing
20. 2nd main gear
21. 3rd main gear
22. 3rd-4th mainshaft spacer
23. 4th main adjusting shim
24. 4th main gear
25. 5th main gear
26. 6th main gear
28. Mainshaft C-ring
29. C-ring holder
30. Snap ring
31. Snap ring
32. Mainshaft rear bearing adjusting shim
33. 5th-6th mainshaft spacer
34. 6th main adjusting shim
MT-39
http://vnx.su
Mainshaft
TRANSAXLE ASSEMBLY
Shift Control Components
PCIB0871E
1.
3rd-4th bracket
2.
Retaining pin
3.
Check plug
4.
5th-6th bracket
5.
Stopper ring
6.
Reverse bracket
7.
Reverse lever assembly
8.
Shifter cap
9.
Reverse shift fork
10. Reverse fork rod
11. Check spring
13. Check ball
14. Reverse bracket fork rod
15. 5th-6th shift fork
16. 5th-6th fork rod
17. Interlock pin
19. Check spring
20. Check spring
21. 3rd-4th fork rod
22. 3rd-4th shift fork
23. 1st-2nd fork rod
24. 1st-2nd fork rod bracket
25. 1st-2nd shift fork
26. Transaxle case
27. Stopper bolt
28. Shift check
29. O-ring
30. Control assembly
MT-40
http://vnx.su
TRANSAXLE ASSEMBLY
Final Drive Components
A
MT
PCIB0872E
1.

(clutch housing side)
2.
Differential side bearing (clutch

housing side)
3.
Differential case
4.
Final gear
5.
Differential side bearing (transaxle

case side)
6.

7.
Differential side bearing adjusting shim
8.
Pinion mate shaft
9.
Side gear
10. Side gear thrust washer
11. Pinion mate gear
12. Pinion mate thrust washer
13. Retaining pin
DISASSEMBLY
1.
2.
3.
4.
Remove filler plug from clutch housing.

Remove drain plug and plug from transaxle case.
Remove park/neutral position switch and back-up lamp switch
Remove shift check and stopper bolt from transaxle case, and
then remove control assembly from transaxle case.
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MT-41
http://vnx.su
TRANSAXLE ASSEMBLY
5.
Remove check plugs (4 pieces), check springs (4 pieces), check

balls (4 pieces) and shift check sleeve (2 pieces).
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6.
7.
Remove transaxle case mounting bolts.

Remove bore plug from transaxle case.
CAUTION:
8. While spreading the snap ring of mainshaft rear bearing located
at bore plug hole, remove transaxle case from clutch housing.
9. Remove oil gutter, baffle plate from transaxle case.
10. Remove snap ring, mainshaft rear bearing adjusting shim from
transaxle case.
11. Remove input shaft rear bearing adjusting shim and reverse
idler gear adjusting shim.
SCIA0983E
12. Remove differential side bearing outer race from transaxle case
using the puller, and then remove differential side bearing
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13. Remove welch plug from transaxle case.
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MT-42
http://vnx.su
TRANSAXLE ASSEMBLY
14. Remove differential oil seal from transaxle case.
CAUTION:
15. Remove magnet from clutch housing.
MT
SCIA0397E
16. With shift lever in 5th position, remove mounting bolts from
reverse lever assembly. Lift reverse lever assembly to remove.
CAUTION:
Be careful not to lose shifter cap.
17. Pull out reverse fork rod then remove reverse shift fork.
G
SCIA0960E
18. Remove retaining pin of reverse bracket using a pin punch.

19. Pull out reverse bracket and reverse bracket fork rod.
20. Remove check ball (2 pieces) and interlock pin from clutch
housing.
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21. Shift 3rd-4th fork rod to 3rd position. Remove retaining pin of 5th
- 6th shift fork using a pin punch.
L
SCIA0962E
22. Remove stopper rings for 5th-6th bracket.

23. Pull out 5th-6th fork rod and remove 5th-6th shift fork and 5th6th bracket.
24. Remove check balls (2 pieces) and interlock pin.
SCIA0963E
MT-43
http://vnx.su
TRANSAXLE ASSEMBLY
25. Remove retaining pin of 3rd-4th bracket using a pin punch.
26. Remove stopper rings for 3rd-4th shift fork.
27. Pull out 3rd-4th fork rod and remove 3rd-4th shift fork and 3rd4th bracket.
28. Remove shift check sleeve from clutch housing.
SCIA0393E
29.
30.
31.
32.
Remove retaining pin of 1st-2nd shift fork using a pin punch.

Pull out 1st-2nd fork rod with 1st-2nd bracket.
Remove 1st-2nd shift fork.
Remove retaining pin of 1st-2nd bracket using a pin punch and
separate fork rod and 1st-2nd bracket.
SCIA0394E
33. Remove gear components from clutch housing in the following

procedure.
a. Remove input shaft assembly, mainshaft assembly and reverse
idler gear assembly as a set, tapping input shaft with plastic
hammer.
CAUTION:
Always withdraw mainshaft straight out. Failure to do so
can damage resin oil channel on clutch housing side.
b. Remove final drive assembly.
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34. Remove mainshaft bearing retainer and then mainshaft front

bearing from clutch housing using the puller.
35. Remove oil channel from clutch housing.
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36. Remove differential oil seal from clutch housing.

CAUTION:
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MT-44
http://vnx.su
TRANSAXLE ASSEMBLY
37. Remove differential side bearing outer race from clutch housing
using the puller.
MT
SCIA1069J
38. Remove input shaft oil seal from clutch housing.

CAUTION:
G
SCIA0398E
ASSEMBLY
1.
Install input shaft oil seal to clutch housing using the drift.
Dimension
A: 1.8 - 2.8 mm (0.071 - 0.110 in)

I
CAUTION:
PCIB0873E
2.
Apply multi-purpose grease to differential oil seal lip, and then

install oil seal to clutch housing using the drift.
CAUTION:
SCIA1070J
MT-45
http://vnx.su
TRANSAXLE ASSEMBLY
3.
Install oil channel on mainshaft side.

CAUTION:
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4.
Install mainshaft front bearing to clutch housing using the drift.

CAUTION:
SCIA0401E
5.
Install mainshaft bearing retainer to clutch housing and tighten

mounting bolt to the specified torque. Refer to MT-38, "Gear
Components" .
CAUTION:
Install with punched surface facing up.
PCIB0789E
6.
Install differential side bearing outer race to clutch housing using

the drifts.
SCIA0987E
7.
Install final drive assembly into clutch housing.
SCIA0888E
MT-46
http://vnx.su
TRANSAXLE ASSEMBLY
8.
Install input shaft assembly, mainshaft assembly, and reverse

idler gear assembly into clutch housing.
CAUTION:
Be sure not to damage input shaft oil seal.
MT
SCIA0964E
9.
Install 1st-2nd bracket onto 1st-2nd fork rod, and then install
retaining pin to 1st-2nd bracket.
CAUTION:
G
SCIA0889E
10. Install 1st-2nd fork rod and 1st-2nd shift fork, and then install
retaining pin to 1st-2nd shift fork.
CAUTION:
11. Install shift check sleeve to clutch housing.
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12. Install interlock pin to 3rd-4th fork rod.

13. Install 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod.
14. Install stopper rings onto 3rd-4th shift fork.
CAUTION:
15. Install retaining pin onto 3rd-4th bracket.
CAUTION:
16. Install 2 check balls to clutch housing.
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17. Install 5th-6th bracket, 5th-6th shift fork, and 5th-6th fork rod
with interlock pin.
18. Install stopper rings onto 5th-6th bracket.
CAUTION:
SCIA0963E
MT-47
http://vnx.su
TRANSAXLE ASSEMBLY
19. Install retaining pin onto 5th-6th shift fork.
CAUTION:
20. Install 2 check balls.
plug.
CAUTION:
22. Install reverse bracket fork rod and reverse bracket.
23. Install retaining pin onto reverse bracket.
CAUTION:
24. Install reverse shift fork and reverse fork rod.
25. Install reverse lever assembly following the procedures below.
a. Install shifter cap onto reverse lever assembly cam, and then
install them onto reverse shift fork.
CAUTION:
Do not drop shifter cap.
SCIA0962E
SCIA0961E
b.
While lifting reverse shift fork, align cam with reverse bracket.
PCIB0791E
c.
Install reverse lever assembly to clutch housing, and then

tighten mounting bolts to the specified torque. Refer to MT-40,
plug to clutch housing.
CAUTION:
27. Install the magnet onto clutch housing.
SCIA0960E
28. Install differential oil seal until it is flush with end face of transaxle case using the drift.
CAUTION:
Do not reuse differential oil seal.
29. Install selected differential side bearing adjusting shim and differential side bearing outer race.
For selection of adjusting shim, refer to MT-51, "Differential
Side Bering Preload" .
30. Install selected reverse idler gear adjusting shim onto reverse
MT-48
http://vnx.su
SCIA0887E
TRANSAXLE ASSEMBLY
For selection of adjusting shims, refer to MT-52, "Reverse Idler Gear End Play" .
31. Install selected input shaft rear bearing adjusting shim onto input shaft.
For selection of adjusting shims, refer to MT-53, "Input Shaft End Play" .
32. Install baffle plate and oil gutter to transaxle case.
33. Install transaxle case following the procedures below.
a. Install selected mainshaft rear bearing adjusting shim into transaxle case.
For selection of adjusting shims, refer to MT-54, "Mainshaft End Play" .
b. Temporarily install snap ring of mainshaft rear bearing into transaxle case.
CAUTION:
c. Apply recommended sealant to mating surfaces of transaxle
case and clutch housing.
CAUTION:
Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.
MT
G
PCIB0816E
d.
With snap ring of mainshaft rear bearing temporarily installed,

place transaxle case over clutch housing.
SCIA0892E
e.
f.
Through bore plug mounting hole, with snap ring stretched, and
lift up mainshaft assembly from the control assembly mounting
hole.
Securely install snap ring onto mainshaft rear bearing.
SCIA0893E
MT-49
http://vnx.su
TRANSAXLE ASSEMBLY
g.
Tighten mounting bolts to the specified torque.

Bolt A:
: 52 Nm (5.3 kg-m, 38 ft-lb)
Bolt B:
: 65 Nm (6.6 kg-m, 48 ft-lb)
CAUTION:
Always replace bolts B as they are self-sealing bolts.
h. Apply gear oil to O-ring and install it to control assembly. Then
SCIA1064E
install control assembly to transaxle case. Tighten bolts to the
specified torque. Refer to MT-40, "Shift Control Components" .
CAUTION:
i. Install shift check to transaxle case, and then tighten shift check to the specified torque. Refer to MT-40,
CAUTION:
Does not reuse shift check.
j. Install stopper bolt to transaxle case, and then tighten stopper bolt to the specified torque. Refer to MT-40,
CAUTION:
Do not reuse stopper bolt.
34. Install bore plug to transaxle case using the drift.
CAUTION:
Do not reuse bore plug.
SCIA0894E
35. Install welch plug to transaxle case using the drift.

CAUTION:
Do not reuse welch plug.
SCIA0403E
36. Install 2 check balls, 2 check springs and 2 check plugs to transaxle case, and then tighten check plug to the specified torque.
Refer to MT-40, "Shift Control Components" .
CAUTION:
SCIA1667E
MT-50
http://vnx.su
TRANSAXLE ASSEMBLY
37. Apply recommended sealant to threads of park/neutral position
switch and back-up lamp switch. Then install them to transaxle
case and tighten to the specified torque. Refer to MT-37, "Case
and Housing Components" .
38. Install gaskets onto drain plug and plug, and then install them
into transaxle case. Tighten drain plug and plug to the specified
torque. Refer to MT-37, "Case and Housing Components" .
CAUTION:
39. Install gasket onto filler plug, and then install it into clutch housing. Tighten filler plug to the specified torque. Refer to MT-37,
"Case and Housing Components" .
CAUTION:
After oil is filled, tighten filler plug to specified torque.
MT
SCIA0895E
ADJUSTMENT
Differential Side Bering Preload
When adjusting differential side bearing preload, select adjusting shim for differential side bearing. To select adjusting shim,
measure clearance L between transaxle case and differential
side bearing outer race. Refer to MT-105, "DIFFERENTIAL
SIDE BEARING ADJUSTING SHIM(S)" .
CAUTION:
Up to 2 adjusting shims can be selected.
Calculate dimension L (thickness of adjusting shim) using the
following procedure to satisfy specification of preload for differential side bearing.
Preload: 0.15 - 0.21 mm (0.0059 - 0.0083 in)
DimensionL = (L1 - L2 ) + Preload
L:
Distance between transaxle case end face
L1 :
and mounting face of adjusting shim
L2 :
Distance between differential side bearing
outer race and clutch housing end face
1.
2.
I
PCIB0795E

L1 between transaxle case end face and mounting face of
adjusting shim.
Install differential side bearing outer race onto differential side
bearing on final gear side. Holding lightly differential side bearing outer race horizontally by hand, rotate final gear five times or
more (for smooth movement of bearing roller).
SCIA1078E
MT-51
http://vnx.su
TRANSAXLE ASSEMBLY
3.
Using depth micrometer and straightedge as shown in the figure, measure dimension L2 between differential side bearing
outer race and clutch housing end face.
SCIA1079E
4.
Install selected differential side bearing adjusting shim, and then

install differential side bearing outer race using the drift.
SCIA0898E
Reverse Idler Gear End Play
When adjusting reverse idler gear end play, select adjusting

shim for reverse idler gear. To select adjusting shim, measure
clearance between transaxle case and reverse idler gear. Refer
to MT-104, "REVERSE IDLER GEAR ADJUSTING SHIM" .
CAUTION:
Calculate dimension Q (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for
reverse idler gear.
End play: 0.04 - 0.10 mm (0.0016 - 0.0039 in)
DimensionQ = (Q1 - Q2 ) - End play
Q:
Q1 : Distance between transaxle case end face and
Q2 : Distance between clutch housing end face and
end face of reverse idler gear (Rear)
1.
PCIB0796E

Q1 between transaxle case end face and mounting face of
adjusting shim.
SCIA1003E
MT-52
http://vnx.su
TRANSAXLE ASSEMBLY
2.
3.
Using depth micrometer and straightedge as shown in the figure, measure dimension Q2 between clutch housing end face
and end face of reverse idler gear (Rear).
Install selected reverse idler gear adjusting shim onto reverse
MT
PCIB0797E
Input Shaft End Play
When adjusting input shaft end play, select adjusting shim for
input shaft rear bearing. To select adjusting shim, measure
clearance between transaxle case and input shaft rear bearing.
Refer to MT-104, "INPUT SHAFT REAR BEARING ADJUSTING
SHIM" .
CAUTION:
Calculate dimension O (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for input
shaft rear bearing.
G
SCIA1001E
End play: 0 - 0.06 mm (0 - 0.0024 in)

DimensionO = (O1 - O2 ) - End play
O:
Distance between transaxle case end face and
O1
:
O2
Distance between clutch housing end face
:
and end face of input shaft rear bearing
1.

O1 between transaxle case end face and mounting face of
adjusting shim.
M
SCIA1002E
2.
3.
Using depth micrometer and straightedge as shown in the figure, measure dimension O2 between clutch housing end face
and end face of input shaft rear bearing.
Install selected input shaft rear bearing adjusting shim onto input
shaft.
PCIB0792E
MT-53
http://vnx.su
TRANSAXLE ASSEMBLY
Mainshaft End Play
When adjusting mainshaft end play, select adjusting shim for

mainshaft rear bearing. To select adjusting shim, measure clearance M between transaxle case and mainshaft rear bearing.
Refer to MT-104, "MAINSHAFT REAR BEARING ADJUSTING
SHIM" .
CAUTION:
Calculate dimension P (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for mainshaft rear bearing.
End play: 0 - 0.06 mm (0 - 0.0024 in)
DimensionP = M - End play
P: Thickness of adjusting shim
M: Distance between mainshaft rear bearing end
face and transaxle case end face
1.
2.
3.
4.
PCIB0793E
Install mainshaft assembly to clutch housing.

Install snap ring to transaxle case.
Install transaxle case to clutch housing, and temporarily assemble them with fixing bolts. Install temporarily snap ring to mainshaft rear bearing.
Install dial indicator to bore plug mounting hole, and expand
snap ring. Lift mainshaft assembly through control assembly
installation hole, and push it against transaxle case. This state
shall be defined as base. Moving distance of mainshaft assembly, with snap ring fit on main rear bearing, becomes M.
PCIB0874E
MT-54
http://vnx.su
INPUT SHAFT AND GEARS

PFP:32200
A
ECS008C4
DISASSEMBLY
1.
Before disassembling, measure end play for 3rd, 4th, and 5th
input gears.
End play standard value

3rd input gear
: 0.18 - 0.31 mm (0.0071 - 0.0122 in)
4th input gear
: 0.20 - 0.30 mm (0.0079 - 0.0118 in)
5th input gear
: 0.06 - 0.16 mm (0.0024 - 0.0063 in)
2.
MT
Remove oil channel.

SCIA0914E
3.
Press out input shaft rear bearing using the drift and a puller.
F
H
SCIA0915E
4.
Remove the snap ring.
SCIA0916E
5.
Press out input shaft bearing spacer and 5th stopper using the
drift and a puller.
SCIA0917E
MT-55
http://vnx.su

6.
7.
Press out 5th input gear and 5th synchronizer hub assembly
using the drift and a puller.
Remove 5th needle bearing.
SCIA0918E
8.
9.
Press out 5th input gear bushing, thrust washer, 4th input gear,
4th needle bearing, 4th input gear bushing, 3rd-4th synchronizer
hub assembly and 3rd input gear using the drift and a puller.
Remove 3rd needle bearing.
SCIA0919E
10. Press out input shaft front bearing using a puller.
SCIA0920E

Input Shaft and Gears
Check items below. If necessary, replace them with new ones.
Damage, peeling, dent, uneven wear, bending, etc. of shaft
Excessive wear, damage, peeling, etc. of gears
SCIA1073J
MT-56
http://vnx.su

Synchronizer
A
Damage and excessive wear of contact surfaces of coupling

sleeve, synchronizer hub and shifting insert
Coupling sleeve and synchronizer hub must move smoothly.
MT
SMT387A
If any crack, damage, or excessive wear is found on cam face of

baulk ring or working face of insert, replace it.
G
SMT867D
BAULK RING CLEARANCE
Single-cone synchronizer (4th and 5th)

Push baulk ring on the cone, and measure the clearance
between baulk ring and cone. If measurement is below limit,
Clearance
Standard value
4th
5th
Limit value
: 0.9 - 1.45 mm (0.035 - 0.057 in)

: 0.95 - 1.4 mm (0.037 - 0.055 in)
: 0.7 mm (0.028 in)
SMT140
Double-cone synchronizer (3rd)

Check the clearance between outer baulk ring, synchronizer
cone and inner baulk ring as follows.
CAUTION:
The clearances A and B are controlled with outer baulk
ring, synchronizer cone and inner baulk ring as a set.
Replace them as a set if the clearances are outside the limit
value.
SCIA0950E
MT-57
http://vnx.su

1.
Measure the clearance A at 2 points or more diagonally opposite using a dial indicator. And then calculate mean value.
Clearance A
Standard value
Limit value
: 0.6 - 0.8 mm (0.024 - 0.031 in)

: 0.2 mm (0.008 in)
SCIA0951E
2.
Measure the clearance B at 2 points or more diagonally opposite using a feeler gauge. And then calculate mean value.
Clearance B
Standard value
Limit value
: 0.6 - 1.1 mm (0.024 - 0.043 in)

: 0.2 mm (0.008 in)
SCIA1084E
Bearing
Damage and rough rotation of bearing
MTF0041D
MT-58
http://vnx.su

ASSEMBLY
1.
2.
3.
A
Install 3rd needle bearing to input shaft.
Install 3rd input gear and 3rd baulk ring to input shaft.
Install 3rd-4th spread spring, 3rd-4th shifting insert and 3rd-4th synchronizer hub onto 3rd-4th coupling
B
sleeve.
CAUTION:
Be careful with orientation of 3rd-4th synchronizer hub.
MT
Do not reuse 3rd-4th synchronizer hub.
E
SCIA0921E
Be careful with orientation of 3rd-4th coupling sleeve.

Do not reuse 3rd-4th coupling sleeve.
G
I
PCIB0799E
Be sure not to hook center projection of 2 spread springs

on same shifting insert.
SCIA1083E
4.
Press in 3rd-4th synchronizer hub assembly using the press

stand.
CAUTION:
Align grooves of 3rd-4th shifting insert and 3rd outer baulk
ring.
SCIA0922E
MT-59
http://vnx.su

5.
6.
7.
Press in 4th input gear bushing using the press stand.

Install 4th baulk ring.
Install 4th needle bearing and 4th input gear to input shaft.
PCIB0800E
8.
Select thrust washer so that dimension C2 satisfies the standard value below. Then install thrust washer onto input shaft.
Refer to MT-103, "INPUT SHAFT THRUST WASHER" .
Standard for dimension C2
: 154.7 - 154.8 mm (6.091 - 6.094 in)
CAUTION:
Only one thrust washer can be selected.
SCIA0925E
9.

CAUTION:
Do not reuse 5th input gear bushing.
10. Install 5th needle bearing and 5th input gear to input shaft.
11. Install 5th baulk ring.
SCIA0926E
12. Install 5th synchronizer hub and 5th spread spring, 5th shifting insert onto 5th coupling sleeve.
MT-60
http://vnx.su

CAUTION:
Be careful with orientation of 5th synchronizer hub and
shifting insert.
Do not reuse 5th synchronizer hub.
MT
SCIA0927E
Be careful with orientation of 5th coupling sleeve.

Do not reuse 5th coupling sleeve.
G
SCIA0994E

K
SCIA1083E
13. Press in 5th synchronizer hub assembly using the press stand.
CAUTION:
Align grooves of 5th shifting insert and 5th baulk ring.
SCIA0928E
MT-61
http://vnx.su

14. Press in 5th stopper and then input shaft bearing spacer using
the drift.
SCIA0929E
15. Install snap ring onto input shaft, and make sure that end play
(gap between snap ring and groove) of input shaft bearing
spacer satisfies the standard value.
End play standard value : 0 - 0.1 mm (0 - 0.004 in)
If measurement is outside the standard range, select snap

ring. Refer to MT-102, "INPUT SHAFT BEARING SPACER" .
CAUTION:
SCIA0930E
16. Press in input shaft rear bearing using the drift.

CAUTION:
Install input shaft rear bearing with its brown surface facing
the input gear side.
SCIA0931E
17. Press in input shaft front bearing using the drifts.

18. Install oil channel onto input shaft.
PCIB0825E
19. Check end play of 3rd, 4th, and 5th input gears.
3rd input gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in)
4th input gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
SCIA0914E
MT-62
http://vnx.su

ECS008C5
DISASSEMBLY
1.
Before disassembling, measure end play for 3rd, 4th, 5th and
6th input gears.
B

3rd input gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in)
2.
MT
Remove oil channel.

SCIA0966E
3.
4.
Press out input shaft rear bearing using the drift and a puller.
Remove snap ring.
SCIA0967E
5.
6.
Press out 6th input gear, 6th needle bearing and 6th input gear
bushing using the drift and a puller.
Remove 6th baulk ring.
K
SCIA0968E
7.
8.
Press out 5th input gear and 5th-6th synchronizer hub assembly
using the drift and a puller.
Remove 5th needle bearing.
SCIA0918E
MT-63
http://vnx.su

9.
Press out 5th input gear bushing, thrust washer, 4th input gear,
4th needle bearing, 4th input gear bushing, 3rd-4th synchronizer
hub assembly and 3rd input gear using the drift and a puller.
10. Remove 3rd needle bearing.
SCIA0919E
11. Press out input shaft front bearing using a puller.
SCIA0920E

Input Shaft and Gears
Damage, peeling, dent, uneven wear, bending, etc. of shaft
Excessive wear, damage, peeling, etc. of gears
SCIA1074J
Synchronizer
Damage and excessive wear of contact surfaces of coupling

sleeve, synchronizer hub and shifting insert
SMT387A
MT-64
http://vnx.su

MT
SMT867D
Single-cone synchronizer (4th, 5th and 6th)

between baulk ring and cone. If measurement is below limit,
Clearance
Standard value
4th
5th and 6th
Limit value
: 0.9 - 1.45 mm (0.035 - 0.057 in)

: 0.95 - 1.4 mm (0.037 - 0.055 in)
: 0.7 mm (0.028 in)
SMT140
Double-cone synchronizer (3rd)

CAUTION:
The clearances A and B are controlled with outer baulk
ring, synchronizer cone and inner baulk ring as a set.
value.
K
SCIA0950E
1.
Measure the clearance A at 2 points or more diagonally opposite using a dial indicator. And then calculate mean value.
Clearance A
Standard value
Limit value
: 0.6 - 0.8 mm (0.024 - 0.031 in)

: 0.2 mm (0.008 in)
SCIA0951E
MT-65
http://vnx.su

2.
Clearance B
Standard value
Limit value
: 0.6 - 1.1 mm (0.024 - 0.043 in)

: 0.2 mm (0.008 in)
SCIA1084E
Bearing
MTF0041D
MT-66
http://vnx.su

ASSEMBLY
1.
2.
3.
A
Install 3rd needle bearing to input shaft.
Install 3rd input gear and 3rd baulk ring to input shaft.
Install 3rd-4th spread spring,3rd-4th shifting insert and 3rd-4th synchronizer hub onto 3rd-4th coupling
B
sleeve.
CAUTION:
Be careful with orientation of 3rd-4th synchronizer hub.
MT
Do not reuse 3rd-4th synchronizer hub.
E
SCIA0921E
Be careful with orientation of 3rd-4th coupling sleeve.

Do not reuse 3rd-4th coupling sleeve.
G
I
PCIB0799E

SCIA1083E
4.
Press in 3rd-4th synchronizer hub assembly using the press

stand.
CAUTION:
Align grooves of 3rd-4th shifting insert and 3rd outer baulk
ring.
SCIA0922E
MT-67
http://vnx.su

5.
6.
7.

Install 4th baulk ring.
Install 4th needle bearing and 4th input gear to input shaft.
PCIB0800E
8.
Select thrust washer so that dimension C2 satisfies the standard value below. Then install thrust washer onto input shaft.
Refer to MT-103, "INPUT SHAFT THRUST WASHER" .
Standard value for dimension C2
: 154.7 - 154.8 mm (6.091 - 6.094 in)
CAUTION:
SCIA0925E
9.

CAUTION:
Do not reuse 5th input gear bushing.
10. Install 5th needle bearing and 5th input gear to input shaft.
11. Install 5th baulk ring.
SCIA0926E
12. Install 5th-6th synchronizer hub, 5th-6th spread spring and 5th-6th shifting insert onto 5th-6th coupling
sleeve.
MT-68
http://vnx.su

CAUTION:
Be careful with orientation of 5th-6th synchronizer hub.
Do not reuse 5th-6th synchronizer hub.
MT
SCIA0921E
Be careful with orientation of 5th-6th coupling sleeve.

Do not reuse 5th-6th coupling sleeve.
G
PCIB0801E

K
SCIA1083E
13. Press in 5th-6th synchronizer hub assembly using the press

stand.
CAUTION:
Align grooves of 5th-6th shifting insert and 5th baulk ring
and 6th baulk ring.
SCIA0928E
MT-69
http://vnx.su

14. Install 6th needle bearing, 6th input gear, 6th baulk ring onto 6th
input gear bushing, and then press in 6th bushing onto input
shaft using the drift.
SCIA0969E
15. Install snap ring onto input shaft, and make sure that end play
(gap between snap ring and groove) of 6th input gear bushing
satisfies the standard value.
: 0 - 0.1 mm (0 - 0.004 in)
If measurement is outside the standard range, select snap

ring. Refer to MT-102, "6TH INPUT GEAR BUSHING" .
CAUTION:
SCIA0970E
16. Press in input shaft rear bearing using the drift.

CAUTION:
Install input shaft rear bearing with its brown surface facing
the 6th input gear side.
SCIA0971E
17. Press in input shaft front bearing using the drifts.

18. Install oil channel onto input shaft.
PCIB0826E
19. Check end play of 3rd, 4th, 5th and 6th input gears.
3rd input gear
: 0.18 - 0.31 mm (0.0071 - 0.0122 in)
4th input gear
: 0.20 - 0.30 mm (0.0079 - 0.0118 in)
5th input gear
: 0.06 - 0.16 mm (0.0024 - 0.0063 in)
6th input gear
: 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0966E
MT-70
http://vnx.su
MAINSHAFT AND GEARS

MAINSHAFT AND GEARS
PFP:32241
A
ECS008C6
DISASSEMBLY
1.
Before disassembling, measure the end play of 1st and 2nd

main gears.

1st main gear
: 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd main gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
MT
SCIA0933E
2.
3.
Remove snap ring.

Remove C-ring holder, and then remove mainshaft C-ring.
F
H
PCIB0802E
4.
Remove mainshaft rear bearing using the drift and pullers.
SCIA0935E
5.
Remove snap ring.

M
SCIA0936E
MT-71
http://vnx.su
MAINSHAFT AND GEARS

6.
7.
8.
Press out 4th main gear and 5th main gear using the drift and a
puller.
Remove 4th main gear adjusting shim.
Remove 3rd-4th mainshaft spacer.
SCIA0937E
9.
Press out 3rd main gear, 2nd main gear, 2nd needle bearing,
2nd main gear bushing, 1st-2nd synchronizer hub assembly, 1st
main gear, 1st needle bearing, and 1st main gear bushing
reverse main gear using the drift.
SCIA0938E

Mainshaft and Gears
Damage, peeling, dent, uneven wear, bending, and other nonstandard conditions of the shaft.
Excessive wear, damage, peeling, and other non-standard conditions of the gears.
SCIA1075J
Synchronizer
Damage and unusual wear on contact surfaces of coupling

sleeve, synchronizer hub and shifting insert.
SMT387A
MT-72
http://vnx.su
MAINSHAFT AND GEARS

MT
SMT867D

Triple-cone synchronizer (1st and 2nd)

CAUTION:
The clearances A, B and C are controlled with outer
baulk ring, synchronizer cone and inner baulk ring as a set.
value.
PCIB1358E
1.
Measure the clearance A at 2 points or more diagonally opposite using a feeler gauge when pressing baulk ring toward clutch
gear taper cone. And then calculate mean value.
Clearance A
Standard value
Limit value
: 0.6 - 1.2 mm (0.024 - 0.047 in)

: 0.3 mm (0.012 in)
K
PCIB1359E
2.
Clearance B
Standard value
Limit value
: 0.6 - 1.1 mm (0.024 - 0.043 in)

: 0.2 mm (0.008 in)
PCIB1360E
MT-73
http://vnx.su
MAINSHAFT AND GEARS

3.
Measure the clearance C at 2 points or more diagonally opposite using a feeler gauge when pressing baulk ring toward clutch
Clearance C
Standard value
Limit value
: 0.7 - 1.1 mm (0.028 - 0.043 in)

: 0.3 mm (0.012 in)
PCIB1361E
Bearing
MTF0041D
ASSEMBLY
1.
Press in reverse main gear using the drifts and the press stand.
SCIA0939E
CAUTION:
Be careful with orientation of reverse main gear.
Do not reuse reverse main gear.
SCIA0992E
MT-74
http://vnx.su
MAINSHAFT AND GEARS

2.
3.
Press in 1st main gear bushing using the drifts and the press
stand.
Install 1st needle bearing, and then 1st main gear.
MT
SCIA0940E
4.
Install 1st-2nd spread spring, 1st-2nd shifting insert and 1st-2nd synchronizer hub onto 1st-2nd coupling
sleeve.
CAUTION:
Be careful with orientation of 1st-2nd synchronizer hub.
Do not reuse 1st-2nd synchronizer hub.
H
SCIA0921E
Be careful with orientation of 1st-2nd coupling sleeve.

Do not reuse 1st-2nd coupling sleeve.
PCIB0803E

on same 1st-2nd shifting insert.
M
SCIA1083E
MT-75
http://vnx.su
MAINSHAFT AND GEARS

5.
Install 1st inner baulk ring, 1st synchronizer cone, 1st outer
baulk ring onto mainshaft, and then press in 1st-2nd synchronizer hub assembly onto mainshaft using the drifts and the press
stand.
CAUTION:
Outer baulk ring, synchronizer cone, and inner baulk ring
on 2nd gear-side must have been removed.
Be careful with orientation of coupling sleeve.
SCIA0941E
6.
7.
8.
Press in 2nd main gear bushing using the drift and the press
stand.
Install 2nd outer baulk ring, 2nd synchronizer cone, and 2nd
inner baulk ring.
Install 2nd needle bearing and 2nd main gear.
SCIA0942E
9.
Press in 3rd main gear using the drift and the press stand.
CAUTION:
Be careful with orientation of 3rd main gear.
Do not reuse 3rd main gear.
10. Install 3rd-4th mainshaft spacer.
SCIA0943E
11. Select 4th main gear adjusting shim so that dimension C1 satisfies the standard value below, and install 4th main gear adjusting shim onto mainshaft. Refer to MT-103, "4TH MAIN GEAR
ADJUSTING SHIM" .
: 173.85 - 173.95 mm (6.844 - 6.848 in)
CAUTION:
Only one adjusting shim can be selected.
PCIB0804E
MT-76
http://vnx.su
MAINSHAFT AND GEARS

12. Press in 4th main gear using the drifts.
CAUTION:
Be careful with orientation of 4th main gear.
Do not reuse 4th main gear.
MT
SCIA0945E

CAUTION:
G
SCIA0946E
14. Install snap ring onto mainshaft, and check that end play of 5th
main gear satisfies the standard value.
: 0 - 0.1 mm (0 - 0.004 in)
If measurement is outside the standard range, reselect snap

ring. Refer to MT-102, "5TH MAIN GEAR" .
SCIA0947E
15. Press in mainshaft rear bearing using the drifts.

L
SCIA0948E
16. Install mainshaft C-ring onto mainshaft, and check that end play
of mainshaft rear bearing satisfies the standard value.
: 0 - 0.06 mm (0 - 0.0024 in)
If measurement is outside the standard range, reselect mainshaft C-ring. Refer to MT-102, "MAINSHAFT C-RING" .
SCIA0949E
MT-77
http://vnx.su
MAINSHAFT AND GEARS

17. Install C-ring holder, and then install snap ring.
CAUTION:
PCIB0802E
18. Check end play of 1st and 2nd main gears.

1st main gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd main gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0933E
ECS008C7
DISASSEMBLY
1.
Before disassembling, measure the end play of 1st and 2nd

main gears.
1st main gear
: 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd main gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0973E
2.
3.
Remove snap ring.

Remove C-ring holder, and then remove mainshaft C-ring.
PCIB0805E
MT-78
http://vnx.su
MAINSHAFT AND GEARS

4.
5.
Press out mainshaft rear bearing, 6th main adjusting shim and
6th main gear using the drift and a puller.
Remove 5th-6th mainshaft spacer.
MT
SCIA0976E
6.
7.
8.
Press out 4th main gear and 5th main gear using the drift and a
puller.
Remove 4th main gear adjusting shim.
Remove 3rd-4th mainshaft spacer.
G
SCIA0937E
9.
Press out 3rd main gear, 2nd main gear, 2nd needle bearing,
2nd main gear bushing, 1st-2nd synchronizer hub assembly, 1st
main gear, 1st needle bearing, and 1st main gear bushing
reverse main gear using the drift.
SCIA0938E

Mainshaft and Gears
L
SCIA1076J
MT-79
http://vnx.su
MAINSHAFT AND GEARS

Synchronizer
Damage and unusual wear on contact surfaces of coupling

sleeve, synchronizer hub and shifting insert.
SMT387A

SMT867D

Triple-cone synchronizer (1st and 2nd)

CAUTION:
The clearances A, B and C are controlled with outer
baulk ring, synchronizer cone and inner baulk ring as a set.
value.
PCIB1358E
1.
Measure the clearance A at 2 points or more diagonally opposite using a feeler gauge when pressing baulk ring toward clutch
Clearance A
Standard value
Limit value
: 0.6 - 1.2 mm (0.024 - 0.047 in)

: 0.3 mm (0.012 in)
PCIB1359E
MT-80
http://vnx.su
MAINSHAFT AND GEARS

2.
Clearance B
Standard value
Limit value
: 0.6 - 1.1 mm (0.024 - 0.043 in)

: 0.2 mm (0.008 in)
MT
PCIB1360E
3.
Measure the clearance C at 2 points or more diagonally opposite using a feeler gauge when pressing baulk ring toward clutch
Clearance C
Standard value
Limit value
: 0.7 - 1.1 mm (0.028 - 0.043 in)

: 0.3 mm (0.012 in)
G
PCIB1361E
Bearing
H
MTF0041D
ASSEMBLY
1.
Press in reverse main gear using the drifts and the press stand.
SCIA0939E
CAUTION:
Be careful with orientation of reverse main gear.
MT-81
http://vnx.su
MAINSHAFT AND GEARS
Do not reuse reverse main gear.
SCIA0992E
2.
3.
Press in 1st main gear bushing using the drifts and the press
stand.
Install 1st needle bearing, and then 1st main gear.
SCIA0940E
4.
Install 1st-2nd spread spring, 1st-2nd shifting insert and 1st-2nd

synchronizer hub onto 1st-2nd coupling sleeve.
CAUTION:
Be careful with orientation of 1st-2nd synchronizer hub.
Do not reuse 1st-2nd synchronizer hub.
SCIA0921E
Be careful with orientation of 1st-2nd coupling sleeve.

Do not reuse 1st-2nd coupling sleeve.
PCIB0803E

on same 1st-2nd shifting insert.
SCIA1083E
MT-82
http://vnx.su
MAINSHAFT AND GEARS

5.
Install 1st inner baulk ring, 1st synchronizer cone, 1st outer
baulk ring onto mainshaft, and then press in 1st-2nd synchronizer hub assembly onto mainshaft using the drifts and the press
stand.
CAUTION:
Outer baulk ring, synchronizer cone, and inner baulk ring
on 2nd gear-side must have been removed.
Be careful with orientation of coupling sleeve.
MT
SCIA0941E
6.
7.
8.
Press in 2nd main gear bushing using the drift and the press
stand.
Install 2nd outer baulk ring, 2nd synchronizer cone, and 2nd
inner baulk ring.
Install 2nd needle bearing and 2nd main gear.
G
SCIA0942E
9.
Press in 3rd main gear using the drift and the press stand.
CAUTION:
Be careful with orientation of 3rd main gear.
Do not reuse 3rd main gear.
10. Install 3rd-4th mainshaft spacer.
SCIA0943E
11. Select 4th main gear adjusting shim so that dimension C1 satisfies the standard value below, and install 4th main gear adjusting shim onto mainshaft. Refer to MT-103, "4TH MAIN GEAR
ADJUSTING SHIM" .

: 173.85 - 173.95 mm (6.844 - 6.848 in)
CAUTION:
PCIB0804E
MT-83
http://vnx.su
MAINSHAFT AND GEARS

CAUTION:
SCIA0945E

CAUTION:
14. Install 5th-6th mainshaft spacer.
SCIA0946E

CAUTION:
SCIA0977E
16. Select 6th main adjusting shim and then install it onto mainshaft.
MT-84
http://vnx.su
MAINSHAFT AND GEARS
Calculate thickness S of 6th main adjusting shim following

the procedure below so that end play dimension between 6th
main gear and mainshaft rear bearing becomes the dimension shown below. Refer to MT-104, "6TH MAIN GEAR
ADJUSTING SHIM" .
End play: 0 - 0.1 mm (0 - 0.004 in)

DimensionS = (S1 - S2 ) - End play
S:
S1 : Dimension from mainshaft standard face to
mainshaft rear bearing press-fit end face
S2 : Dimension from mainshaft standard face to
6th main gear end face
a.
b.
MT
CAUTION:
Using height gauge, measure dimension S1 and S2 .
Install selected 6th main adjusting shim to mainshaft.
G
SCIA0995E
17. Press in mainshaft rear bearing using the drifts.
SCIA0978E
18. Install mainshaft C-ring onto mainshaft, and check that end play
of mainshaft rear bearing satisfies the standard value.
: 0 - 0.06 mm (0 - 0.0024 in)
If measurement is outside the standard range, reselect mainshaft C-ring. Refer to MT-102, "MAINSHAFT C-RING" .
SCIA0979E
19. Install C-ring holder, and then install snap ring.

CAUTION:
PCIB0805E
MT-85
http://vnx.su
MAINSHAFT AND GEARS

20. Check end play of 1st and 2nd main gears.
1st main gear
: 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd main gear
: 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0973E
MT-86
http://vnx.su
REVERSE IDLER SHAFT AND GEARS

PFP:32281
A
ECS008C8
DISASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
Remove reverse idler gear (rear), reverse coupling sleeve and reverse insert spring simultaneously.
Remove reverse idler gear needle bearing.
Remove thrust needle bearing.
Remove reverse baulk ring.
Remove reverse idler gear (front).
Remove retaining pin from reverse idler shaft.
CAUTION:

Reverse Idler Shaft and Gears
MT
I
SCIA0953J
Synchronizer
J
Damage and unusual wear on contact surfaces of reverse coupling sleeve, reverse synchronizer hub and reverse insert
spring.
Reverse coupling sleeve and reverse synchronizer hub must

move smoothly.
M
SMT637A

reverse baulk ring or working face of insert, replace it.
SMT867D
MT-87
http://vnx.su


between baulk ring and cone. If the measurement is below limit,
Clearance
Standard value
Limit value
: 0.95 - 1.4 mm (0.037 - 0.055 in)

: 0.7 mm (0.028 in)
SMT140
Bearing
Damage and rough rotation of bearing.
ASSEMBLY
Paying attention to the following caution, assemble in reverse order of disassembly.
CAUTION:
Be careful with orientation of reverse insert spring.
SCIA0954E

DISASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
Remove reverse idler gear (rear), reverse coupling sleeve and reverse insert spring simultaneously.
Remove reverse baulk ring.
Remove reverse idler gear (front).
Remove retaining pin from reverse idler shaft.
CAUTION:
MT-88
http://vnx.su
ECS008C9

Reverse Idler Shaft and Gears
MT
D
SCIA0953J
Synchronizer
Damage and unusual wear on contact surfaces of reverse coupling sleeve, reverse synchronizer hub, and reverse insert
spring.
Reverse coupling sleeve and reverse synchronizer hub must

move smoothly.
H
SMT637A

reverse baulk ring or working face of insert, replace it.
SMT867D

between baulk ring and cone. If the measurement is below limit,
Clearance
Standard value
Limit value
: 0.95 - 1.4 mm (0.037 - 0.055 in)

: 0.7 mm (0.028 in)
SMT140
Bearing
Damage and rough rotation of bearing.
ASSEMBLY
Paying attention to the following caution, assemble in reverse order of disassembly.
MT-89
http://vnx.su

CAUTION:
Be careful with orientation of reverse insert spring.
SCIA0954E
MT-90
http://vnx.su
FINAL DRIVE
FINAL DRIVE
PFP:38411
A
ECS008CA
PRE-INSPECTION
1.
Check the clearance between side gear and differential case as

follows.
Clean final drive assembly sufficiently to prevent side gear thrust
washer, differential case, side gear, and other parts from sticking
by gear oil.
MT
PCIB0875E
2.
3.
Put differential case vertically so that side gear to be measured faces upward.
Place the preload adapter and a dial indicator onto side gear.
Move side gear up and down, and measure the clearance.
Clearance between side gear and differential case

: 0.1 - 0.2 mm (0.004 - 0.008 in)
4.
5.
CAUTION:
There should be no resistance and gears should rotate
freely.
If not within specification, adjust the clearance by changing side
gear thrust washer thickness.
Turn differential case upside down, and measure the clearance
between side gear and differential case on the other side in the
same way.
SMT611A
DISASSEMBLY
1.
2.
Remove final gear mounting bolts, and then separate the final gear from differential case.
Remove differential side bearing (clutch housing side) using the
drift and pullers.
M
SCIA0906E
3.
Remove differential side bearing (transaxle case side) using the

drift and pullers.
SCIA0907E
MT-91
http://vnx.su
FINAL DRIVE
4.
5.
Remove retaining pin from differential case using a pin punch,

and then remove pinion mate shaft.
Rotate pinion mate gears, and remove pinion mate gears, pinion
mate thrust washers, side gears, and side gear thrust washers
from differential case.
SCIA0908E

Gear, Washer, Shaft and Case
Check side gears, side gear thrust washers, pinion mate shaft,
pinion mate gears, pinion mate thrust washers and differential
case. If necessary, replace with a new one.
MTK0135D
Bearing
Check for bearing damage and rough rotation. If necessary,
replace with a new one.
CAUTION:
When replacing tapered roller bearing, replace outer and inner
races as a set.
SPD715
ASSEMBLY
1.
2.
3.
Apply gear oil to sliding area of differential case, each gear, and thrust washer.
Install side gear thrust washers and side gears into differential
case.
While rotating pinion mate thrust washers and pinion mate
gears, aligning them diagonally, install them into differential
case.
SMT839
MT-92
http://vnx.su
FINAL DRIVE
4.
Insert pinion mate shaft into differential case.

CAUTION:
Be sure not to damage pinion mate thrust washers.
MT
MTK0132D
5.
a.
b.
Measure end play of side gears following the procedure below.

Then select side gear thrust washer.
Put differential case vertically so that its side gear to be measured faces upward.
Place the preload adapter and a dial indicator onto side gears.
G
PCIB0875E
c.
Move side gears up and down to measure end play, and select
thrust washer so that it satisfies the standard value. Refer to MT103, "DIFFERENTIAL SIDE GEAR THRUST WASHER" .

: 0.1 - 0.2 mm (0.004 - 0.008 in)
CAUTION:
freely.
Place differential case upside down. Measure the end
play for opposite side-gears likewise securely.
Install retaining pin into pinion mate shaft using a pin punch.
CAUTION:
6.
SMT611A
SCIA0908E
7.
Press in differential side bearing (transaxle case side) to differential case using the drifts.
SCIA0910E
MT-93
http://vnx.su
FINAL DRIVE
8.
Press in differential side bearing (clutch housing side) to differential case using the drifts.
SCIA0911E
9.
Install final gear into differential case, and tighten final gear
mounting bolts to the specified torque. Refer to MT-23, "Final
Drive Components" .
SCIA0912E
ECS008CB
PRE-INSPECTION
1.
Check the clearance between side gear and differential case as

follows.
Clean final drive assembly sufficiently to prevent side gear thrust
washer, differential case, side gear, and other parts from sticking
by gear oil.
PCIB0875E
2.
3.
Put differential case vertically so that side gear to be measured faces upward.
Place the preload adapter and a dial indicator onto side gear.
Move side gear up and down, and measure the clearance.
: 0.1 - 0.2 mm (0.004 - 0.008 in)
4.
5.
CAUTION:
freely.
If not within specification, adjust the clearance by changing side
gear thrust washer thickness.
Turn differential case upside down, and measure the clearance
between side gear and differential case on the other side in the
same way.
DISASSEMBLY
1.
Remove final gear mounting bolts, and then separate the final gear from differential case.
MT-94
http://vnx.su
SMT611A
FINAL DRIVE
2.
Remove differential side bearing (clutch housing side) using the

drift and pullers.
MT
SCIA0906E
3.
Remove differential side bearing (transaxle case side) using the

drift and pullers.
E
G
SCIA0907E
4.
5.
Remove retaining pin from differential case using a pin punch,

and then remove pinion mate shaft.
Rotate pinion mate gears, and remove pinion mate gears, pinion
mate thrust washers, side gears, and side gear thrust washers
from differential case.
SCIA0908E

Check side gears, side gear thrust washers, pinion mate shaft,
pinion mate gears, pinion mate thrust washers and differential
case. If necessary, replace with a new one.
MTK0135D
MT-95
http://vnx.su
FINAL DRIVE
Bearing
Check for bearing damage and rough rotation. If necessary,
replace with a new one.
CAUTION:
When replacing tapered roller bearing, replace outer and inner
races as a set.
SPD715
ASSEMBLY
1.
2.
3.
Apply gear oil to sliding area of differential case, each gear, and thrust washer.
Install side gear thrust washers and side gears into differential
case.
While rotating pinion mate thrust washers and pinion mate
gears, aligning them diagonally, install them into differential
case.
SMT839
4.
Insert pinion mate shaft into differential case.

CAUTION:
Be sure not to damage pinion mate thrust washers.
MTK0132D
5.
a.
b.
Measure end play of side gears following the procedure below.

Then select side gear thrust washer.
Put differential case vertically so that its side gear to be measured faces upward.
Place the preload adapter and a dial indicator onto side gears.
PCIB0875E
MT-96
http://vnx.su
FINAL DRIVE
c.
Move side gears up and down to measure end play, and select
thrust washer so that it satisfies the standard value. Refer to MT103, "DIFFERENTIAL SIDE GEAR THRUST WASHER" .

: 0.1 - 0.2 mm (0.004 - 0.008 in)
CAUTION:
freely.
Place differential case upside down. Measure the end
play for opposite side-gears likewise securely.
Install retaining pin into pinion mate shaft using a pin punch.
CAUTION:
6.
MT
SMT611A
G
SCIA0908E
7.
Press in differential side bearing (transaxle case side) to differential case using the drifts.
SCIA0910E
8.
Press in differential side bearing (clutch housing side) to differential case using the drifts.
SCIA0911E
9.
Install final gear into differential case, and tighten final gear
mounting bolts to the specified torque. Refer to MT-41, "Final
Drive Components" .
SCIA0912E
MT-97
http://vnx.su
SHIFT CONTROL
SHIFT CONTROL
Inspection (RS5F51A)
PFP:32982
ECS008CC
Check contact surfaces and sliding area for wear, damage,

bending, etc. If necessary, replace parts.
SCIA0913E
SHIFT FORK
Check if the width of shift fork hook (sliding area with coupling
sleeve) is within allowable specification below.
Item
One-side wear specification
Sliding width of new part
1st-2nd
0.2 mm (0.008 in)
7.80 - 7.93 mm
(0.3071 - 0.3122 in)
3rd-4th
0.2 mm (0.008 in)
7.80 - 7.93 mm
(0.3071 - 0.3122 in)
5th
0.2 mm (0.008 in)
6.10 - 6.23 mm
(0.2402 - 0.2453 in)
Reverse
0.2 mm (0.008 in)
12.80 - 12.93 mm
(0.5039 - 0.5091 in)
MT-98
http://vnx.su
SMT801D
SHIFT CONTROL
Inspection (RS6F51A)
ECS008CD
Check contact surfaces and sliding area for wear, damage,

bending, etc. If necessary, replace parts.
MT
G
SCIA0913E
SHIFT FORK
Check if the width of shift fork hook (sliding area with coupling
sleeve) is within allowable specification below.
Item
One-side wear specification
Sliding width of new part
1st-2nd
0.2 mm (0.008 in)
7.80 - 7.93 mm
(0.3071 - 0.3122 in)
3rd-4th
0.2 mm (0.008 in)
7.80 - 7.93 mm
(0.3071 - 0.3122 in)
5th-6th
0.2 mm (0.008 in)
6.10 - 6.23 mm
(0.2402 - 0.2453 in)
Reverse
0.2 mm (0.008 in)
12.80 - 12.93 mm
(0.5039 - 0.5091 in)
K
SMT801D
MT-99
http://vnx.su

PFP:00030
ECS008CE
TRANSAXLE
Engine model
QR20DE
Transaxle model
QR25DE
YD22DDTi
RS5F51A
Model code number
EQ000
Number of speed
RS6F51A
EQ008
EQ068
Synchromesh type
6
Warner
Shift pattern
5 speed
SCIA0821E
6 speed
SCIA0955E
Gear ratio
1st
3.500
1.944
3rd
1.258
4th
0.947
5th
0.772
6th
Input gear
1st
0.772
3.374
3.252
3.374
14
12
14
2nd
18
31
4th
38
44
6th
45
44
46
Reverse
14
12
14
1st
49
41
49
2nd
35
3rd
39
4th
36
5th
34
6th
Reverse idler
gear
3.500
0.630
3rd
5th
Main gear
0.733
Reverse
Number of teeth
3.416
2nd
33
29
Reverse
38
Front
37
Rear
46
38
Oil level
mm (in)
165.0 - 171.0 (6.50 - 6.73)
Oil capacity (Reference)
(Imp pt)
Approx. 2.2 (3-7/8)
MT-100
http://vnx.su
34
46

Engine model
QR20DE
Transaxle model
YD22DDTi
RS5F51A
Model code number

Remarks
QR25DE
EQ000
EQ008
Reverse synchronizer
RS6F51A
EQ068
Installed
Double-cone synchronizer
3rd
Triple-cone synchronizer
1st and 2nd
MT
FINAL GEAR
Engine model
QR20DE
Transaxle model
YD22DDTi
RS5F51A
Model code number
EQ000
Final gear ratio

Number of teeth
QR25DE
Final gear/Pinion
EQ068
4.750
4.428
76/16
62/14
Side gear/Pinion mate gear
RS6F51A
EQ008
14/10
Gear End Play
ECS008CF
Unit: mm (in)
Gear
End play
1st main gear
0.20 - 0.30 (0.0079 - 0.0118)
2nd main gear
0.06 - 0.16 (0.0024 - 0.0063)
3rd input gear
0.18 - 0.31 (0.0071 - 0.0122)
4th input gear
0.20 - 0.30 (0.0079 - 0.0118)
5th input gear
0.06 - 0.16 (0.0024 - 0.0063)
6th input gear (For RS6F51A models)
0.06 - 0.16 (0.0024 - 0.0063)
Baulk Ring Clearance
I
ECS00CV4
Unit: mm (in)
Measurement point
3rd
(Double-cone synchronizer)
Standard value
Limit value
Clearance between synchronizer cone and

inner baulk ring end face A
0.6 - 0.8 (0.024 - 0.031)
0.2 (0.008)
Clearance between outer baulk ring pawl

and synchronizer cone B
0.6 - 1.1 (0.024 -0.043)
0.2 (0.008)
M
PCIB0249E
1st and 2nd

(Triple-cone synchronizer)
Clearance between synchronizer cone and

clutch gear end face A
0.6 - 1.2 (0.024 - 0.047)
0.3 (0.012)
Clearance between outer baulk ring pawl

and synchronizer cone B
0.6 - 1.1 (0.024 - 0.043)
0.2 (0.008)
Clearance between inner baulk ring and

clutch gear end face C
0.7 - 1.1 (0.028 - 0.043)
0.3 (0.012)
4th
0.9 - 1.45 (0.035 - 0.057)
0.7 (0.028)
5th
0.95 - 1.4 (0.037 - 0.055)
0.7 (0.028)
6th (For RS6F51A models)
0.95 - 1.4 (0.037 - 0.055)
0.7 (0.028)
Reverse
0.95 - 1.4 (0.037 - 0.055)
0.7 (0.028)
PCIB0835J
MT-101
http://vnx.su

Available Snap Rings
ECS008CH
INPUT SHAFT BEARING SPACER

For RS5F51A Models
End play
0 - 0.1 mm (0 - 0.004 in)
Thickness
mm (in)
1.71 (0.0673)
1.76 (0.0693)
1.81 (0.0713)
1.86 (0.0732)
1.91 (0.0752)
1.96 (0.0772)
Part number*
Thickness
32204 8H510
32204 8H511
32204 8H512
32204 8H513
32204 8H514
32204 8H515
mm (in)
2.01 (0.0791)
2.06 (0.0811)
2.11 (0.0831)
2.16 (0.0850)
2.21 (0.0870)
2.26 (0.0890)
Part number*
32204 8H516
32204 8H517
32204 8H518
32204 8H519
32204 8H520
32204 8H521
*: Always check with the Parts Department for the latest parts information.
6TH INPUT GEAR BUSHING

For RS6F51A Models
End play
0 - 0.1 mm (0 - 0.004 in)
Thickness
mm (in)
1.76 (0.0693)
1.81 (0.0713)
1.86 (0.0732)
1.91 (0.0752)
1.96 (0.0772)
Part number*
Thickness
32204 8H511
32204 8H512
32204 8H513
32204 8H514
32204 8H515
mm (in)
2.01 (0.0791)
2.06 (0.0811)
2.11 (0.0831)
2.16 (0.0850)
2.21 (0.0870)
Part number*
32204 8H516
32204 8H517
32204 8H518
32204 8H519
32204 8H520
5TH MAIN GEAR

For RS5F51A Models
End play
0 - 0.1 mm (0 - 0.004 in)
Thickness
mm (in)
1.85 (0.0728)
1.90 (0.0748)
1.95 (0.0768)
2.00 (0.0787)
Part number*
Thickness
32204 8H500
32204 8H501
32204 8H502
32204 8H503
mm (in)
2.05 (0.0807)
2.10 (0.0827)
2.15 (0.0846)
2.20 (0.0866)
Part number*
32204 8H504
32204 8H505
32204 8H506
32204 8H507
Available C-Rings
ECS008CI
MAINSHAFT C-RING
End play
Thickness
0 - 0.06 mm (0 - 0.0024 in)

mm (in)
2.535 (0.0998)
2.565 (0.1010)
2.595 (0.1022)
2.625 (0.1033)
2.655 (0.1045)
2.685 (0.1057)
2.715 (0.1069)
2.745 (0.1081)
2.775 (0.1093)
2.805 (0.1104)
Part number*
Thickness
32348 8H800
32348 8H801
32348 8H802
32348 8H803
32348 8H804
32348 8H805
32348 8H806
32348 8H807
32348 8H808
32348 8H809
mm (in)
2.835 (0.1116)
2.865 (0.1128)
2.895 (0.1140)
2.925 (0.1152)
2.955 (0.1163)
2.985 (0.1175)
3.015 (0.1187)
3.045 (0.1199)
3.075 (0.1211)
MT-102
http://vnx.su
Part number*
32348 8H810
32348 8H811
32348 8H812
32348 8H813
32348 8H814
32348 8H815
32348 8H816
32348 8H817
32348 8H818

Available Thrust Washer
ECS008CJ
INPUT SHAFT THRUST WASHER
MT
D
SCIA1008E
Standard length C2
Thickness
154.7 - 154.8 mm (6.091 - 6.094 in)
mm (in)
Part number*
3.84 (0.1512)
3.90 (0.1535)
3.96 (0.1559)
Thickness
32347 8H500
32347 8H501
32347 8H502
mm (in)
Part number*
4.02 (0.1583)
4.08 (0.1606)
4.14 (0.1630)
32347 8H503
32347 8H504
32347 8H505
DIFFERENTIAL SIDE GEAR THRUST WASHER

Allowable clearance between side gear and differential case with
washer
Thickness
0.1 - 0.2 mm (0.004 - 0.008 in)
mm (in)
Part number*
0.75 (0.0295)
0.80 (0.0315)
0.85 (0.0335)
0.90 (0.0354)
0.95 (0.0374)
38424 81X00
38424 81X01
38424 81X02
38424 81X03
38424 81X04
Available Adjusting Shims
ECS008CK
4TH MAIN GEAR ADJUSTING SHIM
SCIA1009E
Standard length C1
Thickness
mm (in)
0.52 (0.0205)
0.60 (0.0236)
0.68 (0.0268)
0.76 (0.0299)
173.85 - 173.95 mm (6.844 - 6.848 in)

Part number*
Thickness
32238 8H500
32238 8H501
32238 8H502
32238 8H503
mm (in)
0.84 (0.0331)
0.92 (0.0362)
1.00 (0.0394)
1.08 (0.0425)
MT-103
http://vnx.su
Part number*
32238 8H504
32238 8H505
32238 8H506
32238 8H507

INPUT SHAFT REAR BEARING ADJUSTING SHIM
End play
0 - 0.06 mm (0 - 0.0024 in)
Thickness
mm (in)
Part number*
32225 8H500
32225 8H501
32225 8H502
32225 8H503
32225 8H504
32225 8H505
32225 8H506
32225 8H507
32225 8H508
32225 8H509
32225 8H510
32225 8H511
0.40 (0.0157)
0.44 (0.0173)
0.48 (0.0189)
0.52 (0.0205)
0.56 (0.0220)
0.60 (0.0236)
0.64 (0.0252)
0.68 (0.0268)
0.72 (0.0283)
0.76 (0.0299)
0.80 (0.0315)
0.84 (0.0331)
Thickness
mm (in)
0.88 (0.0346)
0.92 (0.0362)
0.96 (0.0378)
1.00 (0.0394)
1.04 (0.0409)
1.08 (0.0425)
1.12 (0.0441)
1.16 (0.0457)
1.20 (0.0472)
1.24 (0.0488)
1.28 (0.0504)
1.32 (0.0520)
Part number*
Thickness
mm (in)
Part number*
32225 8H524
32225 8H560
32225 8H561
32225 8H562
32225 8H563
32225 8H564
32225 8H565
32225 8H566
32225 8H567**
32225 8H568**
1.36 (0.0535)
1.40 (0.0551)
1.44 (0.0567)
1.48 (0.0583)
1.52 (0.0598)
1.56 (0.0614)
1.60 (0.0630)
1.64 (0.0646)
1.68 (0.0661)
1.72 (0.0677)
32225 8H512
32225 8H513
32225 8H514
32225 8H515
32225 8H516
32225 8H517
32225 8H518
32225 8H519
32225 8H520
32225 8H521
32225 8H522
32225 8H523
**: RS5F51A models only.
MAINSHAFT REAR BEARING ADJUSTING SHIM

End play
0 - 0.06 mm (0 - 0.0024 in)
Thickness
mm (in)
0.44 (0.0173)
0.48 (0.0189)
0.52 (0.0205)
0.56 (0.0220)
0.60 (0.0236)
0.64 (0.0252)
0.68 (0.0268)
0.72 (0.0283)
0.76 (0.0299)
Part number*
Thickness
32238 8H510
32238 8H511
32238 8H512
32238 8H513
32238 8H514
32238 8H515
32238 8H516
32238 8H517
32238 8H518
mm (in)
0.80 (0.0315)
0.84 (0.0331)
0.88 (0.0346)
0.92 (0.0362)
0.96 (0.0378)
1.00 (0.0394)
1.04 (0.0409)
1.08 (0.0425)
Part number*
32238 8H519
32238 8H520
32238 8H521
32238 8H522
32238 8H523
32238 8H524
32238 8H560
32238 8H561
REVERSE IDLER GEAR ADJUSTING SHIM

End play
0.04 - 0.10 mm (0.0016 - 0.0039 in)
Thickness
mm (in)
1.76 (0.0693)
1.80 (0.0709)
1.84 (0.0724)
1.88 (0.0740)
1.92 (0.0756)
1.96 (0.0772)
2.00 (0.0787)
2.04 (0.0803)
2.08 (0.0819)
2.12 (0.0835)
2.16 (0.0850)
2.20 (0.0866)
Part number*
Thickness
32237 8H800
32237 8H801
32237 8H802
32237 8H803
32237 8H804
32237 8H805
32237 8H806
32237 8H807
32237 8H808
32237 8H809
32237 8H810
32237 8H811
mm (in)
2.24 (0.0882)
2.28 (0.0898)
2.32 (0.0913)
2.36 (0.0929)
2.40 (0.0945)
2.44 (0.0961)
2.48 (0.0976)
2.52 (0.0992)
2.56 (0.1008)
2.60 (0.1024)
2.64 (0.1039)
Part number*
32237 8H812
32237 8H813
32237 8H814
32237 8H815
32237 8H816
32237 8H817
32237 8H818
32237 8H819
32237 8H820
32237 8H821
32237 8H822
6TH MAIN GEAR ADJUSTING SHIM

For RS6F51A Models
End play
0 - 0.1 mm (0 - 0.004 in)
Thickness
mm (in)
0.88 (0.0346)
0.96 (0.0378)
1.04 (0.0409)
1.12 (0.0441)
Part number*
Thickness
32237 8H560
32237 8H561
32237 8H562
32237 8H563
mm (in)
1.20 (0.0472)
1.28 (0.0504)
1.36 (0.0535)
MT-104
http://vnx.su
Part number*
32237 8H564
32237 8H565
32237 8H566

Available Shims
ECS008CL
Differential Side Bearing Preload and Adjusting Shim
BEARING PRELOAD
Differential side bearing preload: L*
0.15 - 0.21 mm (0.0059 - 0.0083 in)
*: Install shims which are deflection of differential case + L in thickness.
DIFFERENTIAL SIDE BEARING ADJUSTING SHIM(S)

Thickness
mm (in)
0.48 (0.0189)
0.52 (0.0205)
0.56 (0.0220)
0.60 (0.0236)
0.64 (0.0252)
0.68 (0.0268)
Part number*
MT
Thickness
31438 80X00
31438 80X01
31438 80X02
31438 80X03
31438 80X04
31438 80X05
mm (in)
0.72 (0.0283)
0.76 (0.0299)
0.80 (0.0315)
0.84 (0.0331)
0.88 (0.0346)
0.92 (0.0362)
Part number*
31438 80X06
31438 80X07
31438 80X08
31438 80X09
31438 80X10
31438 80X11
MT-105
http://vnx.su
MT-106
http://vnx.su
AUTOMATIC TRANSAXLE
SECTION
AT
AUTOMATIC TRANSAXLE
AT
CONTENTS
TROUBLE DIAGNOSIS INDEX ............................. 6
Alphabetical & P No. Index for DTC ......................... 6
PRECAUTIONS .......................................................... 8
(SRS) AIR BAG and SEAT BELT PRE-TENSIONER .................................................................. 8
Precautions for On Board Diagnostic (EURO-OBD)
System of A/T and Engine Euro-OBD ............. 8
Precautions for Trouble Diagnosis ........................... 8
Precautions for Harness Repair ............................... 8
Precautions .............................................................. 9
Service Notice or Precautions ................................ 10
Wiring Diagrams and Trouble Diagnosis .................11
PREPARATION ......................................................... 12
A/T FLUID ................................................................. 16
Checking A/T Fluid ................................................. 16
Changing A/T Fluid ................................................ 17
OVERALL SYSTEM ................................................. 18
Cross-Sectional View ............................................. 18
Hydraulic Control Circuit ........................................ 19
A/T Electrical Parts Location .................................. 20
Circuit Diagram ...................................................... 21
Shift Mechanism ..................................................... 22
TCM Function ......................................................... 31
CAN Communication .............................................. 32
Input/Output Signal of TCM .................................... 34
Line Pressure Control ............................................ 34
Shift Control ........................................................... 35
Lock-up Control ...................................................... 36
Engine Brake Control (Overrun Clutch Control) ..... 37
Control Valve .......................................................... 39
EURO-OBD
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION .......................................................................... 40
Introduction ............................................................ 40
EURO-OBD Function for A/T System .................... 40
One or Two Trip Detection Logic of EURO-OBD ... 40

EURO-OBD Diagnostic Trouble Code (DTC) ......... 40
Malfunction Indicator (MI) ....................................... 44
CONSULT-II ............................................................ 44
Diagnostic Procedure Without CONSULT-II ........... 52
TROUBLE DIAGNOSIS INTRODUCTION ........... 57
Introduction ............................................................. 57
Work Flow ............................................................... 61
TROUBLE DIAGNOSIS BASIC INSPECTION ... 64
A/T Fluid Check ...................................................... 64
Stall Test ................................................................. 65
Line Pressure Test .................................................. 68
Road Test ............................................................... 70
TROUBLE DIAGNOSIS GENERAL DESCRIPTION .......................................................................... 85
Symptom Chart ....................................................... 85
TCM Terminals and Reference Value ..................... 94
DTC U1000 CAN COMMUNICATION LINE .............. 97
Description .............................................................. 97
On Board Diagnosis Logic ...................................... 97
Possible Cause ....................................................... 97
DTC Confirmation Procedure ................................. 97
Wiring Diagram AT CAN ................................ 98
Diagnostic Procedure ............................................. 99
DTC P0705 PARK/NEUTRAL POSITION (PNP)
SWITCH .................................................................. 100
Description ............................................................ 100
Possible Cause ..................................................... 100
Wiring Diagram AT PNP/SW ....................... 102
DTC P0710 A/T FLUID TEMPERATURE SENSOR
CIRCUIT .................................................................. 106
Description ............................................................ 106
Possible Cause ..................................................... 106
Wiring Diagram AT FTS .............................. 108
AT-1
http://vnx.su

Component Inspection ...........................................111
DTC P0720 VEHICLE SPEED SENSORA/T (REVOLUTION SENSOR) ............................................... 112
Description ............................................................ 112
Possible Cause ..................................................... 112
Wiring Diagram AT VSSA/T ......................... 114
DTC P0725 ENGINE SPEED SIGNAL ................... 119
Description ............................................................ 119
Possible Cause ..................................................... 119
Wiring Diagram AT ENGSS ......................... 121
DTC P0731 A/T 1ST GEAR FUNCTION ................. 125
Description ............................................................ 125
On Board Diagnostic Logic ................................... 125
Possible Cause ..................................................... 125
Wiring Diagram AT 1STSIG ......................... 127
DTC P0732 A/T 2ND GEAR FUNCTION ................ 130
Description ............................................................ 130
Possible Cause ..................................................... 130
Wiring Diagram AT 2NDSIG ........................ 132
DTC P0733 A/T 3RD GEAR FUNCTION ................ 135
Description ............................................................ 135
Possible Cause ..................................................... 135
Wiring Diagram AT 3RDSIG ........................ 137
DTC P0734 A/T 4TH GEAR FUNCTION ................ 140
Description ............................................................ 140
Possible Cause ..................................................... 141
Wiring Diagram AT 4THSIG ........................ 143
DTC P0740 TORQUE CONVERTER CLUTCH
SOLENOID VALVE ................................................. 148
Description ............................................................ 148
Possible Cause ..................................................... 148
Wiring Diagram AT TCV .............................. 150
DTC P0745 LINE PRESSURE SOLENOID VALVE. 154
Description ............................................................ 154
Possible Cause ..................................................... 154
Wiring Diagram AT LPSV ............................ 156

DTC P0750 SHIFT SOLENOID VALVE A ............... 161
Description ............................................................ 161
Possible Cause ..................................................... 161
Wiring Diagram AT SSV/A ........................... 163
DTC P0755 SHIFT SOLENOID VALVE B ............... 167
Description ............................................................ 167
Possible Cause ..................................................... 167
Wiring Diagram AT SSV/B ........................... 169
DTC P1705 ACCELERATOR PEDAL POSITION
(APP) SENSOR ....................................................... 173
Description ............................................................ 173
Possible Cause ..................................................... 173
Wiring Diagram AT TPS ............................... 175
DTC P1760 OVERRUN CLUTCH SOLENOID
VALVE ...................................................................... 178
Description ............................................................ 178
Possible Cause ..................................................... 178
Wiring Diagram AT OVRCSV ...................... 180
DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP
SENSOR CIRCUIT AND TCM POWER SOURCE).184
Description ............................................................ 184
Wiring Diagram AT BA/FTS ......................... 186
DTC VEHICLE SPEED SENSOR MTR ................... 192
Description ............................................................ 192
Possible Cause ..................................................... 192
Wiring Diagram AT VSSMTR ....................... 194
DTC CONTROL UNIT (RAM), CONTROL UNIT
(ROM) ...................................................................... 198
Description ............................................................ 198
Possible Cause ..................................................... 198
AT-2
http://vnx.su
DTC CONTROL UNIT(EEPROM) ........................... 200

Description ........................................................... 200
Possible Cause .................................................... 200
TROUBLE DIAGNOSES FOR SYMPTOMS .......... 202
Wiring Diagram AT NONDTC ...................... 202
O/D OFF Indicator Lamp Does Not Come On ..... 204
Engine Cannot Be Started In P and N Position. 206
In P Position, Vehicle Moves Forward Or Backward When Pushed .............................................. 207
In N Position, Vehicle Moves ............................. 208
Large Shock. N R Position .......................... 209
Vehicle Does Not Creep Backward In R Position. 210
Vehicle Does Not Creep Forward In D, 2 Or 1
Position ................................................................ 212
Vehicle Cannot Be Started From D1 ..................... 214
A/T Does Not Shift: D1 D2 Or Does Not Kickdown:
D4 D2 ............................................................... 217
A/T Does Not Shift: D2 D3 ............................... 220
A/T Does Not Shift: D3 D4 ............................... 222
A/T Does Not Perform Lock-up ............................ 224
A/T Does Not Hold Lock-up Condition ................. 225
Lock-up Is Not Released ...................................... 227
Engine Speed Does Not Return To Idle (Light Braking D4 D3 ) ....................................................... 228
Vehicle Does Not Start From D1 ........................... 230
A/T Does Not Shift: D4 D3 , When Overdrive Control Switch ON OFF ..................................... 231
A/T Does Not Shift: D3 22 , When Selector Lever
D 2 Position ................................................ 232
A/T Does Not Shift: 22 11 , When Selector Lever
2 1 Position ................................................. 233
Vehicle Does Not Decelerate By Engine Brake ... 235
TCM Self-diagnosis Does Not Activate ................ 237
EXC.F/EURO-OBD
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ........................................................................ 242
CONSULT-II ......................................................... 242
Diagnostic Procedure Without CONSULT-II ......... 246
TROUBLE DIAGNOSIS INTRODUCTION ......... 251
Introduction .......................................................... 251
Work Flow ............................................................ 255
TROUBLE DIAGNOSIS BASIC INSPECTION . 256
A/T Fluid Check .................................................... 256
Stall Test ............................................................... 257
Line Pressure Test ............................................... 260
Road Test ............................................................. 262
TROUBLE DIAGNOSIS GENERAL DESCRIPTION ........................................................................ 277
Symptom Chart .................................................... 277
TCM Terminals and Reference Value ................... 286
TROUBLE DIAGNOSES FOR SYMPTOMS .......... 289
Wiring Diagram AT NONDTC ...................... 289
O/D OFF Indicator Lamp Does Not Come On ..... 291
Engine Cannot Be Started In P and N Position. 293
In P Position, Vehicle Moves Forward Or Backward When Pushed .............................................. 294

In N Position, Vehicle Moves .............................. 295
Large Shock. N R Position .......................... 296
Vehicle Does Not Creep Backward In R Position. 297
Vehicle Does Not Creep Forward In D, 2 Or 1
Position ................................................................. 299
Vehicle Cannot Be Started From D1 ..................... 301
A/T Does Not Shift: D1 D2 Or Does Not Kickdown:
D4 D2 ................................................................ 304
A/T Does Not Shift: D2 D3 ................................ 307
A/T Does Not Shift: D3 D4 ................................ 309
A/T Does Not Perform Lock-up ............................ 311
A/T Does Not Hold Lock-up Condition .................. 312
Lock-up Is Not Released ...................................... 314
Engine Speed Does Not Return To Idle (Light Braking D4 D3 ) ........................................................ 315
Vehicle Does Not Start From D1 ........................... 317
A/T Does Not Shift: D4 D3 , When Overdrive Control Switch ON OFF ..................................... 318
A/T Does Not Shift: D3 22 , When Selector Lever
D 2 Position ................................................. 319
A/T Does Not Shift: 22 11 , When Selector Lever
2 1 Position ................................................. 320
Vehicle Does Not Decelerate By Engine Brake .... 322
TCM Self-diagnosis Does Not Activate ................ 324
ALL
CAN COMMUNICATION LINE ............................... 329
Description ............................................................ 329
Possible Cause ..................................................... 329
Wiring Diagram AT CAN .............................. 330
VEHICLE SPEED SENSORA/T (REVOLUTION
SENSOR) ................................................................ 332
Description ............................................................ 332
CONSULT-II Reference Value .............................. 332
Possible Cause ..................................................... 332
Wiring Diagram AT VSSA/T ........................ 334
DTC VEHICLE SPEED SENSOR MTR .................. 339
Description ............................................................ 339
Possible Cause ..................................................... 339
Wiring Diagram AT VSSMTR ...................... 341
ACCELE RATOR PEDAL POSITION (APP) SENSOR ......................................................................... 345
Description ............................................................ 345
Possible Cause ..................................................... 345
AT-3
http://vnx.su
AT
Wiring Diagram AT TPS .............................. 347

SHIFT SOLENOID VALVE A .................................. 350
Description ............................................................ 350
Possible Cause ..................................................... 350
Wiring Diagram AT SSV/A ........................... 352
SHIFT SOLENOID VALVE B .................................. 356
Description ............................................................ 356
Wiring Diagram AT SSV/B ........................... 358
OVERRUN CLUTCH SOLENOID VALVE ............... 362
Description ............................................................ 362
Possible Cause ..................................................... 362
Wiring Diagram AT OVRCSV ...................... 364
TORQUE CONVERTER CLUTCH SOLENOID
VALVE ..................................................................... 368
Description ............................................................ 368
Possible Cause ..................................................... 368
Wiring Diagram AT TCV .............................. 370
BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) ........ 374
Description ............................................................ 374
Possible Cause ..................................................... 374
Wiring Diagram AT BA/FTS ......................... 376
ENGINE SPEED SIGNAL ....................................... 382
Description ............................................................ 382
Wiring Diagram AT ENGSS ......................... 383
LINE PRESSURE SOLENOID VALVE ................... 387
Description ............................................................ 387
Possible Cause ..................................................... 387

Wiring Diagram AT LPSV ............................ 389
MAIN POWER SUPPLY AND GROUND CIRCUIT .394
Description ............................................................ 394
Possible Cause ..................................................... 394
Wiring Diagram AT MAIN ............................. 395
A/T SHIFT LOCK SYSTEM ..................................... 398
Description ............................................................ 398
Shift Lock System Electrical Parts Location .......... 398
Wiring Diagram SHIFT ..................................... 399
KEY INTERLOCK CABLE ...................................... 402
Components .......................................................... 402
Removal ................................................................ 402
Installation ............................................................. 403
ON-VEHICLE SERVICE .......................................... 404
Control Valve Assembly and Accumulators .......... 404
Park/Neutral Position (PNP) Switch ...................... 408
Differential Side Oil Seal Replacement ................. 410
Revolution Sensor Replacement .......................... 412
REMOVAL AND INSTALLATION ............................ 413
Removal ................................................................ 413
Installation ............................................................. 415
OVERHAUL ............................................................. 416
Components .......................................................... 416
Oil Channel ........................................................... 422
Locations of Adjusting Shims, Needle Bearings,
Thrust Washers and Snap Rings .......................... 423
DISASSEMBLY ....................................................... 424
Disassembly .......................................................... 424
REPAIR FOR COMPONENT PARTS ...................... 440
Manual Shaft ......................................................... 440
Oil Pump ............................................................... 443
Control Valve Assembly ........................................ 448
Control Valve Upper Body ..................................... 457
Control Valve Lower Body ..................................... 461
Reverse Clutch ..................................................... 464
High Clutch ........................................................... 469
Forward and Overrun Clutches ............................. 475
Low & Reverse Brake ........................................... 483
Rear Internal Gear, Forward Clutch Hub and Overrun Clutch Hub ...................................................... 487
Output Shaft, Idler Gear, Reduction Pinion Gear and
Bearing Retainer ................................................... 491
Band Servo Piston Assembly ................................ 497
Final Drive ............................................................. 503
ASSEMBLY ............................................................. 507
Assembly (1) ......................................................... 507
Adjustment (1) ....................................................... 508
Assembly (2) ......................................................... 513
Adjustment (2) ....................................................... 520
Assembly (3) ......................................................... 523
AT-4
http://vnx.su

General Specifications ......................................... 530
Shift Schedule ...................................................... 530
Stall Revolution .................................................... 531
Line Pressure ....................................................... 531
Control Valves ...................................................... 531
Accumulator ......................................................... 532
Clutch and Brakes ................................................ 533
Final Drive ............................................................ 535
Planetary Carrier and Oil Pump ........................... 536
Input Shaft ............................................................ 537
Reduction Pinion Gear ......................................... 537
Band Servo ........................................................... 538

Output Shaft ......................................................... 538
Bearing Retainer ................................................... 538
Total End Play ....................................................... 538
Reverse Clutch End Play ...................................... 539
Shift Solenoid Valves ............................................ 539
Solenoid Valves .................................................... 539
A/T Fluid Temperature Sensor .............................. 540
Revolution Sensor ................................................ 540
Dropping Resistor ................................................. 540
AT
AT-5
http://vnx.su
TROUBLE DIAGNOSIS INDEX

Alphabetical & P No. Index for DTC
PFP:00000
ECS003VK
ALPHABETICAL INDEX FOR DTC

NOTE:
Check if the vehicle is a model with Euro-OBD system or not by the Type approval number on
the identification plate. Refer to GI-46, "IDENTIFICATION PLATE".
If DTC U1000 is displayed with other DTC, first perform the trouble diagnosis for DTC U1000
CAN COMMUNICATION LINE. Refer to AT-97, "DTC U1000 CAN COMMUNICATION LINE" .
Type approval number
Model
Available
With Euro-OBD system
Not available (blank)
Without Euro-OBD system

DTC
Items
Reference page
A/T 1ST GR FNCTN
P0731
AT-125
A/T 2ND GR FNCTN
P0732
AT-130
A/T 3RD GR FNCTN
P0733
AT-135
A/T 4TH GR FNCTN
P0734
AT-140
ATF TEMP SEN/CIRC
P0710
AT-106
AT-184
U1000
AT-97
CONTROL UNIT (RAM)
AT-198
CONTROL UNIT (ROM)
AT-198
CONT UNIT (EEP ROM)
AT-200
P0725
AT-119
LINE PRESSURE S/V
P0745
AT-154
OVERRUN CLUTCH S/V
P1760
AT-178
PNP SW/CIRC
P0705
AT-100
SHIFT SOLENOID/V A
P0750
AT-161
SHIFT SOLENOID/V B
P0755
AT-167
T/C CLUTCH SOL/V
P0740
AT-148
THROTTLE POSI SEN
P1705
AT-173
VHCL SPEED SENA/T
P0720
AT-112
AT-192
BATT/FLUID TEMP SEN

CAN COMM CIRCUIT
ENGINE SPEED SIG

INITIAL START
VHCL SPEED SENMTR
CONSULT-II
GST*1
*1: These numbers are prescribed by SAE J2012.
AT-6
http://vnx.su

P NO. INDEX FOR DTC
NOTE:
Check if the vehicle is a model with Euro-OBD system or not by the Type approval number on
the identification plate. Refer to GI-46, "IDENTIFICATION PLATE" .
If DTC U1000 is displayed with other DTC, first perform the trouble diagnosis for DTC U1000
CAN COMMUNICATION LINE. Refer to AT-97, "DTC U1000 CAN COMMUNICATION LINE" .
Type approval number
Model
Available
With Euro-OBD system
Not available (blank)
Without Euro-OBD system
AT
DTC
Items
CONSULT-II
GST*1
Reference page
P0705
PNP SW/CIRC
AT-100
P0710
ATF TEMP SEN/CIRC
AT-106
P0720
VHCL SPEED SENA/T
AT-112
P0725
ENGINE SPEED SIG
AT-119
P0731
A/T 1ST GR FNCTN
AT-125
P0732
A/T 2ND GR FNCTN
AT-130
P0733
A/T 3RD GR FNCTN
AT-135
P0734
A/T 4TH GR FNCTN
AT-140
P0740
T/C CLUTCH SOL/V
AT-148
P0745
LINE PRESSURE S/V
AT-154
P0750
SHIFT SOLENOID/V A
AT-161
P0755
SHIFT SOLENOID/V B
AT-167
P1705
THROTTLE POSI SEN
AT-173
P1760
OVERRUN CLUTCH S/V
AT-178
U1000
CAN COMM CIRCUIT
AT-97
BATT/FLUID TEMP SEN
AT-184
CONTROL UNIT (RAM)
AT-198
CONTROL UNIT (ROM)
AT-198
CONT UNIT (EEP ROM)
AT-200
INITIAL START
VHCL SPEED SENMTR
AT-192
*1: These numbers are prescribed by SAE J2012.
AT-7
http://vnx.su
PRECAUTIONS
PRECAUTIONS
PFP:00001
BELT PRE-TENSIONER
ECS004Q0
The Supplemental Restraint System such as AIR BAG and SEAT BELT PRE-TENSIONER, used along
WARNING:
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
harness connectors.
Precautions for On Board Diagnostic (EURO-OBD) System of A/T and Engine

Euro-OBD
ECS004Q1
CAUTION:
Be sure to turn the ignition switch OFF and disconnect the negative battery terminal before any
repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves,
etc. will cause the MI to light up.
cause the MI to light up due to an open circuit. (Be sure the connector is free from water, grease,
Be sure to route and secure the harnesses properly after work. Interference of the harness with a
bracket, etc. may cause the MI to light up due to a short circuit.
may cause the MI to light up due to a malfunction of the EGR system or fuel injection system, etc.
Be sure to erase the unnecessary malfunction information (repairs completed) from the TCM and
ECM before returning the vehicle to the customer.
Precautions for Trouble Diagnosis
ECS004VN
CAN SYSTEM
Do not apply voltage of 7.0V or higher to the measurement terminals.

Use the tester with its open terminal voltage being 7.0V or less.
Precautions for Harness Repair
ECS004VO
CAN SYSTEM
Solder the repaired parts, and wrap with tape. [Frays of twisted
line must be within 110 mm (4.33 in)]
PKIA0306E
AT-8
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PRECAUTIONS
Do not perform bypass wire connections for the repair

parts.(The spliced wire will become separated and the characteristics of twisted line will be lost.)
AT
PKIA0307E
Precautions
ECS004Q2
Before connecting or disconnecting the TCM harness connector, turn ignition switch OFF and disconnect battery
negative cable from battery negative terminal. Failure to do
so may damage the TCM. Because battery voltage is
applied to TCM even if ignition switch is turned off.
G
SEF289H

from TCM, take care not to damage pin terminals (bend or
break).
Make sure that there are not any bends or breaks on TCM
K
AAT470A
Before replacing TCM, perform TCM input/output signal

inspection and make sure whether TCM functions properly
or not. (See page AT-94, "TCM Terminals and Reference
Value".)
MEF040DA
AT-9
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PRECAUTIONS
After performing each TROUBLE DIAGNOSIS, perform

DTC (Diagnostic Trouble Code) CONFIRMATION PROCEDURE.
Procedure if the repair is completed.
Before proceeding with disassembly, thoroughly clean the outside of the transaxle. It is important to prevent the internal parts
from becoming contaminated by dirt or other foreign matter.
Disassembly should be done in a clean work area.
Use lint-free cloth or towels for wiping parts clean. Common
SAT652J
shop rags can leave fibers that could interfere with the operation
of the transaxle.
Place disassembled parts in order for easier and proper assembly.
All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
Gaskets, seals and O-rings should be replaced any time the transaxle is disassembled.
It is very important to perform functional tests whenever they are indicated.
The valve body contains precision parts and requires extreme care when parts are removed and serviced.
Place disassembled valve body parts in order for easier and proper assembly. Care will also prevent
springs and small parts from becoming scattered or lost.
Properly installed valves, sleeves, plugs, etc. will slide along bores in valve body under their own weight.
Before assembly, apply a coat of recommended ATF to all parts. Apply petroleum jelly to protect O-rings
and seals, or hold bearings and washers in place during assembly. Do not use grease.
Extreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling.
After overhaul, refill the transaxle with new ATF.
When the A/T drain plug is removed, only some of the fluid is drained. Old A/T fluid will remain in torque
converter and ATF cooling system.
Always follow the procedures under Changing A/T Fluid in the AT section when changing A/T fluid. Refer
to Changing A/T Fluid, AT-16, "A/T FLUID" .
ECS004Q3
FAIL-SAFE
The TCM has an electronic Fail-Safe (limp home mode). This allows the vehicle to be driven even if a major
electrical input/output device circuit is damaged.
Under Fail-Safe, the vehicle always runs in third gear, even with a shift lever position of 1, 2 or D. The customer may complain of sluggish or poor acceleration.
Always follow the WORK FLOW, refer to AT-255, "Work Flow" (EXCEPT FOR Euro-OBD) or AT-61, "Work
Flow" (Euro-OBD).
The SELF-DIAGNOSIS results will be as follows:
The first SELF-DIAGNOSIS will indicate damage to the vehicle speed sensor or the revolution sensor.
During the next SELF-DIAGNOSIS, performed after checking the sensor, no damages will be indicated.
TORQUE CONVERTER SERVICE

The torque converter should be replaced under any of the following conditions:
External leaks in the hub weld area.
Converter hub is scored or damaged.
Converter pilot is broken, damaged or fits poorly into crankshaft.
Steel particles are found after flushing the cooler and cooler lines.
Pump is damaged or steel particles are found in the converter.
Vehicle has TCC shudder and/or no TCC apply. Replace only after all hydraulic and electrical diagnoses
have been made. (Converter clutch material may be glazed.)
Converter is contaminated with engine coolant containing antifreeze.
Internal failure of stator roller clutch.
Heavy clutch debris due to overheating (blue converter).
AT-10
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PRECAUTIONS
Steel particles or clutch lining material found in fluid filter or on magnet when no internal parts in unit are
worn or damaged indicates that lining material came from converter.
A
The torque converter should not be replaced if:
The fluid has an odor, is discolored, and there is no evidence of metal or clutch facing particles.
B
The threads in one or more of the converter bolt holes are damaged.
Transaxle failure did not display evidence of damaged or worn internal parts, steel particles or clutch plate
lining material in unit and inside the fluid filter.
Vehicle has been exposed to high mileage (only). The exception may be where the torque converter AT
clutch dampener plate lining has seen excess wear by vehicles operated in heavy and/or constant traffic,
such as taxi, delivery or police use.
D
EURO-OBD SELF-DIAGNOSIS EURO-OBD
A/T self-diagnosis is performed by the TCM in combination with the ECM. The results can be read through
the blinking pattern of the O/D OFF indicator lamp or the malfunction indicator (MI). Refer to the table on
AT-45, "SELF-DIAGNOSTIC RESULT TEST MODE" for the indicator used to display each self-diagnostic
result.
The self-diagnostic results indicated by the MI are automatically stored in both the ECM and TCM memories.
Always perform the procedure HOW TO ERASE DTC on AT-42, "HOW TO ERASE DTC" to complete the repair and avoid unnecessary blinking of the MI.
The following self-diagnostic items can be detected using ECM self-diagnostic results mode* only when
the O/D OFF indicator lamp does not indicate any malfunctions.
PNP switch
A/T 1st, 2nd, 3rd, or 4th gear function

*: For details of EURO-OBD, refer to EC-51, "ON BOARD DIAGNOSTIC (OBD) SYSTEM" .
Certain systems and components, especially those related to EURO-OBD, may use a new style
slide-locking type harness connector.
For description and how to disconnect, refer to PG-73, "HARNESS CONNECTOR" .

PG-2, "POWER SUPPLY ROUTING"

ECS004Q4
AT-11
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PREPARATION
PREPARATION
PFP:00100
ECS004Q5
Tool number
Tool name
Description
KV381054S0
Puller
Removing differential side oil seals
Removing differential side bearing outer race
Removing idler gear bearing outer race
a: 250 mm (9.84 in)

b: 160 mm (6.30 in)
NT414
ST33400001
Drift
Installing LH differential side oil seal

Installing oil seal on oil pump housing
a: 60 mm (2.36 in) dia.

b: 47 mm (1.85 in) dia.
NT086
KV40100621
Drift
Installing RH differential side oil seal

a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
NT086
ST2505S001
Oil pressure gauge set
Measuring line pressure
Removing idler gear
1. ST25051001 Oil pressure

gauge
2. ST25052000 Hose
3. ST25053000 Joint pipe
4. ST25054000 Adapter
NT097
ST27180001
Puller
a: 100 mm (3.94 in)

b: 110 mm (4.33 in)
c: M8 x 1.25P
NT424
ST23540000
Pin punch
Removing and installing parking rod plate and

manual plate pins
a: 2.3 mm (0.091 in) dia.

b: 4 mm (0.16 in) dia.
NT442
AT-12
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PREPARATION
Tool number
Tool name
Description
ST25710000
Pin punch
Aligning groove of manual shaft and hole of

transaxle case
a: 2 mm (0.08 in) dia.
AT
NT410
KV32101000
Pin punch
Removing and installing manual shaft retaining pin
Removing and installing pinion mate shaft lock pin
a: 4 mm (0.16 in) dia.
NT410
KV31102400
Clutch spring compressor
Removing and installing clutch return springs
Installing low and reverse brake piston
a: 320 mm (12.60 in)

b: 174 mm (6.85 in)
H
NT423
KV40100630
Drift
Installing reduction gear bearing inner race
Installing idler gear bearing inner race
a: 67.5 mm (2.657 in) dia.

b: 44 mm (1.73 in) dia.
c: 38.5 mm (1.516 in) dia.
NT107
ST30720000
Bearing installer
Installing idler gear bearing outer race
a: 77 mm (3.03 in) dia.

b: 55.5 mm (2.185 in) dia.
NT115
ST35321000
Drift
Installing output shaft bearing
a: 49 mm (1.93 in) dia.

b: 41 mm (1.61 in) dia.
NT073
ST33230000
Drift
Installing differential side bearing inner race
a: 51 mm (2.01 in) dia.

b: 28.5 mm (1.122 in) dia.
NT084
AT-13
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PREPARATION
Tool number
Tool name
Description
ST33220000
Drift
Selecting differential side bearing adjusting shim
a: 37 mm (1.46 in) dia.

b: 31 mm (1.22 in) dia.
c: 22 mm (0.87 in) dia.
NT085
ST3306S001
Differential side bearing
puller set
Removing differential side bearing inner race
a: 38 mm (1.50 in) dia.

b: 28.5 mm (1.122 in) dia.
c: 130 mm (5.12 in)
d: 135 mm (5.31 in)
e: 100 mm (3.94 in)
1. ST33051001 Puller
AMT153
ST3127S000
Preload gauge
Checking differential side bearing preload
Installing idler gear
Installing differential side bearing inner race
1. GG9103000 Torque
wrench
2. HT62900000 Socket
adapter
NT124
ST35271000
Drift
a: 72 mm (2.83 in) dia.

b: 63 mm (2.48 in) dia.
NT115
KV38107700
Preload adapter
NT087
KV38105210
Preload adapter
NT075
AT-14
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PREPARATION
ECS004Q6
A
Tool name
Description
Puller
Removing idler gear bearing inner race
Removing and installing band servo piston

snap ring
AT
NT077
Puller
Removing reduction gear bearing inner

race
a: 60 mm (2.36 in) dia.

b: 35 mm (1.38 in) dia.
NT411
Drift
Installing differential side oil seal
a: 90 mm (3.54 in) dia.
NT083
Drift
Installing needle bearing on bearing

retainer
a: 36 mm (1.42 in) dia.
J
NT083
Drift
Removing needle bearing from bearing

retainer
a: 33.5 mm (1.319 in) dia.
L
NT083
Drift
Installing differential side bearing outer

race (RH side)
a: 75 mm (2.95 in) dia.
NT083
Drift
Installing differential side bearing outer

race (LH side)
a: 100 mm (3.94 in) dia.
NT083
AT-15
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A/T FLUID
A/T FLUID
Checking A/T Fluid
1.
2.
PFP:KLE40
ECS004Q7
Warm up engine.
Check for A/T fluid leakage.
SMA146B
3.
a.
b.
c.
Before driving, A/T fluid level can be checked at A/T fluid temperatures of 30 to 50C (86 to 122F) using COLD range on A/
T fluid level gauge.
Park vehicle on level surface and set parking brake.
Start engine and move selector lever through each gear position. Leave selector lever in P position.
Check A/T fluid level with engine idling.
SMA827CA
d.
e.
f.
4.
5.
Remove A/T fluid level gauge and note reading. If level is at low
side of either range, and A/T fluid to the A/T fluid charging pipe.
CAUTION:
When wiping away the A/T fluid level gauge, always use
lint-free paper, not a cloth one.
Re-insert A/T fluid level gauge into A/T fluid charging pipe as far
as it will go.
CAUTION:
Firmly fix the A/T fluid level gauge to the A/T fluid charging
pipe using a stopper attached.
SMA051D
Remove A/T fluid level gauge and note reading. If reading is at
low side of range, add A/T fluid to the A/T fluid charging pipe.
CAUTION:
Do not overfill.
Drive vehicle for approximately 5 minutes in urban areas.
Recheck A/T fluid level at A/T fluid temperatures of 50 to 80C (122 to 176F) using HOT range on A/T
fluid level gauge.
CAUTION:
When wiping away the A/T fluid level gauge, always use lint-free paper, not a cloth one.
Firmly fix the A/T fluid level gauge to the A/T fluid charging pipe using a stopper attached.
AT-16
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A/T FLUID
6.
Check A/T fluid condition.

If A/T fluid is very dark or smells burned, checking operation
of A/T. Flush cooling system after repair of A/T.
If A/T fluid contains frictional material (clutches, bands, etc.),
replace radiator and flush cooler line using cleaning solvent
and compressed air after repair of A/T. Refer to CO-12,
"RADIATOR" , CO-15, "RADIATOR (ALUMINUM TYPE)" .
Install the removed A/T fluid level gauge in the A/T fluid charging
pipe.
CAUTION:
Firmly fix the A/T fluid level gauge to the A/T fluid charging
pipe using a stopper attached.
7.
Changing A/T Fluid

1.
2.
3.
AT
SAT638A
D
ECS004Q8
Warm up A/T fluid.

Stop engine.
Drain A/T fluid from drain plug and refill with new A/T fluid. Always refill same volume with drained fluid.
CAUTION:
Do not reuse drain plug gasket.
(7-1/2 lmp qt)
Drain plug:
: 34 Nm (3.5 kg-m, 25 ft-lb)
4.
5.
Fluid capacity (With torque converter):

Approx. 8.5
Run engine at idle speed for five minutes.

Check A/T fluid level and condition. Refer to AT-16, "Checking
A/T Fluid" . If A/T fluid is still dirty, repeat steps 2 through 5.
SMA027D
AT-17
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OVERALL SYSTEM
OVERALL SYSTEM
Cross-Sectional View
PFP:00000
ECS00CTA
SCIA0688E
1.
Band servo piston
2.
Reverse clutch drum
3.
Converter housing
4.
Oil pump
5.
Brake band
6.
Reverse clutch
7.
High clutch
8.
Front planetary gear
9.
Low one-way clutch
10. Rear planetary gear
11. Forward clutch
12. Overrun clutch
13. Low & reverse brake
14. Output gear
15. Idler gear
16. Forward one-way clutch
17. Pinion reduction gear
18. Final gear
19. Differential case
20. Input shaft
21. Torque converter
22. Side cover
AT-18
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OVERALL SYSTEM
Hydraulic Control Circuit
ECS004QC
AT
SCIA0689E
AT-19
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OVERALL SYSTEM
A/T Electrical Parts Location
ECS004Q9
SCIA5367E
AT-20
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OVERALL SYSTEM
Circuit Diagram
ECS004QA
AT
TCWA0228E
AT-21
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OVERALL SYSTEM
Shift Mechanism
ECS004QD
CONSTRUCTION
SAT998I
1.
Torque converter
2.
Oil pump
3.
Input shaft
4.
Brake band
5.
Reverse clutch
6.
High clutch
7.
Front sun gear
8.
Front pinion gear
9.
Front internal gear
10. Front planetary carrier
11. Rear sun gear
13. Rear internal gear
14. Rear planetary carrier
12. Rear pinion gear

15. Forward clutch
17. Overrun clutch
18. Low one-way clutch
20. Parking pawl
21. Parking gear
22. Output shaft
23. Idle gear
24. Output gear
FUNCTION OF CLUTCH AND BRAKE

Clutch and brake components
Abbr.
Function
5 Reverse clutch
R/C
To transmit input power to front sun gear 7 .
6 High clutch
H/C
To transmit input power to front planetary carrier 10 .
15 Forward clutch
F/C
To connect front planetary carrier 10 with forward one-way clutch 16 .
17 Overrun clutch
O/C
To connect front planetary carrier 10 with rear internal gear 13 .
4 Brake band
B/B
To lock front sun gear 7 .
16 Forward one-way clutch
F/O.C
When forward clutch 15 is engaged, to stop rear internal gear 13 from rotating in
opposite direction against engine revolution.
18 Low one-way clutch
L/O.C
To stop front planetary carrier 10 from rotating in opposite direction against

engine revolution.
19 Low & reverse brake
L & R/B
To lock front planetary carrier 10 .
AT-22
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OVERALL SYSTEM
CLUTCH AND BAND CHART
Shift position
Rever
se
clutch
5
High
clutch
6
Forward
clutch
15
Overrun
clutch
17
Band servo
2nd
apply
3rd
releas
e
4th
apply
Forward
one-way
clutch
16
Low
oneway
clutch
18
Low &
revers
e
brake
19
A
Lockup
PARK
POSITION
REVERSE
POSITION
NEUTRAL
POSITION
Automatic
shift
123
4
1st
*1D
2nd
*1A
3rd
*1A
4th
*2C
*3C
1st
3rd
*1
F
B
Automatic
shift
1 23
*2C
B
B
2nd
B
*2C
H
Locks (held
stationary) in
1st speed
1 23
*1: Operates when overdrive control switch is set in OFF position.
*2: Oil pressure is applied to both 2nd apply side and 3rd release side of band servo piston. However, brake band does not contract because oil pressure area on the release side is greater than that on the apply side.
*3: Oil pressure is applied to 4th apply side in condition *2 above, and brake band contracts.
*4: A/T will not shift to 4th when overdrive control switch is set in OFF position.
1st
3rd
AT
2nd
D*4
Remarks
: Operates.
A: Operates when throttle opening is less than 3/16, activating engine brake.
B: Operates during progressive acceleration.
C: Operates but does not affect power transmission.
D: Operates when throttle opening is less than 3/16, but does not affect engine brake.
AT-23
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OVERALL SYSTEM
POWER TRANSMISSION
N and P Positions
N position
Power from the input shaft is not transmitted to the output shaft because the clutches do not operate.
P position
Similar to the N position, the clutches do not operate. The parking pawl engages with the parking gear to
mechanically hold the output shaft so that the power train is locked.
SAT991I
AT-24
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OVERALL SYSTEM
11 Position
Forward clutch
Forward one-way clutch
Overrun clutch
Low & reverse brake
Engine brake
As overrun clutch engages, rear internal gear is locked by the operation of low and
reverse brake.
This is different from that of D1 and 21 .
B
Overrun clutch always engages, therefore engine brake can be obtained when decelerating.
AT
L
SCIA1816E
AT-25
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OVERALL SYSTEM
D1 and 21 Positions
Forward clutch
Low one-way clutch
Overrun clutch
engagement conditions
(Engine brake)
Rear internal gear is locked to rotate counterclockwise because of the functioning of

these three clutches.
D1 : Overdrive control switch OFF and throttle opening is less than 3/16
21 : Always engaged
At D1 and 21 positions, engine brake is not activated due to free turning of low oneway clutch.
SAT377J
AT-26
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OVERALL SYSTEM
D2 , 22 and 12 Positions
Forward clutch
Forward one-way
clutch
Brake band
Overrun clutch
Rear sun gear drives rear planetary carrier and combined front internal gear. Front internal gear now
rotates around front sun gear accompanying front planetary carrier.
As front planetary carrier transfers the power to rear internal gear through forward clutch and forward oneway clutch, this rotation of rear internal gear increases the speed of rear planetary carrier compared with
that of the 1st speed.
22 and 12 : Always engaged
AT
L
SAT378J
AT-27
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OVERALL SYSTEM
D3 , 23 and 13 Positions
High clutch
Forward clutch
Forward one-way
clutch
Overrun clutch
Input power is transmitted to front planetary carrier through high clutch. And front planetary carrier is connected to rear internal gear by operation of forward clutch and forward one-way clutch.
This rear internal gear rotation and another input (the rear sun gear) accompany rear planetary carrier to
turn at the same speed.
23 and 13 : Always engaged
SAT379J
AT-28
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OVERALL SYSTEM
D4 (O/D) Position
High clutch
Brake band
Forward clutch (Does not affect power

transmission)
Engine brake
Input power is transmitted to front carrier through high clutch.

This front carrier turns around the sun gear which is fixed by brake band and makes
front internal gear (output) turn faster.
B
At D4 position, there is no one-way clutch in the power transmission line and engine
brake can be obtained when decelerating.
AT
L
SAT380J
AT-29
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OVERALL SYSTEM
R Position
Reverse clutch
Low & reverse brake
Engine brake
Front planetary carrier is stationary because of the operation of low and reverse brake.
Input power is transmitted to front sun gear through reverse clutch, which drives front
internal gear in the opposite direction.
As there is no one-way clutch in the power transmission line, engine brake can be
obtained when decelerating.
SAT381J
AT-30
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OVERALL SYSTEM
TCM Function
ECS004QE
The function of the TCM is to:
Receive input signals sent from various switches and sensors.
Determine required line pressure, shifting point, lock-up operation, and engine brake operation.
Send required output signals to the respective solenoids.
CONTROL SYSTEM OUTLINE

The automatic transaxle senses vehicle operating conditions through various switches and sensors. It always AT
controls the optimum shift position and reduces shifting and lock-up shocks.
SWITCHES & SENSORS
TCM
ACTUATORS
PNP switch
Accelerator pedal position (APP)
sensor
Engine speed signal
A/T fluid temperature sensor
Revolution sensor
Shift control
Line pressure control
Lock-up control
Overrun clutch control
Timing control
Fail-safe control
Self-diagnosis
CONSULT-II communication line
control
CAN system
Shift solenoid valve A

Shift solenoid valve B
Overrun clutch solenoid valve
Torque converter clutch solenoid
valve
Line pressure solenoid valve
O/D OFF indicator lamp
CONTROL SYSTEM
H
SCIA4505E
AT-31
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OVERALL SYSTEM
CAN Communication
ECS00CTB
SYSTEM DESCRIPTION
ABS MODELS
System diagram
PKIA6457E
Input/output signal chart

Signals
TCM
ECM
Combination meter
PN range signal

AT-32
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OVERALL SYSTEM
ESP MODELS
System diagram
AT
PKIA6460E
Input/output signal chart

Signals
TCM
ECM
Combination meter
PN range signal

AT-33
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OVERALL SYSTEM
Input/Output Signal of TCM
Line
pressure
control
Vehicle
speed
control
Shift
control
Lock-up
control
Engine
brake
control
Fail-safe
function
(*3)
Self-diagnostics
function
Vehicle speed sensor A/T

(Revolution sensor)
Vehicle speed sensor MTR(*1)
Closed throttle position signal(*5)
(*2) X
(*2) X
(*4) X
Wide open throttle position signal(*5)
(*2) X
(*2) X
Control item
Input
ECS00CTC
(*4) X
Engine speed signal

PNP switch
Stop lamp switch
X
X
signal(*5)
A/T fluid temperature sensors
TCM power supply voltage signal
Shift solenoid valve A/B

Line pressure solenoid
Output
(*4) X
O/D OFF indicator
(*4) X
X
X
Torque converter clutch solenoid

valve
X
X
lamp(*6)
*1: Spare for vehicle speed sensorA/T (revolution sensor)

*2: Spare for accelerator pedal position signal
*3: If these input and output signals are different, the TCM triggers the fail-safe function.
*4: Used as a condition for starting self-diagnostics; if self-diagnostics are not started, it is judged that there is some kind of error.
*5: Input by CAN communications.
*6: Output by CAN communications.
Line Pressure Control
ECS004QF
TCM has various line pressure control characteristics to match the driving conditions.
An ON-OFF duty signal is sent to the line pressure solenoid valve based on TCM characteristics.
Hydraulic pressure on the clutch and brake is electronically controlled through the line pressure solenoid
valve to accommodate engine torque. This results in smooth shift operation.
NORMAL CONTROL
The line pressure to throttle opening characteristics is set for suitable
clutch operation.
SAT003J
AT-34
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OVERALL SYSTEM
BACK-UP CONTROL (ENGINE BRAKE)
A
If the selector lever is shifted to 2 position while driving in D4 (O/D)

or D3 , great driving force is applied to the clutch inside the transaxle.
Clutch operating pressure (line pressure) must be increased to deal
with this driving force.
AT
SAT004J
DURING SHIFT CHANGE

The line pressure is temporarily reduced corresponding to a change
in engine torque when shifting gears (that is, when the shift solenoid
valve is switched for clutch operation) to reduce shifting shock.
SAT005J
AT LOW FLUID TEMPERATURE
Fluid viscosity and frictional characteristics of the clutch facing change with fluid temperature. Clutch
engaging or band-contacting pressure is compensated for, according to fluid temperature, to stabilize
shifting quality.
The line pressure is reduced below 60C (140F) to prevent
shifting shock due to low viscosity of A/T fluid when temperature
is low.
L
SAT006J
Line pressure is increased to a maximum irrespective of the

throttle opening when fluid temperature drops to 10C (14F).
This pressure rise is adopted to prevent a delay in clutch and
brake operation due to extreme drop of fluid viscosity at low
temperature.
SAT007J
Shift Control
ECS00CTD
The shift is regulated entirely by electronic control to accommodate vehicle speed and varying engine operations. This is accomplished by electrical signals transmitted by the revolution sensor and the ECM (accelerator
pedal position sensor). This results in improved acceleration performance and fuel economy.
AT-35
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OVERALL SYSTEM
CONTROL OF SHIFT SOLENOID VALVES A AND B
The TCM activates shift solenoid valves A and B according to signals from the throttle position sensor and revolution sensor to select
the optimum gear position on the basis of the shift schedule memorized in the TCM.
The shift solenoid valve performs simple ON-OFF operation. When
set to ON, the drain circuit closes and pilot pressure is applied to
the shift valve.
SAT008J
RELATION BETWEEN SHIFT SOLENOID VALVES A AND B GEAR POSITIONS

Gear position
Shift solenoid valve

D1 , 21 , 11
D 2 , 2 2 , 12
D3
D4 (O/D)
N-P
ON (Closed)
OFF (Open)
OFF (Open)
ON (Closed)
ON (Closed)
ON (Closed)
ON (Closed)
OFF (Open)
OFF (Open)
ON (Closed)
CONTROL OF SHIFT VALVES A AND B
SAT009J
Pilot pressure generated by the operation of shift solenoid valves A and B is applied to the end face of shift
valves A and B.
The drawing above shows the operation of shift valve B. When the shift solenoid valve is ON, pilot pressure
applied to the end face of the shift valve overcomes spring force, moving the valve upward.
Lock-up Control
ECS00CTE
The torque converter clutch piston in the torque converter is locked to eliminate torque converter slip to
increase power transmission efficiency. The solenoid valve is controlled by an ON-OFF duty signal sent from
the TCM. The signal is converted to an oil pressure signal which controls the torque converter clutch piston.
CONDITIONS FOR LOCK-UP OPERATION

When vehicle is driven in 3rd and 4th gear position, vehicle speed and throttle opening are detected. If the
detected values fall within the lock-up zone memorized in the TCM, lock-up is performed.
Overdrive control switch
ON
Selector lever
Gear position
Closed throttle position switch
OFF
D position
D3
D4
More than set value

Less than set opening
OFF
AT-36
http://vnx.su
OVERALL SYSTEM
TORQUE CONVERTER CLUTCH SOLENOID VALVE CONTROL
Lock-up Control System Diagram
AT
SCIA5623E
Lock-up Released
In the lock-up released state, the torque converter clutch control valve is set into the unlocked state by the
torque converter clutch solenoid applying pressure is drained and the torque converter clutch piston
release pressure is generated.
In this way, the torque converter clutch piston is not coupled.
Lock-up Applied
In the lock-up applied state, the torque converter clutch control valve is set into the locked state by the
torque converter clutch solenoid applying pressure is generated and the torque converter clutch piston
release pressure is drained.
In this way, the torque converter clutch piston is pressed and coupled.
SMOOTH LOCK-UP CONTROL

When shifting from the lock-up released state to the lock-up applied state, the current output to the torque converter clutch solenoid is controlled with the TCM. In this way, when shifting to the lock-up applied state, the
torque converter clutch is temporarily set to the half-clutched state to reduce the shock.
Half-Clutched State
The current output from the TCM to the torque converter clutch solenoid is varied to steadily increase the
torque converter clutch solenoid pressure.
In this way, the lock-up applying pressure gradually rises and while the torque converter clutch piston is
put into half-clutched status, the torque converter clutch piston operating pressure is increased and the
coupling is completed smoothly.
Engine Brake Control (Overrun Clutch Control)
ECS00CTF
Forward one-way clutch is used to reduce shifting shocks in downshifting operations. This clutch transmits
engine torque to the wheels. However, drive force from the wheels is not transmitted to the engine because
the one-way clutch rotates idle. This means the engine brake is not effective.
The overrun clutch operates when the engine brake is needed.
AT-37
http://vnx.su
OVERALL SYSTEM
OVERRUN CLUTCH OPERATING CONDITIONS
SCIA5658E
Selector lever position
Gear position
Throttle opening
D position
D1 , D2 , D3 gear position
Less than 3/16
2 position
21 , 22 gear position
1 position
11 , 12 gear position
At any position
OVERRUN CLUTCH SOLENOID VALVE CONTROL

The overrun clutch solenoid valve is operated by an ON-OFF signal
transmitted by the TCM to provide overrun clutch control (engine
brake control).
When this solenoid valve is ON, the pilot pressure drain port
closes. When it is OFF, the drain port opens.
During the solenoid valve ON pilot pressure is applied to the end
face of the overrun clutch control valve.
SAT015J
OVERRUN CLUTCH CONTROL VALVE OPERATION

When the solenoid valve is ON, pilot pressure is applied to the
overrun clutch control valve. This pushes up the overrun clutch control valve. The line pressure is then shut off so that the clutch does
not engage.
When the solenoid valve is OFF, pilot pressure is not generated. At
this point, the overrun clutch control valve moves downward by
spring force. As a result, overrun clutch operation pressure is provided by the overrun clutch reducing valve. This causes the overrun
clutch to engage.
In the 2 and 1 position, the overrun clutch control valve remains
pushed down so that the overrun clutch is engaged at all times.
SCIA3458E
AT-38
http://vnx.su
OVERALL SYSTEM
Control Valve
ECS004QG
FUNCTION OF CONTROL VALVES

Valve name
Function
Pressure regulator valve, plug and sleeve

plug
Regulates oil discharged from the oil pump to provide optimum line pressure for all driving conditions.
Pressure modifier valve and sleeve
Used as a signal supplementary valve to the pressure regulator valve. Regulates pressure-modifier pressure (signal pressure) which controls optimum line pressure for all
driving conditions.
AT
Pilot valve
Regulates line pressure to maintain a constant pilot pressure level which controls lock-up
mechanism, overrun clutch, shift timing.
Accumulator control valve
Regulates accumulator back-pressure to pressure suited to driving conditions.
Manual valve
Directs line pressure to oil circuits corresponding to select positions.

Hydraulic pressure drains when the shift lever is in Neutral.
Shift valve A
Simultaneously switches three oil circuits using output pressure of shift solenoid valve A
to meet driving conditions (vehicle speed, throttle opening, etc.).
Provides automatic downshifting and upshifting (1st 2nd 3rd 4th gears/4th
3rd 2nd 1st gears) in combination with shift valve B.
Shift valve B
Simultaneously switches two oil circuits using output pressure of shift solenoid valve B in
relation to driving conditions (vehicle speed, throttle opening, etc.).
Provides automatic downshifting and upshifting (1st 2nd 3rd 4th gears/4th
3rd 2nd 1st gears) in combination with shift valve A.
Switches hydraulic circuits to prevent engagement of the overrun clutch simultaneously

with application of the brake band in D4 . (Interlocking occurs if the overrun clutch
engages during D4 .)
Overrun clutch control valve
1st reducing valve
Reduces low & reverse brake pressure to dampen engine-brake shock when downshifting from the 1st position 12 to 11 .
Overrun clutch reducing valve
Reduces oil pressure directed to the overrun clutch and prevents engine-brake shock.
In the 1st and 2nd positions, line pressure acts on the overrun clutch reducing valve to
increase the pressure-regulating point, with resultant engine brake capability.
Torque converter relief valve
Prevents an excessive rise in torque converter pressure.
Torque converter clutch control valve, plug

and sleeve
Activates or inactivates the lock-up function.

Also provides smooth lock-up through transient application and release of the lock-up
system.
1-2 accumulator valve and piston
Lessens the shock find when the 2nd gear band servo contracts, and provides smooth
shifting.
3-2 timing valve
Switches the pace that oil pressure is released depending on vehicle speed; maximizes
the high clutch release timing, and allows for soft downshifting.
Shuttle valve
Determines if the overrun clutch solenoid valve should control the 3-2 timing valve or the
overrun clutch control valve and switches between the two.
Cooler check valve
At low speeds and with a small load when a little heat is generated, saves the volume of
cooler flow, and stores the oil pressure for lock-up.
AT-39
http://vnx.su
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

[EURO-OBD]

Introduction
[EURO-OBD]
PFP:00000
ECS004QH
The A/T system has two self-diagnostic systems.

The first is the emission-related on board diagnostic system (EURO-OBD) performed by the TCM in combination with the ECM. The malfunction is indicated by the MI (malfunction indicator) and is stored as a DTC in the
ECM memory but not the TCM memory.
The second is the TCM original self-diagnosis indicated by the O/D OFF indicator lamp. The malfunction is
stored in the TCM memory. The detected items are overlapped with EURO-OBD self-diagnostic items. For
detail, refer to AT-45, "SELF-DIAGNOSTIC RESULT TEST MODE" .
EURO-OBD Function for A/T System
ECS004QI
The ECM provides emission-related on board diagnostic (EURO-OBD) functions for the A/T system. One
function is to receive a signal from the TCM used with EURO-OBD-related parts of the A/T system. The signal
is sent to the ECM when a malfunction occurs in the corresponding EURO-OBD-related part. The other function is to indicate a diagnostic result by means of the MI (malfunction indicator) on the instrument panel. Sensors, switches and solenoid valves are used as sensing elements.
The MI automatically illuminates in One or Two Trip Detection Logic when a malfunction is sensed in relation
to A/T system parts.
One or Two Trip Detection Logic of EURO-OBD
ECS004QJ
ONE TRIP DETECTION LOGIC

If a malfunction is sensed during the first test drive, the MI will illuminate and the malfunction will be stored in
the ECM memory as a DTC. The TCM is not provided with such a memory function.
TWO TRIP DETECTION LOGIC

When a malfunction is sensed during the first test drive, it is stored in the ECM memory as a 1st trip DTC
(diagnostic trouble code) or 1st trip freeze frame data. At this point, the MI will not illuminate. First Trip
If the same malfunction as that experienced during the first test drive is sensed during the second test drive,
the MI will illuminate. Second Trip
A/T-related parts for which the MI illuminates during the first or second test drive are listed below.
MI
Items
One trip detection
Shift solenoid valve A DTC: P0750
Shift solenoid valve B DTC: P0755
Throttle position sensor DTC: P1705
Except above
Two trip detection
The trip in the One or Two Trip Detection Logic means a driving mode in which self-diagnosis is performed
during vehicle operation.
EURO-OBD Diagnostic Trouble Code (DTC)
ECS004QK
HOW TO READ DTC AND 1ST TRIP DTC

(
With CONSULT-II or
GST) CONSULT-II or GST (Generic Scan Tool) Examples: P0705, P0710,
P0720, P0725, etc.
These DTCs are prescribed by SAE J2012.
Output of the diagnostic trouble code indicates that the indicated circuit has a malfunction. However, in case of the Mode II and GST they do not indicate whether the malfunction is still occurring
or occurred in the past and returned to normal.
CONSULT-II can identify them as shown below. Therefore, using CONSULT-II (if available) is recommended.
AT-40
http://vnx.su

[EURO-OBD]
A sample of CONSULT-II display for DTC is shown in the following
page. DTC or 1st trip DTC of a malfunction is displayed in SELF
DIAGNOSIS mode for ENGINE with CONSULT-II. Time data indicates how many times the vehicle was driven after the last detection
of a DTC.
AT
SAT014K
If the DTC is being detected currently, the time data will be 0.

E
G
SAT015K
If a 1st trip DTC is stored in the ECM, the time data will be 1t.
K
SAT016K

The ECM has a memory function, which stores the driving condition such as fuel system status, calculated
load value, engine coolant temperature, short term fuel trim, long term fuel trim, engine speed and vehicle
speed at the moment the ECM detects a malfunction.
Data which are stored in the ECM memory, along with the 1st trip DTC, are called 1st trip freeze frame data,
and the data, stored together with the DTC data, are called freeze frame data and displayed on CONSULT-II
or GST. The 1st trip freeze frame data can only be displayed on the CONSULT-II screen, not on the GST. For
detail, refer to EC-102, "CONSULT-II Function (ENGINE)" .
Only one set of freeze frame data (either 1st trip freeze frame data of freeze frame data) can be stored in the
longer stored. Remember, only one set of freeze frame data can be stored in the ECM.
The ECM has the following priorities to update the data.
Priority
Items
1
Freeze frame data
2
3
Misfire DTC: P0300 - P0306

Fuel Injection System Function DTC: P0171, P0172, P0174, P0175
Except the above items (Includes A/T related items)
Both 1st trip freeze frame data and freeze frame data (along with the DTCs) are cleared when the ECM memory is erased.
AT-41
http://vnx.su

[EURO-OBD]
HOW TO ERASE DTC
The diagnostic trouble code can be erased by CONSULT-II, GST or ECM DIAGNOSTIC TEST MODE as
described following.
If the battery terminal is disconnected, the diagnostic trouble code will be lost within 24 hours.
When you erase the DTC, using CONSULT-II or GST is easier and quicker than switching the mode
selector on the ECM.
The following emission-related diagnostic information is cleared from the ECM memory when erasing DTC
related to EURO-OBD. For details, refer toEC-52, "Emission-related Diagnostic Information" (WITH EUROOBD) or EC-562, "Emission-related Diagnostic Information" (WITHOUT EURO-OBD).
Diagnostic trouble codes (DTC)
1st trip diagnostic trouble codes (1st trip DTC)
Freeze frame data
Test values
HOW TO ERASE DTC (WITH CONSULT-II)
1.
2.
3.
4.
5.
6.
If a DTC is displayed for both ECM and TCM, it needs to be erased for both ECM and TCM.
If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least
5 seconds and then turn it ON (engine stopped) again.
Turn CONSULT-II ON and touch A/T.
Touch SELF DIAGNOSIS.
Touch ERASE. (The DTC in the TCM will be erased.) Then touch BACK twice.
Touch ENGINE.
AT-42
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[EURO-OBD]
7.

A
AT
J
SCIA5680E
HOW TO ERASE DTC (WITH GST)

1.
2.
3.
Perform TCM SELF-DIAGNOSTIC PROCEDURE (NO TOOLS). Refer to AT-52 . (The engine warm-up
step can be skipped when performing the diagnosis only to erase the DTC.)
Select Mode 4 with Generic Scan Tool (GST). For details, refer to EC-112, "Generic Scan Tool (GST)
Function" .
2.
3.
HOW TO ERASE DTC (NO TOOLS)

1.
Perform TCM SELF-DIAGNOSTIC PROCEDURE (NO TOOLS). Refer to AT-52 . (The engine warm-up
step can be skipped when performing the diagnosis only to erase the DTC.)
Perform EURO-OBD SELF-DIAGNOSTIC PROCEDURE (NO TOOLS). Refer to AT-52 .
AT-43
http://vnx.su

[EURO-OBD]

1.
2.
ECS004QL
The malfunction indicator will light up when the ignition switch is

turned ON without the engine running. This is for checking the
lamp.
If the malfunction indicator does not light up, refer to DI-33,
"Schematic" .
(Or see MI & CONSULT-II in EC section. Refer to EC-63,
"Malfunction Indicator (MI)" (WITH EURO-OBD) or EC-565,
"Malfunction Indicator (MI)" (WITHOUT EURO-OBD) or EC102, "CONSULT-II Function (ENGINE)" (WITH EURO-OBD)
or EC-601, "CONSULT-II Function (ENGINE)" (WITHOUT
EURO-OBD).
SAT652J
When the engine is started, the malfunction indicator should go
off.
If the lamp remains on, the on board diagnostic system has detected an emission-related (EURO-OBD)
malfunction. For detail, refer to EC-51, "ON BOARD DIAGNOSTIC (OBD) SYSTEM" .
CONSULT-II
ECS004QM
After performing SELF-DIAGNOSTIC PROCEDURE (WITH CONSULT-II) AT-45 , place check marks for
results on the DIAGNOSTIC WORKSHEET, AT-58 . Reference pages are provided following the items.
NOTICE:
1. The CONSULT-II electrically displays shift timing and lock-up timing (that is, operation timing of each solenoid).
Check for time difference between actual shift timing and the CONSULT-II display. If the difference is
noticeable, mechanical parts (except solenoids, sensors, etc.) may be malfunctioning. Check mechanical
parts using applicable diagnostic procedures.
2. Shift schedule (which implies gear position) displayed on CONSULT-II and that indicated in Service Manual may differ slightly. This occurs because of the following reasons:
Actual shift schedule has more or less tolerance or allowance,
Shift schedule indicated in Service Manual refers to the point where shifts start, and
Gear position displayed on CONSULT-II indicates the point where shifts are completed.
3. Shift solenoid valve A or B is displayed on CONSULT-II at the start of shifting. Gear position is displayed upon completion of shifting (which is computed by TCM).
4. Additional CONSULT-II information can be found in the Operation Manual supplied with the CONSULT-II
unit.
FUNCTION
Function
Reference page
Work support
This mode enables a technician to adjust some devices faster and more accurately by
following the indications on CONSULT-II.
Self-diagnostic results can be read and erased quickly.
AT-45
Data monitor
AT-46

monitor
Function test
Conducted by CONSULT-II instead of a technician to determine whether each system

is OK or NG.
DTC work support
Select the operating condition to confirm Diagnosis Trouble Codes.
TCM part number
TCM part number can be read.
AT-47
AT-44
http://vnx.su

[EURO-OBD]
SELF-DIAGNOSTIC PROCEDURE (WITH CONSULT-II)
1.
Turn on CONSULT-II and touch ENGINE for EURO-OBD

detected items or touch A/T for TCM self-diagnosis.
If A/T is not displayed, check TCM power supply and ground circuit. Refer to AT-94, "TCM Terminals and Reference Value" . If
result is NG, refer to PG-2, "POWER SUPPLY ROUTING" .
AT
D
SAT014K
2.

Display shows malfunction experienced since the last erasing
operation.
CONSULT-II performs real time diagnosis.
Also, any malfunction detected while in this mode will be displayed at real time.
G
SAT987J
SELF-DIAGNOSTIC RESULT TEST MODE

Items (CONSULT-II screen terms)
CAN COMM CIRCUIT
Malfunction is detected when...
Malfunction is detected in CAN communication line.
TCM does not receive the proper voltage signal from the sensor.
VHCL SPEED SENMTR
SHIFT SOLENOID/V A
SHIFT SOLENOID/V B
OVERRUN CLUTCH S/V
T/C CLUTCH SOL/V
U1000
TCM receives an excessively low or high voltage from this sensor
P1705
TCM detects an improper voltage drop when it tries to operate the solenoid valve.
P0750
P0755
P1760
P0740
ATF TEMP SEN/CIRC
TCM receives an excessively low or high voltage from the sensor.
BATT/FLUID TEMP SEN
A/T cannot be shifted to the 1st gear position even if electrical circuit is
good.
P0731*1
A/T cannot be shifted to the 2nd gear position even if electrical circuit is
good.
P0732*1
A/T cannot be shifted to the 3rd gear position even if electrical circuit is
good.
P0733*1
A/T cannot be shifted to the 4th gear position even if electrical circuit is
good.
P0734*1
P0745
CONTROL UNIT (RAM)
TCM memory (RAM) is malfunctioning
CONTROL UNIT (ROM)
TCM memory (ROM) is malfunctioning
A/T 2ND GR FNCTN

A/T 3RD GR FNCTN
A/T 4TH GR FNCTN
LINE PRESSURE S/V
AT-45
http://vnx.su
M
P0710
TCM does not receive the proper voltage signal from the ECM.
A/T 1ST GR FNCTN
ENGINE SPEED SIG
P0720
VHCL SPEED SENA/T
THROTTLE POSI SEN
EURO-OBD (DTC)
P0725

[EURO-OBD]
CONT UNIT(EEP ROM)
PNP SW/CIRC
INITIAL START
No failure
(NO SELF DIAGNOSTIC FAILURE
INDICATED FURTHER TESTING
MAY BE REQUIRED)
EURO-OBD (DTC)
TCM memory (EEP ROM) is malfunctioning.
TCM does not receive the correct voltage signal (based on the gear
position) from the switch.
This is not a malfunction message (Whenever shutting off a power supply to the TCM, this message appears on the screen).
No failure has been detected.
P0705
*1: These malfunctions cannot be displayed by MI if another malfunction is assigned to lamp MI.
DATA MONITOR MODE (A/T)

X: Standard, : Not applicable,
: Option
SELECT MONITOR ITEM

Monitor item (Unit)
VHCL/S SEA/T (km/h)
SELECTION FROM
MENU
Remarks
TCM INPUT
SIGNALS
MAIN SIGNALS
Revolution sensor
Vehicle speed display may not be accurate under approx. 10 km/h (6 mph). It
may not indicate 0 km/h (0 mph) when
vehicle is stationary.
VHCL/S SEMTR (km/h)
THRTL POS SEN (V)
FLUID TEMP SE (V)
BATTERY VOLT (V)
ENGINE SPEED (rpm)
TURBINE REV (rpm)
OVERDRIVE SW (ON/OFF)
PN POSI SW (ON/OFF)
R POSITION SW (ON/OFF)
D POSITION SW (ON/OFF)
2 POSITION SW (ON/OFF)
1 POSITION SW (ON/OFF)
ASCDCRUISE (ON/OFF)
ACC OD CUT (ON/OFF)
KICKDOWN SW (ON/OFF)
POWERSHIFT SW (ON/OFF)
CLOSED THL/SW (ON/OFF)
W/O THRL/P-SW (ON/OFF)
*SHIFT S/V A (ON/OFF)
*SHIFT S/V B (ON/OFF)
*OVERRUN/C S/V (ON/OFF)
Displays status of check signal (reinput

signal) for TCM control signal output.
Remains unchanged when solenoid
valves are open or shorted.
HOLD SW (ON/OFF)
Not mounted but displayed.
BRAKE SW (ON/OFF)
Stop lamp switch
Signal input with CAN communication.
Not mounted but displayed.
Signal input with CAN communication.
AT-46
http://vnx.su

[EURO-OBD]
SELECT MONITOR ITEM
Monitor item (Unit)
GEAR
SELECTION FROM
MENU
A
Remarks
TCM INPUT
SIGNALS
MAIN SIGNALS
Gear position recognized by the TCM

updated after gear-shifting
SLCT LVR POSI
Selector lever position is recognized by

the TCM.
For fail-safe operation, the specific value
used for control is displayed.
VEHICLE SPEED (km/h)
Vehicle speed recognized by the TCM.
Degree of opening for accelerator recognized by the TCM

For fail-safe operation, the specific value
used for control is displayed.
THROTTLE POSI (0.0/8)
LINE PRES DTY (%)
TCC S/V DUTY (%)
SHIFT S/V A (ON/OFF)
SHIFT S/V B (ON/OFF)
OVERRUN/C S/V (ON/OFF)
SELF-D DP LMP (ON/OFF)
TC SLIP RATIO (0.000)
TC SLIP SPEED (rpm)
Difference between engine speed and

torque converter input shaft speed
Voltage (V)
Displays the value measured by the voltage probe.
Frequency (Hz)
DUTYHI (high) (%)
DUTYLOW (low) (%)
PLS WIDTHHI (ms)
PLS WIDTHLOW (ms)
AT
The value measured by the pulse probe

is displayed.
DTC WORK SUPPORT MODE WITH CONSULT-II
For details, refer to the separate CONSULT-II Operations Manual.
CONSULT-II Setting Procedure

1.
2.

link connector, which is located in instrument lower panel on
driver side.
SCIA0691E
AT-47
http://vnx.su

[EURO-OBD]
SCIA0692E
3.
4.
Turn ignition switch ON. (Do not start engine.)

SAIA0450E
5.
Touch A/T.
If A/T is not indicated, go to GI-35, "CONSULT-II Data Link
Connector (DLC) Circuit" .
SAT014K
6.
Touch DTC WORK SUPPORT.
SCIA5358E
7.
Touch select item menu (1ST, 2ND, etc.).
SAT018K
AT-48
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[EURO-OBD]
8.
Touch START.
A
AT
SAT589J
9.
Perform driving test according to DTC Confirmation Procedure

in TROUBLE DIAGNOSIS FOR DTC.
E
G
SAT019K
When testing conditions are satisfied, CONSULT-II screen

changes from OUT OF CONDITION to TESTING.
SAT591J
10. Stop vehicle.

L
SAT592J
AT-49
http://vnx.su

[EURO-OBD]
If NG appears on the screen, malfunction may exist. Go

to Diagnostic Procedure.
SAT593J
11. Perform test drive to check gear shift feeling in accordance with
instructions displayed.
SAT594J
12. Touch YES or NO.
SAT595J
13. CONSULT-II procedure ended.

If NG appears on the screen, a malfunction may exist. Go to
Diagnostic Procedure.
SAT596J
If NG appears on the screen, a malfunction may exist.

Go to Diagnostic Procedure.
SAT593J
AT-50
http://vnx.su

[EURO-OBD]
DTC WORK SUPPORT MODE
DTC work support item
Description
Following items for A/T 1st gear function (P0731) can be confirmed.
1ST GR FNCTN P0731
Self-diagnosis status (whether the diagnosis is being conducted

or not)
Self-diagnosis result (OK or NG)
Following items for A/T 2nd gear function (P0732) can be confirmed.
2ND GR FNCTN P0732

or not)
Following items for A/T 3rd gear function (P0733) can be confirmed.
3RD GR FNCTN P0733

or not)
Following items for A/T 4th gear function (P0734) can be confirmed.
4TH GR FNCTN P0734

or not)
Check items (Possible cause)
Each clutch
Hydraulic control circuit
AT
Each clutch
Each clutch
Each clutch
AT-51
http://vnx.su

[EURO-OBD]
Diagnostic Procedure Without CONSULT-II
ECS004QN
EURO-OBD SELF-DIAGNOSTIC PROCEDURE (WITH GST)

Refer to EC-112, "Generic Scan Tool (GST) Function" (WITH EURO-OBD).
EURO-OBD SELF-DIAGNOSTIC PROCEDURE (NO TOOLS)

Refer toEC-63, "Malfunction Indicator (MI)"
(WITHOUT EURO-OBD).
(WITH EURO-OBD) or EC-565, "Malfunction Indicator (MI)"
TCM SELF-DIAGNOSTIC PROCEDURE (NO TOOLS)
1. CHECK O/D OFF INDICATOR LAMP

1.
2.
3.
4.
Selector lever in P position.

Turn ignition switch to OFF position.
Wait 5 seconds.
Set overdrive control switch to ON position.
SAT774B
5. Turn ignition switch to ON position. (Do not start engine.)

Does O/D OFF indicator lamp come on for about 2 seconds?
YES >> GO TO 2.
NO
>> Go to AT-204, "O/D OFF Indicator Lamp Does Not
Come On" .
SCIA5468E
2. JUDGEMENT PROCEDURE STEP 1

1.
2.
3.
4.

Move selector lever to D position.
Set overdrive control switch to OFF position.
Turn ignition switch to ON position. (Do not start engine.)
Wait more than 2 seconds after turning ignition switch ON.
>> GO TO 3.
SAT653E
AT-52
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[EURO-OBD]

1.
2.
Move selector lever to 2 position.

B
>> GO TO 4.
AT
D
SAT780B

1.
2.

Set overdrive control switch to OFF position.
>> GO TO 5.
I
SAT781B
Depress accelerator pedal fully and release it.

K
>> GO TO 6.
M
SAT981F
6. CHECK SELF-DIAGNOSIS CODE

Check O/D OFF indicator lamp. Refer to AT-54, "JUDGEMENT OF
SELF-DIAGNOSIS CODE" .
>> DIAGNOSIS END
SCIA5468E
AT-53
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[EURO-OBD]
JUDGEMENT OF SELF-DIAGNOSIS CODE
All judgement flickers are the same.
1st judgement flicker is longer than others.
SCIA4672E
SCIA5591E
All circuits that can be confirmed by self-diagnosis are OK.
Revolution sensor circuit is short-circuited or disconnected.

Go to DTC P0720 VEHICLE SPEED SENSORA/T (REVOLUTION SENSOR).
Refer to AT-112
2nd judgement flicker is longer than others.
3rd judgement flicker is longer than others.
SCIA5592E
SCIA5593E
Vehicle speed sensor circuit is short-circuited or disconnected.

Go to DTC VEHICLE SPEED SENSORMTR.
Refer to AT-192
Accelerator pedal position (APP) sensor circuit is short-circuited

or disconnected.
Go to DTC P1705 ACCELERATOR PEDAL POSITION (APP)
SENSOR.
Refer to AT-173
4th judgement flicker is longer than others.
SCIA5594E
SCIA5595E
Shift solenoid valve A circuit is short-circuited or disconnected.

Go to DTC P0750 SHIFT SOLENOID VALVE A.
Refer to AT-161
Shift solenoid valve B circuit is short-circuited or disconnected.

Go to DTC P0755 SHIFT SOLENOID VALVE B.
Refer to AT-167
AT-54
http://vnx.su

[EURO-OBD]
AT
D
SCIA5596E
SCIA5597E
E
Overrun clutch solenoid valve circuit is short-circuited or disconnected.
Go to DTC P1760 OVERRUN CLUTCH SOLENOID VALVE.
Refer to AT-178
Torque converter clutch solenoid valve circuit is short-circuited or

disconnected.
Go to DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE.
Refer to AT-148
J
SCIA5598E
SCIA5599E
A/T fluid temperature sensor is disconnected or TCM power supply circuit is damaged.
Go to DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE).
Refer to AT-184
Engine speed signal circuit is short-circuited or disconnected.

Go to DTC P0725 ENGINE SPEED SIGNAL.
Refer to AT-119
AT-55
http://vnx.su

[EURO-OBD]
SCIA5600E
SCIA4673E
Line pressure solenoid valve circuit is short-circuited or disconnected.

Go to DTC P0745 LINE PRESSURE SOLENOID VALVE.
Refer to AT-154
CAN communication line is damaged.

Go to DTC U1000 CAN COMMUNICATION LINE.
Refer to AT-97
Lamp comes off.
Flickers as shown below.
SCIA4674E
SCIA4675E
PNP switch, overdrive control switch, closed throttle position signal or wide open throttle position signal circuit is disconnected or
TCM is damaged.
(Because closed throttle position signal and wide open throttle
position signal are input via CAN communication line malfunction
may continue after self-diagnosis.)
Go to TCM Self-diagnosis Does Not Activate
Refer to AT-237
t1 = 2.5 seconds
t2 = 2.0 seconds
t3 = 1.0 second
Battery power is low.

Battery has been disconnected for a long time.
Battery is connected conversely.
(When reconnecting TCM connectors.This is not a malfunction).
t4 = 1.0 second
AT-56
http://vnx.su
TROUBLE DIAGNOSIS INTRODUCTION

[EURO-OBD]

Introduction
The TCM receives a signal from the vehicle speed sensor, throttle
position sensor or PNP switch and provides shift control or lock-up
control via A/T solenoid valves.
The TCM also communicates with the ECM by means of a signal
sent from sensing elements used with the EURO-OBD related parts
of the A/T system for malfunction-diagnostic purposes. The TCM is
capable of diagnosing malfunctioning parts while the ECM can store
malfunctions in its memory.
Input and output signals must always be correct and stable in the
operation of the A/T system. The A/T system must be in good operating condition and be free of valve seizure, solenoid valve malfunction, etc.
It is much more difficult to diagnose a problem that occurs intermittently rather than continuously. Most intermittent problems are
A visual check only, may not find the cause of the problems. A road
be performed. Follow the Work Flow. Refer to AT-61, "Work Flow" .
PFP:00000
A
ECS004QO
AT
D
SAT631IA
H
SAT632I

customer who approaches with a drive ability complaint. The customer can supply good information about such problems, especially
what conditions they occur. A Diagnostic Worksheet like the example (AT-58, "DIAGNOSTIC WORKSHEET" ) should be used.
Start your diagnosis by looking for conventional problems first. This
will help troubleshoot drive ability problems on an electronically controlled engine vehicle.
Also check related Service bulletins for information.
SEF234G
AT-57
http://vnx.su

[EURO-OBD]
Information from Customer
KEY POINTS
WHAT..... Vehicle & A/T model
WHEN..... Date, Frequencies
WHERE..... Road conditions
HOW..... Operating conditions, Symptoms

Customer name
MR/MS
Model & Year
VIN
Trans. model
Engine
Mileage
Incident Date
Manuf. Date
In Service Date
Frequency
Continuous
Symptoms
Vehicle does not move.

No up-shift
Intermittent (
( Any position
( 1st 2nd
No down-shift
times a day)
2nd 3rd
( O/D 3rd
Particular position)
3rd O/D)
3rd 2nd
2nd 1st)
Lockup malfunction
Shift point too high or too low.
Shift shock or slip
( N D
Lockup
Any drive position)
Noise or vibration
No kick down
No pattern select
Others
(
Continuously lit
Not lit
Malfunction indicator (MI)
Continuously lit
Not lit
AT-58
http://vnx.su

[EURO-OBD]
Diagnostic Worksheet
1.
Read the Fail-safe and listen to customer complaints.
AT-58
2.
Check A/T fluid
AT-64
Leakage (Follow specified procedure)

Fluid condition
Fluid level
3.
Perform Stall Test and Line Pressure Test.
AT-65, AT-68
Stall test Mark possible damaged components/others.

Low & reverse brake
Low one-way clutch
Engine
Line pressure is low
Clutches and brakes except high clutch and
brake band are OK
Torque converter one-way clutch

Reverse clutch
Forward clutch
Overrun clutch
AT
Line Pressure test Suspected parts:

4.
Perform all Road Test and mark required procedures.
AT-70
4-1.
AT-71
Check before engine is started.

O/D OFF Indicator Lamp Does Not Come On, AT-204 .
SELF-DIAGNOSTIC PROCEDURE/DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE. Mark detected items.
PNP switch, AT-100 .

A/T fluid temperature sensor, AT-106 .
Vehicle speed sensorA/T (Revolution sensor), AT-112 .
Engine speed signal, AT-119 .
Torque converter clutch solenoid valve, AT-148 .
Line pressure solenoid valve, AT-154 .
Shift solenoid valve A, AT-161 .
Shift solenoid valve B, AT-167 .
Accelerator pedal position (App) sensor, AT-173 .
Overrun clutch solenoid valve, AT-178 .
PNP & overdrive control switches, and throttle position sensor, AT-237 .
Batt/fluid temp sen (A/T fluid temperature sensor and TCM power source), AT-184 .
Vehicle speed sensorMTR, AT-192 .
CAN communication line, AT-97 .
Control unit (RAM), control unit (ROM), AT-198 .
Control unit (EEP ROM), AT-200 .
Battery
Others
4-2.
Check at idle
L
AT-72
Engine Cannot Be Started In P And N Position, AT-206 .

In P Position, Vehicle Moves Forward Or Backward When Pushed, AT-207 .
In N Position, Vehicle Moves, AT-208 .
Large Shock. N R Position, AT-209 .
Vehicle Does Not Creep Backward In R Position, AT-210 .
Vehicle Does Not Creep Forward In D, 2 Or 1 Position, AT-212 .
AT-59
http://vnx.su

[EURO-OBD]
4.
4-3.
Cruise test
AT-74
AT-78
Part-1
Vehicle Cannot Be Started From D1 , AT-214 .
A/T Does Not Shift: D1 D2 Or Does Not Kickdown: D4 D2 , AT-217 .
A/T Does Not Shift: D2 D3 , AT-220 .
A/T Does Not Perform Lock-up, AT-224 .
A/T Does Not Hold Lock-up Condition, AT-225 .
Lock-up Is Not Released, AT-227 .
Engine Speed Does Not Return To Idle (Light Braking D4 D3 ), AT-228 .
Part-2
AT-81
Vehicle Does Not Start From D1 , AT-230 .

Part-3
AT-82
A/T Does Not Shift: D4 D3 When Overdrive Control Switch ON OFF, AT-231 .
Engine Speed Does Not Return To Idle (Engine Brake In D3 ), AT-228 .
A/T Does Not Shift: D3 22 , When Selector Lever D 2 Position, AT-232 .
Engine Speed Does Not Return To Idle (Engine Brake In 22 ), AT-228 .
A/T Does Not Shift: 22 11 , When Selector Lever 2 1 Position, AT-233 .
Vehicle Does Not Decelerate By Engine Brake, AT-235 .
TCM Self-diagnosis Does Not Activate (PNP & Overdrive control switches, and throttle position sensor
circuit checks), AT-237 .
SELF-DIAGNOSTIC PROCEDURE/DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE Mark detected items.
PNP switch, AT-100 .
A/T fluid temperature sensor, AT-106 .
Accelerator pedal position (App) sensor, AT-173 .
A/T fluid temperature sensor and TCM power source, AT-184 .
Battery
Others
5.
For self-diagnosis NG items, inspect each component. Repair or replace the damaged parts.
AT-52
6.
Perform all Road Test and re-mark required procedures.
AT-70
7.
Perform DTC Confirmation Procedure for following MI indicating items and check out NG items.
EC-52
DTC (P0731) A/T 1st gear function, AT-125 .

DTC (P0732) A/T 2nd gear function, AT-130 .
DTC (P0733) A/T 3rd gear function, AT-135 .
DTC (P0734) A/T 4th gear function, AT-140 .
8.
Perform the Diagnostic Procedures for all remaining items marked NG. Repair or replace the damaged parts.
Refer to the Symptom Chart when you perform the procedures. (The chart also shows some other possible
symptoms and the component inspection orders.)
AT-85
9.
Erase DTC from TCM and ECM memories.
AT-42
AT-60
http://vnx.su

[EURO-OBD]
Work Flow
ECS004QP
HOW TO PERFORM TROUBLE DIAGNOSES FOR QUICK AND ACCURATE REPAIR
A good understanding of the malfunction conditions can make troubleshooting faster and more accurate. In
general, each customer feels differently about a problem. It is important to fully understand the symptoms or
conditions for a customer complaint.
Make good use of the two sheets provided, INFORMATION FROM CUSTOMER (AT-58, "Information from
Customer" ) and DIAGNOSTIC WORKSHEET (AT-59, "Diagnostic Worksheet" ), to perform the best troubleshooting possible.
AT
AT-61
http://vnx.su

[EURO-OBD]
WORK FLOW CHART
SAT183K
*1:
AT-58
*2:
AT-59
*3:
AT-10
*4:
AT-64
*5:
AT-65 and AT-68
*6:
AT-70
AT-62
http://vnx.su

[EURO-OBD]
*7:
*8:
AT-40
*9:
*10: AT-100
AT-44
*11:
AT-192 and AT-198 to AT-200
*12: AT-204
AT-52
*13: AT-235
*14: AT-85
*15: AT-42
*16: AT-100
*17: AT-192 and AT-198 to AT-200
*18: EC-52
AT
AT-63
http://vnx.su
TROUBLE DIAGNOSIS BASIC INSPECTION

[EURO-OBD]

A/T Fluid Check
PFP:00000
ECS004QQ
FLUID LEAKAGE CHECK

1.
2.
3.
Clean area suspected of leaking. for example, mating surface

of converter housing and transaxle case.
Start engine, apply foot brake, place selector lever in D position
and wait a few minutes.
Stop engine.
SAT767B
4.
Check for fresh leakage.
SAT288G
FLUID CONDITION CHECK

Fluid color
Suspected problem
Dark or black with burned odor
Wear of frictional material
Milky pink
Water contamination Road water

entering through filler tube or breather
Varnished fluid, light to dark brown and

tacky
Oxidation Over or under filling,

Overheating
FLUID LEVEL CHECK

Refer to AT-16, "Checking A/T Fluid" .
SAT638A
AT-64
http://vnx.su

[EURO-OBD]
Stall Test
ECS004QR
STALL TEST PROCEDURE

1.
2.
Check A/T fluid and engine oil levels. If necessary, add.

Drive vehicle for approx. 10 minutes or until fluid and oil reach
operating temperature. Refer to AT-16, "Checking A/T Fluid" .
AT
D
SAT647B
3.
4.
Set parking brake and block wheels.

Install a tachometer where it can be seen by driver during test.
It is good practice to mark the point of specified engine
rpm on indicator.
SAT513G
5.
Start engine, apply foot brake, and place selector lever in D

position.
K
SAT775B
6.
7.
Accelerate to wide open throttle gradually while applying foot

brake.
Quickly note the engine stall revolution and immediately release
throttle.
During test, never hold throttle wide open for more than 5
seconds.
Stall revolution:
QR20DE:
QR25DE:
2,450 - 2,950 rpm

2,300 - 2,750 rpm
SAT514G
AT-65
http://vnx.su

[EURO-OBD]
8.
9.
Move selector lever to N position.

Cool off ATF.
Run engine at idle for at least one minute.
10. Repeat steps 5 through 9 with selector lever in 2, 1 and R positions.
SAT771B
JUDGEMENT OF STALL TEST

The test result and possible damaged components relating to each result are shown in the illustrations on next
page.
In order to pinpoint the possible damaged components, follow the WORK FLOW shown in AT-61, "Work Flow"
(EURO-OBD).
NOTE:
Stall revolution is too high in D, 2 or 1 position:
Slippage occurs in 1st gear but not in 2nd and 3rd gears...... Low one-way clutch slippage
Slippage occurs in the following gears:

1st through 3rd gears in D position and engine brake functions with overdrive control switch set to OFF.
1st and 2nd gears in 2 position and engine brake functions with accelerator pedal released (fully closed
throttle)...... Forward clutch or forward one-way clutch slippage
Stall revolution is too high in R position:
Engine brake does not function in 1 position...... Low & reverse brake slippage
Engine brake functions in 1 position...... Reverse clutch slippage

Stall revolution within specifications:
Vehicle does not achieve speed of more than 80 km/h (50 MPH)...... One-way clutch seizure in torque
converter housing
CAUTION:
Be careful since automatic fluid temperature increases abnormally.
Slippage occurs in 3rd and 4th gears in D position...... High clutch slippage
Slippage occurs in 2nd and 4th gear in D position...... Brake band slippage
Engine brake does not function in 2nd and 3rd gears in D position, 2nd gear in 2 position, and 1st gear in
1 position with overdrive control switch set to OFF...... Overrun clutch slippage
Stall revolution less than specifications:
Poor acceleration during starts...... One-way clutch slippage in torque converter
AT-66
http://vnx.su

[EURO-OBD]
A
AT
SCIA0707E
AT-67
http://vnx.su

[EURO-OBD]
Line Pressure Test
ECS004QS
LINE PRESSURE TEST PORTS

Location of line pressure test ports are shown in the illustration.
Always replace pressure plugs as they are self-sealing

bolts.
SCIA0709E
LINE PRESSURE TEST PROCEDURE

1.
2.
Check A/T fluid and engine oil levels. If necessary, add fluid or
oil.
Drive vehicle for approx. 10 minutes or until engine oil and ATF
reach operating temperature. Refer to AT-16, "Checking A/T
Fluid" .
SAT647B
3.
Install pressure gauge to corresponding line pressure port.
UAT008
4.

Continue to depress brake pedal fully while line pressure
test is being performed at stall speed.
SAT513G
AT-68
http://vnx.su

[EURO-OBD]
5.
Start engine and measure line pressure at idle and stall speed.
When measuring line pressure at stall speed, follow the
stall test procedure.
AT
SAT493G
LINE PRESSURE
Line pressure
Check lock-up hold.
D, 2 and 1 positions
R position
Idle
500 (5.00, 5.1, 73)
778 (7.78, 7.9, 113)
Stall
1,233 (12.33, 12.6, 179)
1,918 (19.18, 19.6, 278)
JUDGEMENT OF LINE PRESSURE TEST

Judgement
Line pressure is low in all positions.
Line pressure is low in particular position.
Suspected parts
Oil pump wear
Control piston damage
Pressure regulator valve or plug sticking
Spring for pressure regulator valve damaged
Fluid pressure leakage between oil strainer and pressure regulator valve
Clogged strainer
Fluid pressure leakage between manual valve and particular clutch
For example, line pressure is:

Low in R and 1 positions, but
Normal in D and 2 positions.
Therefore, fluid leakage exists at or around low and reverse brake circuit.
At idle
Refer to AT-23 .
Line pressure is high.
Line pressure is low.
At stall
speed
Maladjustment of throttle position sensor
A/T fluid temperature sensor damaged
Line pressure solenoid valve sticking
Short circuit of line pressure solenoid valve circuit
Pressure modifier valve sticking
Open in dropping resistor circuit
Pilot valve sticking
AT-69
http://vnx.su

[EURO-OBD]
Road Test
ECS004QT
DESCRIPTION
1.
2.
The purpose of the test is to determine overall performance of A/

T and analyze causes of problems.
The road test consists of the following three parts:
Check before engine is started
Check at idle
SAT786A
3.
Cruise test
Before road test, familiarize yourself with all test procedures and
items to check.
Conduct tests on all items until specified symptom is found.
Troubleshoot items which check out No Good after road test.
Refer to the following items.
EURO-OBD
TROUBLE DIAGNOSES FOR

SYMPTOMS
AT-40 to AT-52
AT-204 to AT-237
SAT496G
AT-70
http://vnx.su

[EURO-OBD]
1. CHECK BEFORE ENGINE IS STARTED
A

1.
2.
3.
Park vehicle on flat surface.

Move selector lever to P position.
Turn ignition switch OFF. Wait at least 5 seconds.
AT
E
SAT774B
4. Turn ignition switch ON. (Do not start engine.)

YES >> 1. Turn ignition switch OFF.
2. Perform self-diagnosis and note NG items.
Refer to AT-45, "SELF-DIAGNOSTIC PROCEDURE
(WITH CONSULT-II)" , AT-52, "Diagnostic Procedure
Without CONSULT-II" .
3. Go to AT-72, "2. CHECK AT IDLE" .
NO
>> Stop Road Test. Go to AT-204, "O/D OFF Indicator
Lamp Does Not Come On" .
SCIA5468E
AT-71
http://vnx.su

[EURO-OBD]
2. CHECK AT IDLE

1. Park vehicle on flat surface.
3. Move selector lever to P or N position.
4. Turn ignition switch START position.
Is engine started?
YES >> GO TO 2.
NO
>> Stop Road Test. Mark the box on the DIAGNOSTIC
WORKSHEET. Refer to AT-58 .
GO TO AT-206, "Engine Cannot Be Started In P and
N Position" .
SAT769B

2. Move selector lever to R, D, 2 or 1 position.
3. Turn ignition switch START position.
Is engine started?
YES >> Stop Road Test. Mark the box on the DIAGNOSTIC
WORKSHEET. Refer to AT-58 .
N Position" .
Continue Road Test.
NO
>> GO TO 3.
SAT770B
3. CHECK VEHICLE MOVE

1.
2.
3.

Release parking brake.
SAT768B
4. Push vehicle forward or backward.

Does vehicle move when it is pushed forward or backyard?
YES >> Mark the box on the DIAGNOSTIC WORKSHEET.
Refer to AT-58 .
GO TO AT-207, "In P Position, Vehicle Moves Forward Or Backward When Pushed" .
Continue Road Test.
NO
>> GO TO 4.
SAT796A
AT-72
http://vnx.su

[EURO-OBD]
1. Apply parking brake.

2. Start engine.
3. Move selector lever to N position.
4. Release parking brake.
Does vehicle move forward or backward?
Refer to AT-58 .
GO TO AT-208, "In N Position, Vehicle Moves" .
Continue Road Test.
NO
>> GO TO 5.
AT
SAT771B
5. CHECK SHIFT SHOCK

1.
Apply foot brake.
I
SAT797A
2. Move selector lever to R position.

Is there large shock when changing from N to R position?
Refer to AT-58 .
GO TO AT-209, "Large Shock. N R Position" .
Continue Road Test.
NO
>> GO TO 6.
SAT772B

Release foot brake for several seconds.
Does vehicle creep backward when foot brake is released?
YES >> GO TO 7.
NO
>> Mark the box on the DIAGNOSTIC WORKSHEET.
Refer to AT-58 .
GO TO AT-210, "Vehicle Does Not Creep Backward
In R Position" .
Continue Road Test.
SAT799A
AT-73
http://vnx.su

[EURO-OBD]

Move selector lever to D, 2 and 1 positions and check if vehicle
creeps forward.
Does vehicle creep forward in all three positions?
YES >> Go to AT-74, "3. CRUISE TEST" .
NO
Refer to AT-58 .
GO TO AT-212, "Vehicle Does Not Creep Forward In
D, 2 Or 1 Position" .
Continue Road Test.
SAT773B
3. CRUISE TEST
Check all items listed in Parts 1 through 3.
With CONSULT-II
Using CONSULT-II, conduct a cruise test and record the result.

Print the result and ensure that shifts and lock-ups take place as
per Shift Schedule.
SAT601J

1.
2.

SAIA0450E
3.
Touch A/T.
SAT014K
AT-74
http://vnx.su

[EURO-OBD]
4.
Touch DATA MONITOR.

A
AT
SCIA5358E
5.
6.
Touch MAIN SIGNALS or TCM INPUT SIGNALS.

Select Numerical Display, Barchart Display or Line Graph
Display.
G
SCIA5681E
7.
8.
Touch SETTING to recording condition (AUTO TRIG or

MANU TRIG) and touch BACK.
Touch Start.
K
SAT973J
9.
When performing cruise test, touch RECORD.
SAT134K
AT-75
http://vnx.su

[EURO-OBD]
10. After finishing cruise test part 1, touch STOP.
SAT135K
11. Touch STORE and touch BACK.
SAT987J
SAT974J
12.
13.
14.
15.
Touch DISPLAY.
Touch PRINT.
Check the monitor data printed out.
Continue cruise test part 2 and 3.
SAT975J
AT-76
http://vnx.su

[EURO-OBD]
Without CONSULT-II
Accelerator pedal position (APP) sensor can be checked by voltage across terminals 41 and 42 of TCM.
AT
D
SCIA0710E
AT-77
http://vnx.su

[EURO-OBD]
Cruise Test Part 1
1. CHECK STARTING GEAR (D1 ) POSITION

1.
Drive vehicle for approximately 10 minutes to warm engine oil and ATF up to operating temperature.
ATF operating temperature:
2.
3.
4.
5.
50 - 80C (122 - 176F)

Start engine.
SAT774B
6.
SAT775B
7.
Accelerate vehicle by constantly depressing accelerator pedal

half-way.
Read gear position. Refer to AT-46, "DATA MONITOR

MODE (A/T)" .
Does vehicle start from D1 ?
YES >> GO TO 2.
NO
Refer to AT-58 .
GO TO AT-214, "Vehicle Cannot Be Started From D1"
.
Continue Road Test.
AT-78
http://vnx.su
SAT495G

[EURO-OBD]
2. CHECK SHIFT-UP (D1 TO D2 )
A
Check shift-up (D1 to D2 ).
Specified speed when shifting from D1 to D2. Refer to AT-530, "VEHICLE SPEED WHEN SHIFTING GEARS
AND THROTTLE POSITION" .
B
Read gear position, throttle opening and vehicle speed.
Refer to AT-46, "DATA MONITOR MODE (A/T)" .
Does A/T shift from D1 to D2 at the specified speed?
AT
YES >> GO TO 3.
NO
Refer to AT-58 .
D
GO TO AT-217, "A/T Does Not Shift: D1 D2 Or
Does Not Kickdown: D4 D2" .
Continue Road Test.
E
SAT954I
3. CHECK SHIFT-UP (D2
TO D3 )

YES >> GO TO 4.
NO
Refer to AT-58 .
GO TO AT-220, "A/T Does Not Shift: D2 D3" .
Continue Road Test.
J
SAT955I
TO D4 )

YES >> GO TO 5.
NO
Refer to AT-58 .
Continue Road Test.
SAT956I
AT-79
http://vnx.su

[EURO-OBD]
5. CHECK LOCK-UP (D4
TO D4 L/U)
Check lock-up (D4 to D4 L/U).

Specified speed when lock-up occurs. Refer to AT-530, "VEHICLE SPEED WHEN PERFORMING LOCK-UP"
.
Read vehicle speed, throttle opening when lock-up duty
becomes 94%. Refer to AT-46, "DATA MONITOR MODE (A/T)" .
Does A/T perform lock-up at the specified speed?
YES >> GO TO 6.
NO
Refer to AT-58 .
GO TO AT-224, "A/T Does Not Perform Lock-up" .
Continue Road Test.
SAT957I
6. CHECK LOCK-UP HOLD

Check lock-up hold.
When lock-up duty becomes 94%. Refer to AT-46, "DATA MONITOR MODE (A/T)" .
Does A/T hold lock-up condition for more than 30 seconds?
YES >> GO TO 7.
NO
>> Mark the box on the DIAGNOSTIC WORKSHEET. Refer to AT-58 .
GO TO AT-225, "A/T Does Not Hold Lock-up Condition" .
Continue Road Test.
7. CHECK SHIFT-DOWN (D4 L/U TO D4 )

Release accelerator pedal.
When lock-up duty becomes 4%. Refer to AT-46, "DATA
MONITOR MODE (A/T)" .
Is lock-up released when accelerator pedal is released?
YES >> GO TO 8.
NO
Refer to AT-58 .
GO TO AT-227, "Lock-up Is Not Released" .
Continue Road Test.
SAT958I
8. CHECK SHIFT-DOWN (D4
TO D3 )
Decelerate vehicle by applying foot brake lightly.

Read gear position and engine speed. Refer to AT-46, "DATA
Does engine speed return to idle smoothly when A/T is shifted from
D4 to D3 ?
YES >> 1. Stop vehicle.
2. Go to AT-81, "Cruise Test Part 2" .
NO
Refer to AT-58 .
GO TO AT-228, "Engine Speed Does Not Return To
Idle (Light Braking D4 D3 )" .
Continue Road Test.
AT-80
http://vnx.su
SAT959I

[EURO-OBD]
Cruise Test Part 2
A

1.
2.
Confirm gear selector lever is in D position.

Accelerate vehicle by half throttle again.

MODE (A/T)" .
YES >> GO TO 2.
NO
Refer to AT-58 .
GO TO AT-230, "Vehicle Does Not Start From D1" .
Continue Road Test.
AT
E
SAT495G
2. CHECK SHIFT-UP AND SHIFT-DOWN (D3

1.
2.
TO D4 TO D2 )
F
Accelerate vehicle to 80 km/h (50 MPH) as shown in the figure.

Release accelerator pedal and then quickly depress it fully.
Read gear position and throttle opening. Refer to AT-46,

"DATA MONITOR MODE (A/T)" .
Does A/T shift from D4 to D2 as soon as accelerator pedal is
depressed fully?
YES >> GO TO 3.
NO
Refer to AT-58 .
Continue Road Test.
I
SAT404H
TO D3 )
Check shift-up (D2 to D3 )

Specified speed when shifting from D2 to D3 . Refer to AT-530, "VEHICLE SPEED WHEN SHIFTING GEARS

YES >> GO TO 4.
NO
Refer to AT-58 .
Continue Road Test.
SAT960I
AT-81
http://vnx.su

[EURO-OBD]
TO D4 ) AND ENGINE BRAKE
Release accelerator pedal after shifting from D2 to D3 .

Does A/T shift from D3 to D4 and does vehicle decelerate by engine
brake?
2. Go to AT-82, "Cruise Test Part 3" .
NO
Refer to AT-58 .
Continue Road Test.
SAT405H
Cruise Test Part 3

1.
2.
3.
TO 33 )
Confirm overdrive control switch is ON position.

Confirm gear selector lever is in D position.
Accelerate vehicle using half-throttle to D4 .
SAT812A
4.
SAT813A
5.
Set overdrive control switch to OFF position while driving in D4 .

Read gear position and vehicle speed. Refer to AT-46,
Does A/T shift from D4 to D3 (O/D OFF)?
YES >> GO TO 2.
NO
Refer to AT-58 .
GO TO AT-231, "A/T Does Not Shift: D4 D3 , When
Overdrive Control Switch ON OFF" .
Continue Road Test.
AT-82
http://vnx.su
SAT776BA

[EURO-OBD]
2. CHECK ENGINE BRAKE
Check engine brake.

Does vehicle decelerate by engine brake?
YES >> GO TO 3.
NO
Refer to AT-58 .
GO TO AT-235, "Vehicle Does Not Decelerate By
Engine Brake" .
Continue Road Test.
AT
D
SAT776BA
TO 22 )
Move selector lever from D to 2 position while driving in D3 (O/D

OFF).
Read gear position. Refer to AT-46, "DATA MONITOR MODE
(A/T)" .
Does A/T shift from D3 (O/D OFF) to 22 ?
YES >> GO TO 4.
NO
Refer to AT-58 .
GO TO AT-232, "A/T Does Not Shift: D3 22 , When
Selector Lever D 2 Position" .
Continue Road Test.
H
SAT791GA

Check engine brake.
YES >> GO TO 5.
NO
Refer to AT-58 .
Engine Brake" .
Continue Road Test.
SAT791GA
5. CHECK SHIFT-DOWN (22
TO 11 )
Move selector lever from 2 to 1 position while driving in 22 .

(A/T)" .
Does A/T shift from 22 to 11 position?
YES >> GO TO 6.
NO
Refer to AT-58 .
GO TO AT-233, "A/T Does Not Shift: 22 11 , When
Selector Lever 2 1 Position" .
Continue Road Test.
AT-83
http://vnx.su
SAT778B

[EURO-OBD]

Check engine brake.
2. Perform self-diagnosis. Refer to AT-45, "SELF-DIAGNOSTIC PROCEDURE (WITH CONSULT-II)" , AT-52,
"Diagnostic Procedure Without CONSULT-II" .
NO
Refer to AT-58 .
Engine Brake" .
Stop Road Test.
AT-84
http://vnx.su
SAT778B
TROUBLE DIAGNOSIS GENERAL DESCRIPTION

[EURO-OBD]

Symptom Chart
Numbers are arranged in order of inspection.
Perform inspections starting with number one and work up.
Symptom
Condition
2. Control cable adjustment
AT-409
3. PNP switch
AT-100
AT-409
2. PNP switch
AT-100
1. Fluid level
AT-64
2. Line pressure test
AT-68
3. Accelerator pedal position (APP) sensor
AT-173
4. Vehicle speed sensorA/T (Revolution

sensor) and vehicle speed sensorMTR
AT-112,
AT-192
5. Oil pump
AT-443
6. Torque converter
AT-423
ON vehicle
AT-409
OFF vehicle
2. Parking components
ON vehicle
AT-409
2. Forward clutch
AT-475
3. Reverse clutch
AT-464
4. Overrun clutch
AT-475
AT-409
2. Stall test
AT-65
AT-68
4. Line pressure solenoid valve
AT-154
5. Control valve assembly
AT-404
6. Reverse clutch
AT-464
7. High clutch
AT-469
8. Forward clutch
AT-475
9. Overrun clutch
AT-475
Engine starts in position other than

N and P positions.
AT-206
ON vehicle
ON vehicle
Transaxle noise in P and N positions.
OFF vehicle
Vehicle will not run in R position

(but runs in D, 2 and 1 positions). Clutch slips.
Very poor acceleration.
AT-210
Vehicle will not run in R position

(but runs in D, 2 and 1 positions). Clutch slips.
AT-210
Reference Page
PG-2, SC-22
ON vehicle
Vehicle runs in N position.

AT-208
A
ECS004QU
1. Ignition switch and starter
Engine cannot start in P and N

positions.
AT-206
Vehicle moves when changing into

P position, or parking gear does
not disengage when shifted out of
P position.
AT-207
Diagnostic Item
PFP:00000
OFF vehicle
ON vehicle
OFF vehicle
ON vehicle
Vehicle braked when shifting into
R position.
OFF vehicle
AT-416, AT-440
AT-483
1. Fluid level
AT-64
AT-68
AT-154
AT-404
5. High clutch
AT-469
6. Brake band
AT-497
7. Forward clutch
AT-475
8. Overrun clutch
AT-475
AT-85
http://vnx.su
AT

[EURO-OBD]
Symptom
Sharp shock in shifting from N to

D position.
Vehicle will not run in D and 2

positions (but runs in 1 and R
positions).
Vehicle will not run in D, 1, 2

positions (but runs in R position).
Clutch slips. Very poor acceleration.
AT-212
Vehicle will not run in D, 1, 2

positions (but runs in R position).
Clutch slips. Very poor acceleration.
AT-212
Condition
Diagnostic Item
1. Engine idling rpm
EC-44
AT-173
AT-68
4. A/T fluid temperature sensor
AT-184
5. Engine speed signal
AT-119
AT-154
AT-404
8. Accumulator N-D
AT-404
OFF vehicle
9. Forward clutch
AT-475
ON vehicle
AT-409
OFF vehicle
ON vehicle
ON vehicle
OFF vehicle
ON vehicle
Clutches or brakes slip somewhat in

starting.
OFF vehicle
ON vehicle
AT-416, AT-423
1. Fluid level
AT-64
2. Stall test
AT-65
AT-68
AT-154
AT-404
6. Accumulator N-D
AT-404
7. Reverse clutch
AT-464
8. High clutch
AT-469
9. Forward clutch
AT-475
AT-416
Excessive creep.
Reference Page
AT-416, AT-423
1. Fluid level
AT-64
AT-409
AT-173
AT-68
AT-154
AT-404
7. Accumulator N-D
AT-404
8. Shift solenoid valve A
AT-161
9. Shift solenoid valve B
AT-167
10. Overrun clutch solenoid valve
AT-178
11. Torque converter clutch solenoid valve
AT-148
12. Forward clutch
AT-475
13. Reverse clutch
AT-464
AT-483
15. Oil pump
AT-443
AT-423
EC-44
AT-86
http://vnx.su

[EURO-OBD]
Symptom
Condition
ON vehicle
No creep at all.
AT-210 and AT-212
OFF vehicle
Failure to change gear from D1 to

D2 .
ON vehicle
ON vehicle
D3 .
ON vehicle
Gear change directly from D1 to

D3 occurs.
ON vehicle
ON vehicle
OFF vehicle
Engine stops when shifting lever

into R, D, 2 and 1.
AT-387
AT-404
4. Forward clutch
AT-475
5. Oil pump
AT-443
6. Torque converter
AT-423
AT-409
AT-161
AT-404
ON vehicle
OFF vehicle
AT-112, AT-192
AT-173
6. Brake band
AT-497
AT-409
AT-167
AT-404
AT-173
6. High clutch
AT-469
7. Brake band
AT-497
1. PNP switch
AT-100
2. Overdrive control switch
AT-237
AT-161
AT-184
6. Brake band
AT-497
AT-173
L
AT-161
AT-167
1. Fluid level
AT-64
2. Accumulator servo release
AT-404
3. Brake band
AT-497
EC-44
2. Fluid level
AT-64
AT-148
AT-404
5. Torque converter
AT-423
AT-87
AT
AT-112, AT-192
http://vnx.su
AT-112, AT-192

AT-112, AT-192

OFF vehicle
Too high a gear change point from
D1 to D2 , from D2 to D3 ,
from D3 to D4 .
AT-217, AT-220 and AT-222
AT-64

OFF vehicle
Reference Page
1. Fluid level

OFF vehicle

D4 .
Diagnostic Item

[EURO-OBD]
Symptom
Too sharp a shock in change from

D1 to D2 .
Condition
ON vehicle
OFF vehicle
ON vehicle
D2 to D3 .
OFF vehicle
ON vehicle
D3 to D4 .
OFF vehicle
Almost no shock or clutches slipping

in change from D1 to D2 .
ON vehicle
OFF vehicle
ON vehicle
Almost no shock or slipping in
change from D2 to D3 .
OFF vehicle
Almost no shock or slipping in

change from D3 to D4 .
ON vehicle
OFF vehicle
ON vehicle
Vehicle braked by gear change from
D1 to D2 .
OFF vehicle
Diagnostic Item
AT-173
AT-68
AT-404
AT-404
AT-184
6. Brake band
AT-497
AT-173
AT-68
AT-404
AT-184
5. High clutch
AT-469
6. Brake band
AT-497
AT-173
AT-68
AT-404
AT-184
5. Brake band
AT-497
6. Overrun clutch
AT-475
AT-416
1. Fluid level
AT-64
AT-173
AT-68
AT-404
AT-404
6. Brake band
AT-497
1. Fluid level
AT-64
AT-173
AT-68
AT-404
5. High clutch
AT-469
6. Brake band
AT-497
1. Fluid level
AT-64
AT-173
AT-68
AT-404
5. Brake band
AT-497
1. Fluid level
AT-64
2. Reverse clutch
AT-464
AT-483
4. High clutch
AT-469

D2 to D3 .
Reference Page
AT-416, AT-423
ON vehicle
1. Fluid level
AT-64
OFF vehicle
2. Brake band
AT-497
AT-88
http://vnx.su

[EURO-OBD]
Symptom
Condition
ON vehicle

D3 to D4 .
OFF vehicle
ON vehicle
Maximum speed not attained.

Acceleration poor.
OFF vehicle
ON vehicle
D3 .
OFF vehicle
ON vehicle
D2 or from D4 to D2 .
OFF vehicle
ON vehicle
Diagnostic Item
1. Fluid level
AT-64
2. Overrun clutch
AT-362
AT-416
4. Reverse clutch
AT-464
1. Fluid level
AT-64
2. PNP switch
AT-100
AT-237
AT-173
AT-161
AT-167
AT-404
8. Reverse clutch
AT-464
9. High clutch
AT-469
10. Brake band
AT-497
AT-483
12. Oil pump
AT-443
AT-423
1. Fluid level
AT-64
AT-173
AT-178
AT-161
AT-154
AT-404
7. Brake band
AT-497
8. Overrun clutch
AT-475
1. Fluid level
AT-64
AT-173
AT-161
AT-167
AT-404
6. High clutch
AT-469
7. Brake band
AT-497
1. Fluid level
AT-64
AT-173
AT-161
AT-167

OFF vehicle
Gear change shock felt during

deceleration by releasing accelerator pedal.
ON vehicle
Reference Page
AT-404
AT-416, AT-423
7. High clutch
AT-469
8. Brake band
AT-497
AT-173
AT-68
AT-178
AT-404
AT-89
http://vnx.su
AT

[EURO-OBD]
Symptom
Too high a change point from D4
to D3 , from D3 to D2 , from D2
to D1 .
Condition
Diagnostic Item
ON vehicle

Kickdown does not operate when

depressing pedal in D4 within kick
down vehicle speed.
Kickdown operates or engine overruns when depressing pedal in D4

beyond kick down vehicle speed
limit.
Races extremely fast or slips in

changing from D4 to D3 when
depressing pedal.
ON vehicle
ON vehicle
ON vehicle
ON vehicle
depressing pedal.
OFF vehicle
ON vehicle
OFF vehicle
AT-173
AT-112, AT-192
AT-173
AT-112, AT-192
AT-161
AT-167

OFF vehicle

depressing pedal.

Reference Page
AT-112, AT-192
AT-173
AT-161
AT-167
1. Fluid level
AT-64
AT-173
AT-68
AT-154
AT-161
AT-404
7. Brake band
AT-497
8. Forward clutch
AT-475
1. Fluid level
AT-64
AT-173
AT-68
AT-154
AT-161
AT-167
AT-404
8. Brake band
AT-497
9. High clutch
AT-469
10. Forward clutch
AT-475
1. Fluid level
AT-64
AT-173
AT-68
AT-154
AT-404
AT-167
7. Brake band
AT-497
8. High clutch
AT-469
AT-90
http://vnx.su

[EURO-OBD]
Symptom
Condition
ON vehicle
changing from D4 or D3 to D1
when depressing pedal.
OFF vehicle
Diagnostic Item
1. Fluid level
AT-64
AT-173
AT-68
AT-154
AT-161
AT-167
AT-404
8. Forward clutch
AT-475
AT-416
AT-64
AT-409
AT-68
AT-154
5. Oil pump
AT-443
6. Torque converter
AT-423
AT-416
ON vehicle
1. Fluid level
AT-64
OFF vehicle
2. Torque converter
AT-423
AT-173
AT-167
AT-404
AT-409
Vehicle will not run in any position.
OFF vehicle
Failure to change from D3 to 22

when changing lever into 2 position.
AT-232
AT-232
Gear change from 22 to 23 in 2
position.
Engine brake does not operate in

1 position.
AT-230
ON vehicle
AT
J
OFF vehicle
5. Brake band
AT-497
1. PNP switch
AT-100
AT-409
1. PNP switch
AT-100
AT-409
K
ON vehicle
ON vehicle
OFF vehicle
position.
AT-416, AT-423
1. Fluid level
ON vehicle
Transaxle noise in D, 2, 1 and

R positions.
Reference Page
ON vehicle

AT-112, AT-192
AT-404
AT-178
6. Overrun clutch
AT-475
AT-483
1. PNP switch
AT-100
AT-409
AT-91
http://vnx.su

[EURO-OBD]
Symptom
Condition
Diagnostic Item
1. PNP switch
ON vehicle
Does not change from 12 to 11
in 1 position.

Large shock changing from 12 to

11 in 1 position.
Transaxle overheats.
AT-161
AT-404
AT-497
AT-483
ON vehicle
AT-404
OFF vehicle
AT-483
1. Fluid level
AT-64
ON vehicle
OFF vehicle
OFF vehicle
ON vehicle
Offensive smell at fluid charging

pipe.
AT-416, AT-423
6. Brake band
ON vehicle
ATF shoots out during operation.

White smoke emitted from exhaust
pipe during operation.
AT-112, AT-192

AT-100

OFF vehicle
Reference Page
OFF vehicle
EC-44
AT-173
AT-68
AT-154
AT-404
7. Oil pump
AT-443
8. Reverse clutch
AT-464
9. High clutch
AT-469
10. Brake band
AT-497
11. Forward clutch
AT-475
12. Overrun clutch
AT-475
AT-483
AT-423
1. Fluid level
AT-64
2. Reverse clutch
AT-464
3. High clutch
AT-469
4. Brake band
AT-497
5. Forward clutch
AT-475
6. Overrun clutch
AT-475
AT-483
1. Fluid level
AT-64
2. Torque converter
AT-423
3. Oil pump
AT-443
4. Reverse clutch
AT-464
5. High clutch
AT-469
6. Brake band
AT-497
7. Forward clutch
AT-475
8. Overrun clutch
AT-475
AT-483
AT-92
http://vnx.su

[EURO-OBD]
Symptom
Condition
Diagnostic Item
Torque converter is not locked up.
ON vehicle
OFF vehicle
ON vehicle
Torque converter clutch piston slip.
OFF vehicle
Lock-up point is extremely high or

low.
AT-224
A/T does not shift to D4 when driving with overdrive control switch
ON.
A/T does not shift to D4 when driving with overdrive control switch
ON.
Engine is stopped at R, D, 2
and 1 positions.
ON vehicle
OFF vehicle
ON vehicle
AT-173
AT-119
AT-184
AT-68
AT-148
AT-404
8. Torque converter
AT-423
1. Fluid level
AT-64
AT-173
AT-68
AT-148
AT-154
AT-404
7. Torque converter
AT-423
AT-173

AT-112, AT-192
AT-148
AT-404
AT-173
2. PNP switch
AT-100
AT-237
AT-161
AT-178
AT-404
AT-184
AT-68
10. Brake band
AT-497
11. Overrun clutch
AT-475
1. Fluid level
AT-64
AT-148
AT-161
AT-167
AT-404
AT-93
AT
AT-112, AT-192
http://vnx.su
AT-112, AT-192

ON vehicle
Reference Page

[EURO-OBD]
TCM Terminals and Reference Value
ECS004QV
PREPARATION
Measure voltage between each terminal and terminal 25 or 48

by following TCM INSPECTION TABLE.
SAT216J
TCM CONNECTOR TERMINAL LAYOUT
SCIA0495E
TCM INSPECTION TABLE

(Data are reference values.)
Terminal No.
Wire color
R/W
P/B
Item
Condition
Line pressure
solenoid valve
Line pressure
solenoid valve
(with dropping
resistor)
Torque converter
clutch solenoid
valve
Judgementstandard(Approx.)
When releasing accelerator pedal

after warming up engine.
1.5 - 3.0V
When depressing accelerator pedal

fully after warming up engine.
0V

5 - 14V

0V
When A/T performs lock-up.
8 - 15V
When A/T does not perform lock-up.
0V
GY/R
G/R
CAN-H
GY/R
CAN-L
10
BR/W
Power source
or
AT-94
http://vnx.su
When turning ignition switch to ON.
Battery voltage
When turning ignition switch to

OFF.
0V

[EURO-OBD]
Terminal No.
11
12
Wire color
L/W
L/Y
Item
Condition
Shift solenoid
valve A
Shift solenoid
valve B
When shift solenoid valve A operates.

(When driving in D1 or D4 .)
Battery voltage
When shift solenoid valve A does not

operate.
0V
When shift solenoid valve B operates.

Battery voltage
When shift solenoid valve B does not

operate.
AT
D
0V
E
19
BR/W
Power source
Same as No. 10
or
20
25
26
27
28
L/B
BR/Y
Overrun clutch
solenoid valve
Ground
PNP switch 1
position
PNP switch 2
position
and
Power source
(Memory back-up)
When overrun clutch solenoid valve

operates.
Battery voltage

does not operate.
0V
Always
0V
When setting selector lever to 1

position.
Battery voltage
When setting selector lever to other

positions.
0V

position.
Battery voltage

positions.
0V
Always
Battery voltage
When moving at 20 km/h (12 MPH)
450 Hz
When vehicle parks.
Under 1.3V or
over 4.5V
29
W/R
Revolution sensor
30 *2
G/B
CONSULT- II (RX)
31 *2
CONSULT- II (TX)
4.5 - 5.5V
Accelerator pedal
position (APP)
sensor
(Power source)

OFF.
0V
32 *1
or
AT-95
http://vnx.su

[EURO-OBD]
Terminal No.
34
35
Wire color
W/G
Y/G
Item
Condition
PNP switch D
position
PNP switch R
position
and
36
39 *1
L/OR
PNP switch P,
N position
Engine speed signal
When setting selector lever to D

position.
Battery voltage

positions.
0V
When setting selector lever to R

position.
Battery voltage

positions.
0V
When setting selector lever to P,

N position.
Battery voltage

positions.
0V
Refer to EC-94 .
and
L/B
Vehicle speed
sensor
When moving vehicle at 2 to 3 km/h

(1 to 2 MPH) for 1 m (3 ft) or more.
Voltage varies
between less
than 0V and
more than 4.5V
41
G/Y
Accelerator pedal
position (APP)
sensor

slowly after warming up engine.
(Voltage rises gradually in response
to throttle position.)
Fully-closed
throttle: 0.5V
Fully-open throttle: 4V
42
Sensor ground
Always
0V
When ATF temperature is 20C

(68F).
1.5V

(176F).
0.5V
Always
0V
40
47
48
BR

Ground
*1: These terminals are connected to the ECM.

*2: These terminals are connected to the data link connector.
AT-96
http://vnx.su

[EURO-OBD]

Description
PFP:31940
A
ECS008CZ
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many elec- B
AT
ECS008D0
Diagnostic trouble code

:CAN COMM CIRCUIT
:11th judgement flicker

When a malfunction is detected in CAN
communication line.
Possible Cause
shorted.)
ECS00CUO
(CAN communication line is open or shorted.)
ECS008D1
NOTE:
After the repair, perform the following procedure to confirm the malfunction is eliminated.
WITH CONSULT-II
1.
2.
3.
4.

Select DATA MONITOR mode for A/T with CONSULT-II.
Wait at least 6 seconds or start engine and wait for at least 6
seconds.
If DTC is detected, go to AT-99, "Diagnostic Procedure" .
SAT014K
WITH GST
Follow the procedure WITH CONSULT-II
WITHOUT CONSULT-II
1.
2.
3.
4.

Wait at least 6 seconds or start engine and wait at least 6 seconds.
Perform self-diagnosis.
Refer to AT-52, "Diagnostic Procedure Without CONSULT-II" .
SCIA4673E
AT-97
http://vnx.su

[EURO-OBD]
Wiring Diagram AT CAN
ECS008D2
TCWA0234E
AT-98
http://vnx.su

[EURO-OBD]
TERMINALS AND REFERENCE VALUE MEASURED BETWEEN EACH TERMINAL
Terminal No.
Wire color
Item
Condition
Judgement
standard
(Approx.)
G/R
CAN-H
GY/R
CAN-L
ECS008D3
1. CHECK CAN COMMUNICATION CIRCUIT

With CONSULT-II
Turn ignition switch ON and start engine.
Select SELF-DIAG RESULTS mode for A/T with CONSULTII.
Is any malfunction of the CAN COMM CIRCUIT indicated?
YES >> Print out CONSULT-II screen, GO TO LAN section.
Refer to LAN-4, "CAN Communication Unit" .
NO
>> INSPECTION END
AT
1.
2.
G
PCIA0061E
AT-99
http://vnx.su
DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH

[EURO-OBD]

Description
PFP:32006
ECS004QW
The PNP switch assembly includes a transaxle range switch.

The transaxle range switch detects the selector lever position
and sends a signal to the TCM.
SCIA0752E
ECS00CTG

: PNP SW/CIRC
: P0705
(The PNP switch circuit is open or
shorted.)
PNP switch
TCM does not receive the correct voltage

signal from the switch based on the gear
position.
Possible Cause
ECS00CTH
[The park/neutral position (PNP) switch circuit is open or shorted.]
ECS00CTI
CAUTION:
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF
and wait at least 5 seconds before conducting the next test.
WITH CONSULT-II
1.
SAT014K
AT-100
http://vnx.su

[EURO-OBD]
2.
3.
4.
Select DATA MONITOR mode for ENGINE with CONSULT-II.

Start engine and maintain the following conditions for at least 5
consecutive seconds.
VHCL SPEED SE: 10 km/h (6 MPH) or more
THRTL POS SEN: More than 1.3V
Selector lever: D position (O/D ON or OFF)
If the check result is NG, go to AT-103, "Diagnostic Procedure" .
AT
SCIA5682E
WITH GST
Follow the procedure WITH CONSULT-II.
AT-101
http://vnx.su

[EURO-OBD]
Wiring Diagram AT PNP/SW
ECS004QX
TCWA0229E
AT-102
http://vnx.su

[EURO-OBD]
Terminal No.
26
27
34
35
36
Wire color
BR/Y
W/G
Y/G
Item
Condition
PNP switch 1
position
PNP switch 2
position
PNP switch D
position
and
PNP switch R
position
PNP switch N or
P position
Judgement standard
(Approx.)

position.
Battery voltage

positions.
0V

position.
Battery voltage

positions.
0V

position.
Battery voltage

positions.
0V

position.
Battery voltage

positions.
0V
When setting selector lever to N or

P position.
Battery voltage

positions.
0V
AT
H
ECS004QY
1. INSPECTION START

YES or NO
YES >> GO TO 2.
NO
>> GO TO 6.
AT-103
http://vnx.su

[EURO-OBD]
2. CHECK PNP SWITCH CIRCUIT (WITH CONSULT-II)

With CONSULT-II
1. Turn ignition switch to ON. (Do not start engine.)
2. Select TCM INPUT SIGNALS in DATA MONITOR mode for
A/T with CONSULT-II.
SAT014K
3.
Read out P/N, R, D, 2 and 1 position switches moving selector

lever to each position.
Check that the signal of the selector lever position is indicated
properly.
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 3.
SAT701J
3. DETECT MALFUNCTIONING ITEM

Check continuity between PNP switch harness connector terminals.
Lever position
Terminal NO.
3-7
3-8
3-9
3-6
3-5
3-4
1-2
1-2
SCIA5588E
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.
4. CHECK MANUAL CONTROL CABLE ADJUSTMENT

Check PNP switch again with manual control cable disconnected from manual shaft of A/T assembly. Refer to
test group 1.
OK or NG
OK
>> Adjust manual control cable. Refer to AT-409, "Control Cable Adjustment" .
NG
>> Repair or replace PNP switch.
AT-104
http://vnx.su

[EURO-OBD]
Check the following items.
Harness for short open between ignition switch and park/neutral position (PNP) switch.
Harness for short or open between park/neutral position (PNP) switch and TCM.
Fuse
Ignition switch
Refer to PG-2, "POWER SUPPLY ROUTING" .
OK or NG
OK
>> GO TO 7.
NG
>> Repair or replace damaged parts.
AT
6. CHECK PARK/NEUTRAL POSITION (PNP) SWITCH CIRCUIT (WITHOUT CONSULT-II)

E
Without CONSULT-II
2. Check voltage between TCM connector terminals 26 (BR/Y), 27 (L), 34 (W/G), 35 (Y/G), 36 (G) and
ground while moving selector lever through each position.
I
SAT840J
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 3.
7. CHECK DTC
Perform AT-100, "DTC Confirmation Procedure" .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 8.
8. CHECK TCM INSPECTION

1. Perform TCM input/output signal inspection. Refer to AT-94, "TCM Terminals and Reference Value" .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
AT-105
http://vnx.su
DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT

[EURO-OBD]

Description
PFP:31940
ECS004R0
The A/T fluid temperature sensor detects the A/T fluid temperature
SCIA0718E
SAT021J
CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE

Remarks: Specification data are reference values.
Monitor item
Condition
Specification (Approximately)
Cold [20C (68F)]
Hot [80C (176F)]
1.5V
0.5V
2.5 k
0.3 k
ECS00CTJ

: ATF TEMP SEN/CIRC
TCM receives an excessively low or high

voltage from the sensor.
: P0710
Possible Cause
ECS00CTK
ECS00CTL
CAUTION:
NOTE:
AT-106
http://vnx.su

[EURO-OBD]
WITH CONSULT-II
1.
Turn ignition switch ON and select DATA MONITOR mode for

ENGINE with CONSULT-II.
AT
D
SAT014K
2.
3.

minutes (Total). (It is not necessary to maintain continuously.)
CMPSRPM (REF): 450 rpm or more
Selector lever: D position (O/D ON)
If the check result is NG, go toAT-109, "Diagnostic Procedure" .
G
SCIA5682E
WITH GST
Follow the procedure With CONSULT-II.
WITHOUT CONSULT-II
1.
2.
3.
4.
Start engine.
Drive vehicle under the following conditions.
Selector lever position: D position
Vehicle speed: higher than 20km/h (12MPH)
M
SCIA5598E
AT-107
http://vnx.su

[EURO-OBD]
Wiring Diagram AT FTS
ECS004R1
TCWA0230E
AT-108
http://vnx.su

[EURO-OBD]
Terminal No.
Wire color
42
47
BR
Item
Condition
Sensor ground
Judgement standard
(Approx.)
Always
0V

(68F).
1.5V

(176F).
0.5V
AT
ECS004R2
1. INSPECTION START
YES or NO
YES >> GO TO 2.
NO
>> GO TO 3.
2. CHECK INPUT SIGNAL OF A/T FLUID TEMPERATURE SENSOR (WITH CONSULT-II)
With CONSULT-II
1. Start engine.
3. Read out the value of FLUID TEMP SE.
SAT014K
Voltage:
Cold [20C (68F)] Hot [80C (176F)]
Approximately 1.5V 0.5V
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 5.
SAT614J
AT-109
http://vnx.su

[EURO-OBD]
3. CHECK INPUT SIGNAL OF A/T FLUID TEMPERATURE SENSOR (WITHOUT CONSULT-II)

Without CONSULT-II
1. Start engine.
2. Check voltage between TCM connector terminal 47 and ground while warming up A/T.
Voltage:
Cold [20C (68F)] Hot [80C (176F)]
Approximately 1.5V 0.5V
3.
4.
5.

Disconnect TCM connector.
Check continuity between TCM connector terminal 42 and
ground.
SCIA0738E

If OK, check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 5.
SCIA0739E
4. CHECK DTC
OK or NG
OK
>> INSPECTION END
NG
>> 1. Perform TCM input/output signal inspection. Refer to AT-94, "TCM Terminals and Reference
Value" .
5. CHECK A/T FLUID TEMPERATURE SENSOR WITH TERMINAL CORD ASSEMBLY

1.
2.
3.
Turn ignition switch to OFF.

Disconnect terminal cord assembly harness connector in engine compartment.
Check resistance between terminals when A/T is cold.
Resistance:
Cold [20C (68F)]
Approximately 2.5 k
4. Reinstall any part removed.

OK or NG
NG
>> 1. Remove oil pan. Refer to AT-404, "COMPONENTS" .
2. Check the following items:
Refer to AT-111, "Component Inspection" .
Harness of terminal cord assembly for short or open
AT-110
http://vnx.su
SCIA4948E

[EURO-OBD]
ECS004R3
A/T FLUID TEMPERATURE SENSOR
For removal, refer to AT-404, "Control Valve Assembly and

Accumulators" .
Check resistance between two terminals while changing temperature as shown.
Temperature C (F)
Resistance
20 (68)
Approximately 2.5 k
80 (176)
Approximately 0.3 k
AT
D
SCIA5683E
AT-111
http://vnx.su
DTC P0720 VEHICLE SPEED SENSORA/T (REVOLUTION SENSOR)

[EURO-OBD]

Description
PFP:32702
ECS004R4
The revolution sensor detects the revolution of the idler gear parking
pawl lock gear and emits a pulse signal. The pulse signal is sent to
the TCM which converts it into vehicle speed.
SCIA0715E
ECS00CTM

: VHCL SPEED SENAT
Revolution sensor
TCM does not receive the proper voltage

signal from the sensor.
: P0720
Possible Cause
ECS00CTN
Revolution sensor
ECS00CTO
CAUTION:
Be careful not to rev engine into the red zone on the

tachometer.
NOTE:
WITH CONSULT-II
1.

SAT014K
AT-112
http://vnx.su

[EURO-OBD]
2.
Drive vehicle and check for an increase of VHCL/S SEMTR

value increase.
If the check result is OK, go to following step.
AT
SCIA5358E
3.
4.
5.
Select DATA MONITOR mode for ENGINE with CONSULT-II.

Driving location: Driving the vehicle uphill (increased
engine load) will help maintain the driving conditions
required for this test.
G
SAT014K

CMPSRPM (REF): 3,500 rpm or more
Driving location: Driving the vehicle uphill (increased engine load) will help maintain the driving
conditions required for this test.
WITH GST
WITHOUT CONSULT-II
1.
2.
3.
4.
Start engine.
Drive vehicle under the following conditions for more than 5 seconds.
Vehicle speed: 30 km/h (19 MPH) or more
Throttle position: greater than 1.0/8 of the full throttle position
SCIA5591E
AT-113
http://vnx.su

[EURO-OBD]
Wiring Diagram AT VSSA/T
ECS004R5
TCWA0231E
AT-114
http://vnx.su

[EURO-OBD]
Terminal No.
29
42
Wire color
W/R
Item
Condition
450 Hz
When vehicle parks.
Under 1.3V or
over 4.5V
Always
When moving at 20 km/h (12 MPH).

Revolution sensor
Sensor ground
Judgement standard
(Approx.)
AT
0V
ECS004R6
1. CHECK INPUT SIGNAL

E
With CONSULT-II
1. Start engine.
3. Read out the value of VHCL/S SEA/T while driving.
SAT014K
Check the value changes according to driving speed.

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 2.
SAT614J
AT-115
http://vnx.su

[EURO-OBD]
2.
1.
2.
CHECK REVOLUTION SENSOR
With CONSULT-II
Start engine.
Check power supply to revolution sensor by voltage between TCM connector terminals. Refer to AT-395,
"Wiring Diagram AT MAIN" and AT-114, "Wiring Diagram AT VSSA/T" .
Item
Connector
No.
TCM
F46, F47
Terminal No. (Wire color)
Data (Approx.)
10 (BR/W) - 42 (B)
Battery voltage
19 (BR/W) - 42 (B)
3.
If OK check the pulse when vehicle cruises.

Name
Condition
When moving at 20 km/h (12 MPH), use the CONSULT-II
pulse frequency measuring function.
Revolution sensor
CAUTION:
Connect the diagnosis data link cable to the data link
connector.
Item
Connector
No.
Terminal
No. (Wire
color)
Name
Data
(Approx.)
TCM
F47
29 (W/R)
Revolution sensor
450 Hz
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 3.
SCIA2344E
AT-116
http://vnx.su

[EURO-OBD]
3.
1.
2.
3.
4.
CHECK POWER AND SENSOR GROUND

Disconnect the revolution sensor harness connector.
Check voltage between revolution sensor harness connector
terminals.
AT
Item
Connector No.
Terminal No.
(Wire color)
Data
(Approx.)
Revolution sensor
F15
1 (BR/W) - 3 (B)
Battery voltage
E
SCIA2614E
5.

terminal and ground.
Item
Connector No.
Terminal No.
(Wire color)
Data
(Approx.)
Revolution sensor
F15
1 (BR/W) ground
Battery voltage
6. If OK, check harness for short to ground and short power.

OK or NG
SCIA2615E
OK
>> GO TO 4.
NG - 1 >> Battery voltage is not supplied between terminals 1 and 3, terminals 1 and ground.:GO TO 6.
NG - 2 >> Battery voltage is not supplied between terminals 1 and 3 only.: GO TO 7.
4.
1.
2.
3.
CHECK HARNESS BETWEEN TCM AND REVOLUTION SENSOR

Disconnect the TCM connector and revolution sensor harness connector.
Check continuity between TCM connector terminal and revolution sensor harness connector terminal.
Item
Connector No.
Terminal No.
(Wire color)
TCM
F47
29 (W/R)
Revolution sensor
F15
Continuity
2 (W/R)
M
Yes

OK or NG
OK
>> GO TO 5.
NG
5. CHECK TCM
1. Check TCM input/output signal. Refer to AT-94, "TCM Terminals and Reference Value" .
2. If NG, re-check TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> GO TO 8.
NG
AT-117
http://vnx.su
SCIA2616E

[EURO-OBD]
6.
1.
2.
3.
CHECK HARNESS BETWEEN TCM AND REVOLUTION SENSOR (POWER)

Check continuity between TCM connector terminals and revolution sensor harness connector terminals. Refer to AT-21, "Circuit
Diagram" and AT-395, "Wiring Diagram AT MAIN" .
Item
Connector No.
Terminal No.
(Wire color)
TCM
F46
10 (BR/W)
Revolution sensor
F15
1 (Y)
Item
Connector No.
Terminal No.
(Wire color)
TCM
F46
19 (BR/W)
Revolution sensor
F15
1 (Y)
Continuity
Yes
Continuity
SCIA2617E
Yes

OK or NG
OK
>> Fuse or ignition switch are malfunctioning.
NG
7.
1.
2.
3.
CHECK HARNESS BETWEEN TCM AND REVOLUTION SENSOR (SENSOR GROUND)

Check continuity between TCM connector terminal and revolution sensor harness connector terminal.
Item
Connector No.
Terminal No.
(Wire color)
TCM
F47
42 (B)
Revolution sensor
F15
3 (B)
Continuity
Yes

OK or NG
OK
>> GO TO 5.
NG
8. CHECK DTC
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 5.
AT-118
http://vnx.su
SCIA2618E
DTC P0725 ENGINE SPEED SIGNAL

[EURO-OBD]

Description
PFP:24825
A
ECS004R7
The engine speed signal is sent from the ECM to the TCM.
B
ECS00CTP

: ENGINE SPEED SIG
Check item (Possible cause)
AT
signal from ECM.
: P0725
Possible Cause
ECS00CTQ
Harness or connector (The sensor circuit is open or shorted.)
E
ECS00CTR
CAUTION:
NOTE:
WITH CONSULT-II
1.

I
K
SAT014K
2.
3.

SCIA5358E
WITH GST
AT-119
http://vnx.su

[EURO-OBD]
WITHOUT CONSULT-II
1.
2.
3.
4.
Start engine.
SCIA5599E
AT-120
http://vnx.su

[EURO-OBD]
Wiring Diagram AT ENGSS
ECS004R8
AT
TCWA0232E
AT-121
http://vnx.su

[EURO-OBD]
Terminal No.
Wire color
Item
39
L/OR
Engine speed signal
Condition
and
Refer to EC-94, "ECM INSPECTION TABLE" .
Judgement standard
(Approx.)
ECS004R9
1. CHECK DTC WITH ECM

Perform diagnostic test mode II (self-diagnostic results) for engine control. Check ignition signal circuit condition.
OK or NG
OK
>> GO TO 2.
NG
>> Check ignition signal circuit for engine control. Refer to EC-439, "IGNITION SIGNAL" .
AT-122
http://vnx.su

[EURO-OBD]
With CONSULT-II
1. Start engine.
AT
E
SAT014K
3.
Read out the value of ENGINE SPEED.

Check engine speed changes according to throttle position.
SAT645J
Without CONSULT-II
1. Start engine.
2. Check voltage between TCM connector terminal 39 and ground.
Name
Connector No.
Terminal
No. (Wire
color)
Condition
Judgement standard
(Approx.)
Engine
speed signal
F47
39 (L/OR)
- Ground
Refer to EC-94, "ECM

INSPECTION TABLE" .
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.
M
SCIA3265E
AT-123
http://vnx.su

[EURO-OBD]
3.
1.
2.
3.
CHECK HARNESS BETWEEN TCM AND ECM

Disconnect ECM connector and TCM connector.
Check continuity between ECM connector terminal and TCM
connector terminal.
Item
Connector No.
Terminal No.
(Wire color)
TCM
F47
39 (L/OR)
ECM
M118
103 (L/OR)
Continuity
Yes
4.
5.

If OK, check continuity between body ground and transaxle
assembly.
OK or NG
OK
>> GO TO 4.
NG
4. CHECK DTC
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 5.
5. CHECK TCM
OK or NG
OK
>> INSPECTION END
NG
AT-124
http://vnx.su
SCIA3269E
DTC P0731 A/T 1ST GEAR FUNCTION

[EURO-OBD]

Description
PFP:31940
A
ECS004RA
This malfunction will not be detected while the O/D OFF indicator lamp is indicating another self-diagnosis
malfunction.
B
This malfunction is detected when the A/T does not shift into first gear position as instructed by the TCM.
This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such
as control valve sticking, improper solenoid valve operation, etc.
AT
Gear position
ON (Closed)
OFF (Open)
OFF (Open)
ON (Closed)
ON (Closed)
ON (Closed)
OFF (Open)
OFF (Open)
On Board Diagnostic Logic
ECS00CTS
This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM as
follows:
Torque converter slip ratio = A x C/B
A: Output shaft revolution signal from revolution sensor
B: Engine speed signal from ECM
C: Gear ratio determined as gear position which TCM supposes
If the actual gear position is higher than the position (1st) supposed by TCM, the slip ratio will be more than
normal. In case the ratio exceeds the specified value, TCM judges this diagnosis malfunction.
This malfunction will be caused when either shift solenoid valve A is stuck open or shift solenoid valve B is
stuck open.
Gear position supposed by TCM
In case of gear position with no malfunctions
In case of gear position with shift solenoid valve A stuck open
2*
In case of gear position with shift solenoid valve B stuck open
4*
*: P0731 is detected.
J
: A/T 1ST GR FNCTN

: P0731
A/T cannot be shifted to the 1st gear position even if electrical circuit is good.
Each clutch
Possible Cause
ECS00CTT
Each clutch
ECS00CTU
CAUTION:
Be careful not to rev engine into the red zone on the tachometer.
NOTE:
TESTING CONDITION:
Always drive vehicle on a level road to improve the accuracy of test.
AT-125
http://vnx.su

[EURO-OBD]
WITH CONSULT-II
1.
2.
3.
Start engine and select DATA MONITOR mode for A/T with
CONSULT-II.
Make sure that output voltage of A/T fluid temperature sensor is
within the range below.
FLUID TEMP SEN: 0.4 - 1.5V
If out of range, drive the vehicle to decrease the voltage (warm
up the fluid) or stop engine to increase the voltage (cool down
the fluid).
Select 1ST GR FNCTN P0731 of DTC WORK SUPPORT
mode for A/T with CONSULT-II and touch START.
SAT014K
4.
5.
6.
7.
Accelerate vehicle to 15 to 20 km/h (9 to 12 MPH) under the following condition and release the accelerator pedal completely.
THROTTLE POSI: Less than 1.0/8 (at all times during step 4)
Make sure that GEAR shows 2 after releasing pedal.
Depress accelerator pedal to WOT (more than 7.0/8 of THROTTLE POSI) quickly from a speed of 15 to 20 km/h (9 to 12 MPH)
until TESTING changes to STOP VEHICLE or COMPLETED. (It will take approximately 3 seconds.)
If the check result NG appears on CONSULT-II screen, go to ATSCIA5358E
128, "Diagnostic Procedure" .
If STOP VEHICLE appears on CONSULT-II screen, go to the
following step.
Make sure that GEAR shows 1 when depressing accelerator pedal to WOT.
If TESTING does not appear on CONSULT-II for a long time, select SELF-DIAGNOSIS for
ENGINE. In case a 1st trip DTC other than P0731 is shown, refer to applicable TROUBLE DIAGNOSIS FOR DTC.
Stop vehicle.
Follow the instruction displayed. (Check for normal shifting referring to the table below.)
Vehicle condition
No malfunction exists
Malfunction for P0731
exists.
8.
Gear on actual transaxle shift pattern when screen is

changed to 1 2 3 4
1234
2233
4334
Make sure that OK is displayed. (If NG is displayed, refer to

Diagnostic Procedure.)
Refer to AT-128, "Diagnostic Procedure" .
Refer to AT-530, "Shift Schedule" .
WITH GST
AT-126
http://vnx.su
SAT021J

[EURO-OBD]
Wiring Diagram AT 1STSIG
ECS004RB
AT
TCWA0049E
AT-127
http://vnx.su

[EURO-OBD]
Terminal No.
11
12
Wire color
L/W
L/Y
Item
Condition
Shift solenoid
valve A
Shift solenoid
valve B
Judgement standard
(Approx.)

Battery voltage

operate.
0V

Battery voltage

operate.
0V
ECS004RC
1. CHECK SHIFT SOLENOID VALVE

1.
2.
Remove control valve assembly. Refer to AT-404, "Control Valve Assembly and Accumulators" .
Check resistance between terminal cord assembly harness connector terminals and ground.
Solenoid valve
Terminal No.
Ground
Resistance (Approx.)
20 - 30
5 - 20
OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace shift solenoid valve assembly.
SCIA3594E
AT-128
http://vnx.su

[EURO-OBD]
2. CHECK VALVE OPERATION

2. Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminal and ground.
OK or NG
OK
>> GO TO 3.
NG
1.
AT
SCIA3595E
3. CHECK CONTROL VALVE

Disassemble control valve assembly. Refer to AT-448, "Control Valve Assembly" .
Check to ensure that:
Valve, sleeve and plug slide along valve bore under their own weight.
Valve, sleeve and plug are free from burrs, dents and scratches.
Control valve springs are free from damage, deformation and fatigue.
Hydraulic line is free from obstacles.

OK or NG
OK
>> GO TO 4.
NG
>> Repair control valve assembly.
1.
2.
4. CHECK DTC
OK or NG
OK
>> INSPECTION END
NG
>> Check control valve again.Repair or replace control valve assembly.
AT-129
http://vnx.su
DTC P0732 A/T 2ND GEAR FUNCTION

[EURO-OBD]

Description
PFP:31940
ECS004RE
malfunction.
This malfunction is detected when the A/T does not shift into second gear position as instructed by the
TCM. This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction
such as control valve sticking, improper solenoid valve operation, etc.
Gear position
ON (Closed)
OFF (Open)
OFF (Open)
ON (Closed)
ON (Closed)
ON (Closed)
OFF (Open)
OFF (Open)
ECS00CTV
follows:
If the actual gear position is higher than the position (2nd) supposed by TCM, the slip ratio will be more than
This malfunction will be caused when shift solenoid valve B is stuck open.

In case of gear position with shift solenoid valve B stuck open
3*
: A/T 2ND GR FNCTN
: P0732

A/T cannot be shifted to the 2nd gear
position even if electrical circuit is good.
Possible Cause
Each clutch

ECS00CTW
Each clutch
ECS00CTX
CAUTION:
NOTE:
TESTING CONDITION:
AT-130
http://vnx.su

[EURO-OBD]
WITH CONSULT-II
1.
2.
3.
CONSULT-II.
the fluid).
Select 2ND GR FNCTN P0732 of DTC WORK SUPPORT
AT
D
SAT014K
4.
5.
6.
7.
Accelerate vehicle to 35 to 40 km/h (22 to 25 MPH) under the

following condition and release the accelerator pedal completely.
Make sure that GEAR shows 3 or 4 after releasing
pedal.
Depress accelerator pedal to WOT (more than 7.0/8 of THROTTLE POSI) quickly from a speed of 35 to 40 km/h (22 to 25
MPH) until TESTING changes to STOP VEHICLE or COMSCIA5358E
PLETED. (It will take approximately 3 seconds.)
If the check result NG appears on CONSULT-II screen, go to AT133, "Diagnostic Procedure" .
If STOP VEHICLE appears on CONSULT-II screen, go to following step.
Make sure that GEAR shows 2 when depressing accelerator pedal to WOT.
Stop vehicle.
Vehicle condition
Gear on actual transaxle shift pattern when screen is

changed to 1 2 3 4
1234
Malfunction for P0732

exists.
4334
8.
Make sure that OK is displayed. (If NG is displayed, refer to

Diagnostic Procedure.)
WITH GST
AT-131
http://vnx.su
M
SAT021J

[EURO-OBD]
Wiring Diagram AT 2NDSIG
ECS004RF
TCWA0050E
AT-132
http://vnx.su

[EURO-OBD]
Terminal No.
12
Wire color
L/Y
Item
Condition
Shift solenoid
valve B
Judgement standard
(Approx.)

Battery voltage

operate.
0V
AT
ECS004RG

1.
2.
Check resistance between terminal cord assembly harness connector terminal and ground.
Solenoid valve
Terminal No.
1
Ground
Resistance
(Approx.)
5 - 20
OK or NG
OK
>> GO TO 2.
NG
H
SCIA3454E


OK or NG
OK
>> GO TO 3.
NG
>> Repair to replace shift solenoid valve assembly.
1.
M
SCIA2058E


OK or NG
OK
>> GO TO 4.
NG
1.
2.
AT-133
http://vnx.su

[EURO-OBD]
4. CHECK DTC
OK or NG
OK
>> INSPECTION END
NG
>> Check control valve again. Repair or replace control valve assembly.
AT-134
http://vnx.su
DTC P0733 A/T 3RD GEAR FUNCTION

[EURO-OBD]

Description
PFP:31940
A
ECS004RI
malfunction.
B
This malfunction is detected when the A/T does not shift into third gear position as instructed by the TCM.
This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such
as control valve sticking, improper solenoid valve operation, malfunctioning servo piston or brake band, AT
etc.
Gear position
ON (Closed)
OFF (Open)
OFF (Open)
ON (Closed)
ON (Closed)
ON (Closed)
OFF (Open)
OFF (Open)
ECS00CTY
follows:
If the actual gear position is higher than the position (3rd) supposed by TCM, the slip ratio will be more than
This malfunction will be caused when shift solenoid valve A is stuck closed.
In case of gear position with shift solenoid valve A stuck closed
4*
: A/T 3RD GR FNCTN
: P0733

A/T cannot be shifted to the 3rd gear position even if electrical circuit is good.
Possible Cause
Each clutch
K
ECS00CTZ
Each clutch
ECS00CU0
CAUTION:
NOTE:
TESTING CONDITION:
AT-135
http://vnx.su

[EURO-OBD]
WITH CONSULT-II
1.
2.
3.
CONSULT-II.
the fluid).
Select 3RD GR FNCTN P0733 of DTC WORK SUPPORT
SAT014K
4.
5.
6.
7.

Make sure that GEAR shows 4 after releasing pedal.
Depress accelerator pedal steadily with 3.5/8 - 4.5/8 of THROTTLE POSI from a speed of 55 to 70 km/h (34 to 44 MPH) until
TESTING changes to STOP VEHICLE or COMPLETED. (It
will take approximately 3 seconds.)
SCIA5358E
Make sure that GEAR shows 3 when depressing accelerator pedal with 3.5/8 - 4.5/8 of
THROTTLE POSI.
Stop vehicle.
Vehicle condition
Gear on actual transaxle shift pattern when

screen is changed to 1 2 3 4
No malfunction exists.
1234
Malfunction for P0733 exists.
1144
8.
Make sure that OK is displayed. (If NG is displayed, refer to Diagnostic Procedure.)

WITH GST
Follow the procedure With CONSULT-II.
AT-136
http://vnx.su

[EURO-OBD]
Wiring Diagram AT 3RDSIG
ECS004RJ
AT
TCWA0051E
AT-137
http://vnx.su

[EURO-OBD]
Terminal No.
11
Wire color
L/W
Item
Condition
Shift solenoid
valve A
Judgement standard
(Approx.)

Battery voltage

operate.
0V
ECS004RK

1.
2.
Solenoid valve
Terminal No.
2
Ground
20 - 30
OK or NG
OK
>> GO TO 2.
NG
SCIA2049E

Remove control valve assembly. Refer toAT-404, "Control Valve Assembly and Accumulators" .

OK or NG
OK
>> GO TO 3.
NG
1.
SCIA2052E


OK or NG
OK
>> GO TO 4.
NG
1.
2.
AT-138
http://vnx.su

[EURO-OBD]
4. CHECK DTC

OK or NG
OK
>> INSPECTION END
NG
>> Check control valve again. Repair or replace control valve assembly.
AT
AT-139
http://vnx.su
DTC P0734 A/T 4TH GEAR FUNCTION

[EURO-OBD]

Description
PFP:31940
ECS004RM
malfunction.
This malfunction is detected when the A/T does not shift into fourth gear position or line pressure is low as
instructed by the TCM. This is not caused by electrical malfunction (circuits open or shorted) but by
mechanical malfunction such as control valve sticking, improper solenoid valve operation, malfunctioning
oil pump or torque converter clutch, etc.
Gear position
ON (Closed)
OFF (Open)
OFF (Open)
ON (Closed)
ON (Closed)
ON (Closed)
OFF (Open)
OFF (Open)

Monitor item
Line pressure solenoid valve duty
Condition
Specification
Small throttle opening

(Low line pressure)
Large throttle opening

(High line pressure)
Approximately 24%
Approximately 95%
ECS00CU1
follows:
If the actual gear position is much lower than the position (4th) supposed by TCM, the slip ratio will be much
less than normal. In case the ratio does not reach the specified value, TCM judges this diagnosis malfunction.
This malfunction will be caused when shift solenoid valve A is stuck open or shift solenoid valve B is stuck
closed.
In case of gear position with shift solenoid valve A stuck open
3*
In case of gear position with shift solenoid valve B stuck closed
1*
And also, this malfunction will be caused when line pressure is lower than normal same as line pressure solenoid valve stuck open.
: A/T 4TH GR FNCTN

: P0734
A/T cannot be shifted to the 4th gear position even if electrical circuit is good.
AT-140
http://vnx.su
Each clutch

[EURO-OBD]
Possible Cause
ECS00CU2
Each clutch
AT
ECS00CU3
CAUTION:
If conducting this DTC Confirmation Procedure again, always turn ignition switch OFF and
wait at least 5 seconds before continuing.
NOTE:
TESTING CONDITION:
WITH CONSULT-II
1.
2.
3.
CONSULT-II.
the fluid).
Select 4TH GR FNCTN P0734 of DTC WORK SUPPORT
SAT014K
4.
5.

Check that GEAR shows 3 after releasing pedal.
Depress accelerator pedal steadily with 1.0/8 - 2.0/8 of THROTTLE POSI from a speed of 55 to 65 km/h (34 to 40 MPH) until
TESTING has turned to STOP VEHICLE or COMPLETED.
(It will take approximately 3 seconds.)
SCIA5358E
Check that GEAR shows 4 when depressing accelerator pedal with 1.0/8 - 2.0/8 of THROTTLE
POSI.
AT-141
http://vnx.su

[EURO-OBD]
6.
7.
If TESTING does not appear on CONSULT-II for a long

time, select SELF-DIAGNOSIS for ENGINE. In case a 1st
trip DTC other than P0734 is shown, refer to applicable
TROUBLE DIAGNOSIS FOR DTC.
Stop vehicle.
Vehicle condition
Malfunction for P0734 exists.
8.
Gear on actual transaxle shift pattern when

screen is changed to 1 2 3 4
1234
2233
1221
Make sure that OK is displayed. (If NG is displayed, refer to Diagnostic Procedure.)

WITH GST
AT-142
http://vnx.su
SAT021J

[EURO-OBD]
Wiring Diagram AT 4THSIG
ECS004RN
AT
TCWA0052E
AT-143
http://vnx.su

[EURO-OBD]
Terminal No.
11
12
Wire color
R/W
P/B
L/W
L/Y
Item
Condition
Line pressure
solenoid valve
Line pressure
solenoid valve
(with dropping
resistor)
Shift solenoid
valve A
Shift solenoid
valve B
1. CHECK SHIFT UP (D3
Judgement standard
(Approx.)

1.5 - 3.0V

0V

5 - 14V

0V

Battery voltage

operate.
0V

Battery voltage

operate.
0V
ECS004RO
TO D4 )
During AT-78, "Cruise Test Part 1" .

YES >> GO TO 11.
NO
>> GO TO 2.
SAT988H
2. CHECK LINE PRESSURE

Perform line pressure test.
Refer to AT-68, "Line Pressure Test" .
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 7.
AT-144
http://vnx.su

[EURO-OBD]
3. CHECK SOLENOID VALVES

1.
2.
Check resistance between terminal cord assembly harness connector terminals and ground.
AT
Solenoid valve
Terminal No.
Ground
Resistance
(Approx.)
20 - 30
5 - 20
OK or NG
OK
>> GO TO 4.
NG
>> Replace solenoid valve assembly.
SCIA3594E

J

OK or NG
OK
>> GO TO 5.
NG
1.
SCIA3595E
AT-145
http://vnx.su

[EURO-OBD]


OK or NG
OK
>> GO TO 6.
NG
>> Repair control valve.
1.
2.
TO D4 )

YES >> GO TO 11.
NO
>> Check control valve again.Repair or replace control
valve assembly.
SAT988H
7. CHECK VALVE RESISTANCE

1.
2.
Line pressure solenoid valves
Solenoid valve
Terminal No.
4
Ground
Resistance
(Approx.)
2.5 - 5
OK or NG
OK
>> GO TO 8.
NG
SCIA3457E

Line pressure solenoid valves

OK or NG
OK
>> GO TO 9.
NG
1.
SCIA3275E
AT-146
http://vnx.su

[EURO-OBD]

Check line pressure circuit valves for sticking.
Pilot valve

OK or NG
OK
>> GO TO 10.
NG
>> Repair control valve.
1.
2.
AT
TO D4 )

YES >> GO TO 11.
NO
>> Check control valve again. Repair or replace control
valve assembly.
SAT988H
11. CHECK DTC

OK or NG
OK
>> INSPECTION END
NG
>> Perform AT-78, "Cruise Test Part 1" again and return to the start point of this test group.
AT-147
http://vnx.su
DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE

[EURO-OBD]

Description
PFP:31940
ECS004RQ
The torque converter clutch solenoid valve is activated, with the gear
in D4 , by the TCM in response to signals sent from the vehicle
speed and throttle position sensors. Lock-up piston operation will
then be controlled.
Lock-up operation, however, is prohibited when A/T fluid temperature is too low.
When the accelerator pedal is depressed (less than 2/8) in lock-up
condition, the engine speed should not change abruptly. If there is a
big jump in engine speed, there is no lock-up.
SCIA0718E

Monitor item
Torque converter clutch solenoid valve
duty
Condition
Specification
Lock-up OFF
Lock-up ON
Approximately 4%
Approximately 94%
ECS00CU4

: T/C CLUTCH SOL/V
(The solenoid circuit is open or shorted.)
T/C clutch solenoid valve
TCM detects an improper voltage drop

when it tries to operate the solenoid valve.
: P0740
Possible Cause
ECS00CU5
ECS00CU6
CAUTION:
If performing this DTC Confirmation Procedure again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

Select DATA MONITOR mode for A/T with CONSULT-II and
wait at least 1 second.
THROTTLE POSI: 0.5/8 - 1.0/8
If the check result is NG go to AT-151, "Diagnostic Procedure" .
AT-148
http://vnx.su
SAT014K

[EURO-OBD]
WITH GST
A
WITHOUT CONSULT-II
1.
2.
3.
4.
Start engine.
Drive vehicle in D1 D2 D3 D4 D4 lock-up position.
Refer toAT-52, "Diagnostic Procedure Without CONSULT-II" .
AT
SCIA5597E
AT-149
http://vnx.su

[EURO-OBD]
Wiring Diagram AT TCV
ECS004RR
TCWA0043E
AT-150
http://vnx.su

[EURO-OBD]
Terminal No.
Wire color
GY/R
Item
Condition
Torque converter
clutch solenoid
valve
Judgement standard
(Approx.)
8 - 15V
0V
AT
ECS004RS

With CONSULT-II
1. Start engine.
2. Select MAIN SIGNALS in DATA MONITOR mode for A/T with CONSULT-II.
3. Read out the value of TCC S/V DUTY while driving.
Monitor item
Condition
Display value
Lock-up OFF
Lock-up ON
TCC S/V
DUTY (%)
Approx. 4%
Approx. 94%
I
SCIA3257E
Without CONSULT-II
1. Start engine.
2. Check voltage between TCM connector terminal and ground.
K
Name
Torque converter clutch

solenoid
valve
Connector No.
F46
Terminal
No. (Wire
color)
3 (GY/R) Ground
Judgement standard
(Approx.)
Condition
When A/T performs lockup.
8 - 15V
0V
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 2.
M
SCIA3261E
AT-151
http://vnx.su

[EURO-OBD]
2. CHECK TORQUE CONVERTER CLUTCH SOLENOID VALVE CIRCUIT

1.
2.
3.

Check resistance between TCM connector terminal and ground.
Solenoid Valve
Connector No.
Terminal No.
(Wire color)
Resistance
(Approx.)

solenoid valve
F46
3 (GY/R) Ground
5 - 20
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.
SCIA3262E
3.
1.
2.
3.
CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR
Disconnect terminal cord assembly harness connector and TCM connector.
Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal.
Item
Connector No.
Terminal No.
(Wire color)
TCM
F46
3 (GY/R)
Terminal cord assembly

harness connector
F23
5 (GY/R)
Continuity
Yes
4. If OK, check harness for short to ground and short to power.

5. If OK, check continuity between ground and transaxle assembly.
OK or NG
OK
>> GO TO 4.
NG
SCIA3263E

1.
2.
3.

Disconnect terminal cord assembly harness connector in engine room.
Resistance
: 5 - 20
OK or NG
OK
>> GO TO 5.
NG
SCIA3456E
5. CHECK DTC
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 6.
AT-152
http://vnx.su

[EURO-OBD]
6. CHECK TCM
OK or NG
OK
>> INSPECTION END
NG
AT
ECS004RT
TORQUE CONVERTER CLUTCH SOLENOID VALVE
For removal, refer to AT-404, "Control Valve Assembly and Accumulators" .
Resistance Check
Check resistance between terminal and ground.

E
Solenoid valve
Torque converter
clutch solenoid
valve
Resistance
(Approx.)
Terminal No.
Ground
5 - 20
G
SCIA2063E
Operation Check
Check solenoid valve by listening for its operating sound while

K
SCIA2066E
AT-153
http://vnx.su
DTC P0745 LINE PRESSURE SOLENOID VALVE

[EURO-OBD]

Description
PFP:31940
ECS004RU
The line pressure solenoid valve regulates the oil pump discharge
pressure to suit the driving condition in response to a signal sent
from the TCM.
The line pressure duty cycle value is not consistent when the
closed throttle position switch is ON. To confirm the line pressure duty cycle at low pressure, the accelerator (throttle)
should be open until the closed throttle position switch is OFF.
SCIA0735E

Monitor item
Condition
Specification

(Low line pressure)

Approximately 0%
Approximately 95%
NOTE:
The line pressure duty cycle value is not consistent when the closed throttle position switch is ON. To confirm the line pressure duty
cycle at low pressure, the accelerator (throttle) should be open until the closed throttle position switch is OFF.
ECS00CU7

: LINE PRESSURE S/V

: P0745
Possible Cause
ECS00CU8
(The solenoid circuit is open shorted.)
ECS00CU9
NOTE:
WITH CONSULT-II
1.

SAT014K
AT-154
http://vnx.su

[EURO-OBD]
2.
3.
Depress accelerator pedal completely and wait at least 5 seconds.

If check result is NG, go to AT-157, "Diagnostic Procedure" .
AT
SCIA5358E
WITH GST
WITHOUT CONSULT-II
1.
2.
3.
4.
Start engine.
With brake pedal depressed, shift the lever from P N D
N P positions.
Perform safe-diagnosis.
H
SCIA5600E
AT-155
http://vnx.su

[EURO-OBD]
Wiring Diagram AT LPSV
ECS004RV
TCWA0046E
AT-156
http://vnx.su

[EURO-OBD]
Terminal No.
Wire color
Item
Condition
Line pressure
solenoid valve
R/W
Line pressure
solenoid valve
(with dropping
resistor)
P/B
Judgement standard
(Approx.)

1.5 - 2.5V

0V

5 - 14V

0V
AT
D
ECS004RW

1.
2.
3.
With CONSULT-II
Select MAIN SIGNALS in DATA MONITOR mode for A/T with CONSULT-II.
Read out the value of LINE PRES DTY while driving.
Monitor item
Condition
Display value
LINE PRES
DTY (%)
Line pressure low Line pressure high
0% 95%
J
SCIA3251E
1.
2.
Without CONSULT-II
Check voltage between TCM connector terminal and ground.
Name

(with dropping resistor)
Connector No.
F46
F46
Terminal
No. (Wire
color)
1 (R/W) Ground
2 (P/B) Ground
Judgement standard
(Approx.)
Condition
When releasing accelerator pedal after warming

up engine.
1.5 - 3.0V
When depressing accelerator pedal fully after

warming up engine.
0V

up engine.
5 - 14V

warming up engine.
0V
SCIA3267E
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 2.
AT-157
http://vnx.su

[EURO-OBD]
2. CHECK DROPPING RESISTOR

1.
2.
3.

Disconnect dropping resistor harness connector in engine room.
Check resistance between terminal 1 and 2.
Resistance:
Approx.12
OK or NG
OK
>> GO TO 3.
NG
SCIA3276E

1.
2.
3.

Disconnect terminal cord assembly connector in engine room.
Resistance:
2.5 - 5
OK or NG
OK
>> GO TO 4.
NG
SCIA3457E
AT-158
http://vnx.su

[EURO-OBD]
4.
1.
2.
3.
Item
Connector No.
Terminal No.
(Wire color)
TCM
F46
1 (R/W)

harness connector
F23
4 (R/W)
AT
Continuity
Yes
SCIA3272E
4.
Check continuity between terminal cord assembly harness connector terminal and dropping resistor harness connector terminal.
Item
Connector No.
Terminal No.
(Wire color)
Dropping resistor harness

connector
E49
1 (R/W)

harness connector
F23
Continuity
Yes
4 (R/W)
SCIA3273E
5.
Check continuity between dropping resistor harness connector

terminal and TCM connector terminal.
Item
Connector No.
Terminal No.
(Wire color)
TCM
F46
2 (P/B)

connector
E49
2 (P/B)
J
Continuity
Yes

OK or NG
OK
>> GO TO 5.
NG
5. CHECK DTC
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 6.
6. CHECK TCM
OK or NG
OK
>> INSPECTION END
NG
AT-159
http://vnx.su
L
SCIA3274E

[EURO-OBD]
ECS004RX
LINE PRESSURE SOLENOID VALVE
Resistance Check

Solenoid valve
Line pressure
solenoid valve
Resistance
(Approx.)
Terminal No.
4
Ground
2.5 - 5
SCIA3457E
Operation Check

SCIA3275E
DROPPING RESISTOR

Resistance:
Approx.12
SCIA3276E
AT-160
http://vnx.su
DTC P0750 SHIFT SOLENOID VALVE A

[EURO-OBD]

Description
PFP:31940
A
ECS004RY
Shift solenoid valves A and B are turned ON or OFF by the TCM in

response to signals sent from the PNP switch, vehicle speed and
throttle position sensors. Gears will then be shifted to the optimum
position.
AT
D
SCIA0718E
E
Gear position
ON (Closed)
OFF (Open)
OFF (Open)
ON (Closed)
ON (Closed)
ON (Closed)
OFF (Open)
OFF (Open)
CONSULT-II REFERENCE VALUE IN DATE MONITOR MODE

Monitor item
Condition
G
Display value

ON
When shift solenoid valve A does not operate.

OFF
ECS00CUA

: SHIFT SOLENOID/V A


: P0750
Possible Cause
ECS00CUB
ECS00CUC
CAUTION:
NOTE:
AT-161
http://vnx.su

[EURO-OBD]
WITH CONSULT-II
1.
2.

Start engine.
SAT014K
3.
4.
Drive vehicle in D position and allow the transaxle to shift 1

2 (GEAR).
SCIA5358E
WITH GST
WITHOUT CONSULT-II
1.
2.
3.
4.
Start engine.
Drive vehicle in D1 D2 position.
Perform safe-diagnosis.
SCIA5594E
AT-162
http://vnx.su

[EURO-OBD]
Wiring Diagram AT SSV/A
ECS004RZ
AT
TCWA0040E
AT-163
http://vnx.su

[EURO-OBD]
Terminal No.
Wire color
11
Item
Condition
Shift solenoid
valve A
L/W
Judgement standard
(Approx.)

Battery voltage

operate.
0V
ECS004S0

With CONSULT-II
1. Start engine.
3. Read out the value of SHIFT S/V A while driving.
Monitor item
SHIFT S/V A
Condition
Display value

ON

OFF
SCIA3251E
1.
2.
Without CONSULT-II
Start engine.
Name
Connector No.
F46
Terminal
No. (Wire
color)
11 (L/W) Ground
Condition
Judgementstandard(Appro
x.)
When shift solenoid valve

A operates.
(When driving in D1 or
D4 .)
Battery
voltage

A does not operate.
D3 .)
0V
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 2.
AT-164
http://vnx.su
SCIA3248E

[EURO-OBD]
2. CHECK SHIFT SOLENOID VALVE A CIRCUIT

1.
2.
3.

Solenoid Valve
Connector No.
Terminal No.
(Wire color)
Resistance
(Approx.)
F46
11 (L/W) Ground
20 - 30
AT
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.
SCIA3249E
3.
1.
2.
3.
F

Item
Connector No.
Terminal No.
(Wire color)
TCM
F46
11 (L/W)

harness connector
F23
2 (L/W)
Continuity
Yes

OK or NG
OK
>> GO TO 4.
NG
SCIA3250E

Resistance

1.
2.
3.
: 20 - 30
OK or NG
OK
>> GO TO 5.
NG
SCIA3453E
5. CHECK DTC
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 6.
AT-165
http://vnx.su

[EURO-OBD]
6. CHECK TCM
OK or NG
OK
>> INSPECTION END
NG
ECS004S1
SHIFT SOLENOID VALVE A
Resistance Check

Solenoid valve
Shift solenoid
valve A
Resistance
(Approx.)
Terminal No.
2
Ground
20 - 30
SCIA2049E
Operation Check

SCIA2052E
AT-166
http://vnx.su
DTC P0755 SHIFT SOLENOID VALVE B

[EURO-OBD]

Description
PFP:31940
A
ECS004S2

position.
AT
D
SCIA0718E
E
Gear position
ON (Closed)
OFF (Open)
OFF (Open)
ON (Closed)
ON (Closed)
ON (Closed)
OFF (Open)
OFF (Open)

Monitor item
Condition
G
Display value

ON
When shift solenoid valve B does not operate.

OFF
ECS00CUD

: SHIFT SOLENOID/V B


: P0755
Possible Cause
K
ECS00CUE
ECS00CUF
CAUTION:
NOTE:
AT-167
http://vnx.su

[EURO-OBD]
WITH CONSULT-II
1.
2.

Start engine.
SAT014K
3.
4.
Drive vehicle in D position and allow the transaxle to shift 1 2

3 (GEAR).
SCIA5358E
WITH GST
WITHOUT CONSULT-II
1.
2.
3.
4.
Start engine.
Drive vehicle in D D2 D3 position.
SCIA5595E
AT-168
http://vnx.su

[EURO-OBD]
Wiring Diagram AT SSV/B
ECS004S3
AT
TCWA0041E
AT-169
http://vnx.su

[EURO-OBD]
Terminal No.
Wire color
12
Item
Condition
Shift solenoid
valve B
L/Y
Judgement standard
(Approx.)

Battery voltage

operate.
0V
ECS004S4

With CONSULT-II
1. Start engine.
3. Read out the value of SHIFT S/V B while driving.
Monitor item
SHIFT S/V B
Condition
Display value

ON

OFF
SCIA3251E
1.
2.
Without CONSULT-II
Start engine.
Name
Connector No.
F46
Terminal
No. (Wire
color)
12 (L/Y) Ground
Condition
x.)

B operates.
D2 .)
Battery
voltage

B does not operate.
D4 .)
0V
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 2.
AT-170
http://vnx.su
SCIA3253E

[EURO-OBD]
2. CHECK SHIFT SOLENOID VALVE B CIRCUIT

1.
2.
3.

Solenoid Valve
Connector No.
Terminal No.
(Wire color)
Resistance
(Approx.)
F46
12 (L/Y) Ground
5 - 20
AT
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.
SCIA3254E
3.
1.
2.
3.
F

Item
Connector No.
Terminal No.
(Wire color)
TCM
F46
12 (L/Y)

harness connector
F23
1 (L/Y)
Continuity
Yes

OK or NG
OK
>> GO TO 4.
NG
SCIA3255E

Resistance

1.
2.
3.
: 5 - 20
OK or NG
OK
>> GO TO 5.
NG
SCIA3454E
5. CHECK DTC
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 6.
AT-171
http://vnx.su

[EURO-OBD]
6. CHECK TCM
OK or NG
OK
>> INSPECTION END
NG
ECS004S5
SHIFT SOLENOID VALVE B
Resistance Check

Solenoid valve
Shift solenoid
valve B
Resistance
(Approx.)
Terminal No.
1
Ground
5 - 20
SCIA2055E
Operation Check

SCIA2058E
AT-172
http://vnx.su
DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR

[EURO-OBD]

Description
PFP:22620
A
ECS004S6
Accelerator pedal position (APP) sensor

acceleration pedal position sensor, throttle position sensor, etc.
The actuator sends a signal to the TCM.
AT
D
PBIB0498E

Monitor item
(THRTL POS SEN)
Condition
Specification
Fully-closed throttle
Approximately 0.5V
Fully-open throttle
Approximately 4V
ECS00CUG

: THROTTLE POSI SEN

: P1705
Possible Cause
ECS00CUH
(The sensor circuit is open shorted.)
ECS00CUI
CAUTION:
NOTE:
WITH CONSULT-II
1.
2.

Accelerator pedal condition
THRTL POS SEN
Fully released
Less than 4.7V
Partially depressed
0.1 - 4.6V
Fully depressed
1.9 - 4.6V

AT-173
http://vnx.su
SAT014K

[EURO-OBD]
3.
4.
5.

consecutive seconds. Then release accelerator pedal completely.
THRTL POS SEN: Approximately 3V or less
Maintain the following conditions for at least 3 consecutive seconds. Then release accelerator pedal completely.
Accelerator pedal: Wide open throttle
SCIA5358E
WITH GST
WITHOUT CONSULT-II
1.
2.
3.
4.
Start engine.
Vehicle speed: 10km/h (6MPH) or more
SCIA5593E
AT-174
http://vnx.su

[EURO-OBD]
Wiring Diagram AT TPS
ECS004S7
AT
TCWA0233E
AT-175
http://vnx.su

[EURO-OBD]
Terminal No.
32
Wire color
Item
Accelerator pedal
position (APP)
sensor
(Power source)
41
G/Y
42
Accelerator pedal
position (APP)
sensor
Condition
Judgement standard
(Approx.)
When turning ignition switch ON
4.5 - 5.5V
When turning ignition switch OFF
0V

Fully-closed throttle:
0.5V
Fully-open throttle:
4V
or
Sensor ground
Always
0V
ECS004S8

Perform diagnostic test mode II (self-diagnostic results) for engine control.
Refer to EC-63, "Malfunction Indicator (MI)" .
OK or NG
NG
>> Check throttle position sensor circuit for engine control.
AT-176
http://vnx.su

[EURO-OBD]
With CONSULT-II
2. Select TCM INPUT SIGNALS in DATA MONITOR mode for A/T with CONSULT-II.
3. Read out the value of THRTL POS SEN.
Monitor item
Condition
Display value
Fully-closed throttle: 0.8V
THRTL POS SEN (V)
When depressing accelerator pedal slowly after

warming up engine.
(Voltage rises gradually in
response to throttle position.)
AT
D
Fully-open throttle: 4.4V
LCIA0090E
Without CONSULT-II
2. Check voltage between TCM connector terminals.
Name
Accelerator
pedal position (APP)
sensor
Connector No.
F47
Terminal
No. (Wire
color)
Condition
x.)
41 (G/Y) 42 (B)

warming up engine.
(Voltage rises gradually
in response to throttle
position.)
Fullyclosed
throttle:
0.8V
Fully-open
throttle:
4.4V
J
SCIA3247E
OK or NG
OK
>> GO TO 3.
NG
>> Check harness for short or open between ECM and TCM regarding accelerator pedal position
sensor circuit.
3. CHECK DTC
M

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 4.
4. CHECK TCM
OK or NG
OK
>> INSPECTION END
NG
AT-177
http://vnx.su
DTC P1760 OVERRUN CLUTCH SOLENOID VALVE

[EURO-OBD]

Description
PFP:31940
ECS004S9
The overrun clutch solenoid valve is activated by the TCM in

response to signals sent from the park/neutral position (PNP) switch,
overdrive control switch, vehicle speed and throttle position sensors.
The overrun clutch operation will then be controlled.
SCIA0718E
ECS00CUJ

: OVERRUN CLUTCH S/V

: P1760
Possible Cause
ECS00CUK
ECS00CUL
CAUTION:
NOTE:
TESTING CONDITION:
Always drive vehicle on a level road to improve accuracy of test.
WITH CONSULT-II
1.
2.
3.
4.

Start engine.
Accelerate vehicle to a speed of more than 10 km/h (6 MPH)
with D position (O/D ON).
Release accelerator pedal completely with D position (O/D
OFF).
SAT014K
WITH GST
AT-178
http://vnx.su

[EURO-OBD]
WITHOUT CONSULT-II
1.
2.
3.
4.
Start engine.
Drive vehicle under the following conditions:
Selector lever in 3rd position, vehicle speed higher than 10 km/h
(6 MPH).
AT
SCIA5596E
AT-179
http://vnx.su

[EURO-OBD]
Wiring Diagram AT OVRCSV
ECS004SA
TCWA0042E
AT-180
http://vnx.su

[EURO-OBD]
Terminal No.
Wire color
20
Item
Condition
Overrun clutch
solenoid valve
L/B
Judgement standard
(Approx.)

operates.
Battery voltage

does not operate.
0V
ECS004SB
With CONSULT-II
Start engine.
Read out the value of OVERRUN/C S/V while driving.
Monitor item
OVERRUN/C S/V
AT

1.
2.
3.
Condition
Display value
When overrun clutch solenoid valve operates.
ON
When overrun clutch solenoid valve does

not operate.
OFF
I
SCIA3257E
1.
2.
Without CONSULT-II
Start engine.
Name
Overrun
clutch solenoid valve
Connector No.
F46
Terminal
No. (Wire
color)
20 (L/B) Ground
x.)
Condition
When overrun clutch

solenoid valve operates.
Battery
voltage
When overrun clutch

solenoid valve does not
operate.
0V
M
SCIA3258E
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 2.
AT-181
http://vnx.su

[EURO-OBD]
2. CHECK OVERRUN CLUTCH SOLENOID VALVE CIRCUIT

1.
2.
3.

Solenoid Valve
Connector No.
Terminal No.
(Wire color)
Resistance
(Approx.)
Overrun clutch solenoid

valve
F46
20 (L/B) Ground
20 - 30
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.
SCIA3259E
3.
1.
2.
3.
Item
Connector No.
Terminal No.
(Wire color)
TCM
F46
20 (L/B)

harness connector
F23
3 (L/B)
Continuity
Yes

OK or NG
OK
>> GO TO 4.
NG
SCIA3260E

1.
2.
3.

Resistance:
20 - 30
OK or NG
OK
>> GO TO 5.
NG
SCIA3455E
5. CHECK DTC
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 6.
AT-182
http://vnx.su

[EURO-OBD]
6. CHECK TCM
OK or NG
OK
>> INSPECTION END
NG
AT
ECS004SC
OVERRUN CLUTCH SOLENOID VALVE
Resistance Check

E
Solenoid valve
Overrun clutch
solenoid valve
Resistance
(Approx.)
Terminal No.
3
Ground
20 - 30
G
SCIA2059E
Operation Check

K
SCIA2062E
AT-183
http://vnx.su
DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM
POWER SOURCE)
[EURO-OBD]
PFP:31940
POWER SOURCE)
Description
ECS004SI
SCIA0735E
SAT021J

Monitor item
Condition
Cold [20C (68F)]
Hot [80C (176F)]
1.5V
0.5V
2.5 k
0.3 k
ECS00CUP

: BATT/FLUID TEMP SEN

: 8th judgement flicker
ECS00CUQ
WITH CONSULT-II
1.
2.
Start engine.
SAT014K
AT-184
http://vnx.su
POWER SOURCE)
[EURO-OBD]
3.

Selector lever in D, vehicle speed higher than 20 km/h (12
MPH).
AT
SCIA5358E
WITH GST
WITHOUT CONSULT-II
1.
2.
3.
4.
Start engine.
Vehicle speed: higher than 20 km/h (12 MPH)
I
SCIA5598E
AT-185
http://vnx.su
POWER SOURCE)
[EURO-OBD]
Wiring Diagram AT BA/FTS
ECS004SJ
TCWA0235E
AT-186
http://vnx.su
POWER SOURCE)
[EURO-OBD]
Terminal No.
Wire color
10
BR/W
Item
Judgement standard
(Approx.)
Condition
Power source
or
Battery voltage

OFF.
0V
BR/W
28
Power source
(Memory back-up)
Always
Battery voltage
42
Sensor ground
Always
0V

(68F).
1.5V

(176F).
0.5V
BR
Same as No. 10
ECS004SK
1. CHECK TCM POWER SOURCE

1.
2.

Name
Power source
Power source
(Memory back-up)
Connector No.
Terminal
No. (wire
color)
Judgement standard (Approx.)
F46
10 (BR/W)
Battery voltage
F46
19 (BR/W)
Battery voltage
F47
28 (L)
Battery voltage
AT
19
47
Power source
J
SCIA2656E
3.
4.

Name
Power source
Power source
(Memory back-up)
Connector No.
Terminal
No. (Wire
color)
F46
10 (BR/W)
0V
F46
19 (BR/W)
0V
F47
28 (L)
Battery voltage
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
SCIA2657E
AT-187
http://vnx.su
POWER SOURCE)
[EURO-OBD]

Check the following items:
Harness for short or open between ignition switch and TCM connector terminal 10, 19.
Harness for short or open between battery and TCM connector terminal 28.
Fuse.
Ignition switch. Refer to PG-2, "POWER SUPPLY ROUTING" .

OK or NG
OK
>> GO TO 9.
NG
3. CHECK INPUT SIGNAL OF A/T FLUID TEMPERATURE SENSOR

With CONSULT-II
1. Start engine.
Monitor item
Condition
Display value
FLUID TEMP
SE
When ATF temperature is 20C (68F).
1.5V
0.5V
LCIA0090E
Without CONSULT-II
1. Start engine.
2. Check voltage TCM connector terminals while warming up A/T.
Name
A/T fluid
temperature
sensor
Connector No.
Terminal
No. (Wire
color)
F47
47 (BR) 42 (B)
Condition
Judgement standard
(Approx.)
When ATF temperature

is 20C (68F).
1.5V

is 80C (176F).
0.5V
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 4.
SCIA2658E

Harness for short or open between TCM, ECM and terminal cord assembly harness connector
Ground circuit for ECM

OK or NG
OK
>> GO TO 5.
NG
AT-188
http://vnx.su
POWER SOURCE)
[EURO-OBD]
5.
CHECK FLUID TEMPERATURE SENSOR CIRCUIT
1.
2.
3.

Disconnect the TCM connector.
Check resistance between terminals.
Connector
No.
Name
A/T fluid
temperature sensor
F47
Terminal No.
(Wire color)
B
Temperature C (F)
Resistance
(K) (Approx.)
20 (68)
2.5
80 (176)
0.3
AT
47 (BR) - 42 (B)
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 6.
E
SCIA2338E
6.
1.
2.
3.

Check continuity between terminal cord assembly harness connector terminals and TCM connector terminals.
Item
Connector No.
Terminal No.
(Wire color)
TCM
F47
42 (B)

harness connector
F23
7 (B)
Item
Connector No.
Terminal No.
(Wire color)
TCM
F47
47 (BR)

harness connector
F23
6 (BR)
Continuity
Yes
Continuity
SCIA2660E
Yes

OK or NG
OK
>> GO TO 7.
NG
AT-189
http://vnx.su
POWER SOURCE)
[EURO-OBD]

1.
2.
3.

Check resistance between terminal cord assembly harness connector terminals when A/T is cold.
Temperature C (F)
Resistance
20 (68)
Approx. 2.5 k
80 (176)
Approx. 0.3 k

OK or NG
OK
>> GO TO 8.
NG
SCIA4948E

1.
2.
Remove oil pan. Refer toAT-404, "Control Valve Assembly and Accumulators" .
Temperature C (F)
Resistance
20 (68)
Approx. 2.5 k
80 (176)
Approx. 0.3 k

OK or NG
OK
>> GO TO 9.
NG
9. CHECK DTC
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 10.
10. CHECK TCM

OK or NG
OK
>> INSPECTION END
NG
AT-190
http://vnx.su
SCIA5683E
POWER SOURCE)
[EURO-OBD]
ECS004SL
For removal, refer to AT-404, "Control Valve Assembly and

Accumulators" .
Temperature C (F)
Resistance
20 (68)
Approximately 2.5 k
80 (176)
Approximately 0.3 k
AT
D
SCIA5683E
AT-191
http://vnx.su
DTC VEHICLE SPEED SENSOR MTR

[EURO-OBD]

Description
PFP:24814
ECS004SM
The vehicle speed sensorMTR is built into the speedometer assembly. The sensor functions as an auxiliary device to the revolution sensor when it is malfunctioning. The TCM will then use a signal sent
from the vehicle speed sensorMTR.
SCIA0716E
ECS00CUR
: VHCL SPEED SENMTR

: 2nd judgement flicker

Possible Cause
Combination meter
4WD/ABS control unit

ECS00CUS
ECS00CUT
CAUTION:
If conducting this DTC Confirmation Procedure again, always turn ignition switch OFF and wait
WITH CONSULT-II
1.

SAT014K
AT-192
http://vnx.su

[EURO-OBD]
2.
3.
Start engine and accelerate vehicle from 0 to 25 km/h (0 to 16

MPH).
AT
SCIA5358E
WITH GST
Follow the procedure WITH CONSULT-II
WITHOUT CONSULT-II
1.
2.
3.
4.
Start engine.
Selector lever in D and vehicle speed higher than 25 km/h (16
MPH).
H
SCIA5592E
AT-193
http://vnx.su

[EURO-OBD]
Wiring Diagram AT VSSMTR
ECS004SN
LHD MODELS
TCWA0236E
AT-194
http://vnx.su

[EURO-OBD]
RHD MODELS
A
AT
TCWA0237E
AT-195
http://vnx.su

[EURO-OBD]
Terminal No.
Wire color
40
Item
Condition
Vehicle speed
sensor
L/W

Judgement standard
(Approx.)
Voltage varies
between less
than 1V and
more than 4.5V
ECS004SO

With CONSULT-II
Start engine.
Select TCM INPUT SIGNALS in DATA MONITOR mode for
3. Read out the value of VHCL/S SEMTR while driving.
1.
2.
LCIA0090E
Without CONSULT-II
1. Start engine.
2. Check voltage between TCM connector and ground.
Name
Vehicle
speed sensor
Connector No.
F47
Condition
x.)
When moving vehicle at

2 to 3 km/h (1 to 2 MPH)
for 1 m (3 ft) or more.
Voltage
varies
between
less than
0V and
more than
4.5V
Terminal
No. (Wire
color)
40 (L/W) Ground
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

Combination meters. Refer to DI-4, "COMBINATION METERS" .
Harness for short or open between TCM and combination meters.

OK or NG
OK
>> GO TO 3.
NG
AT-196
http://vnx.su
SCIA3246E

[EURO-OBD]
3. CHECK DTC

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 4.
4. CHECK TCM
AT
OK or NG
OK
>> INSPECTION END
NG
AT-197
http://vnx.su
DTC CONTROL UNIT (RAM), CONTROL UNIT (ROM)

[EURO-OBD]

Description
PFP:31036
ECS004SP
The TCM consists of a microcomputer and connectors for signal

input and output and for power supply. The unit controls the A/T.
SAT574J
ECS00CUU
Diagnostic Trouble Code No.

: CONTROL UNIT (RAM),
CONTROL UNIT (ROM)
Malfunction is detected when....

TCM memory (RAM) or (ROM) is malfunctioning.
Possible Cause
Check Item (Possible Cause)
TCM
ECS00CUV
TCM.
ECS00CUW
NOTE:
WITH CONSULT-II
1.
2.

Start engine.
SAT014K
3.
4.
Run engine for at least 2 seconds at idle speed.

SCIA5358E
AT-198
http://vnx.su

[EURO-OBD]
ECS004SQ
1. INSPECTION START (WITH CONSULT-II)
With CONSULT-II
1. Turn ignition switch ON and select SELF DIAGNOSIS mode for A/T with CONSULT-II.
2. Touch ERASE.
3. Perform AT-198, "DTC Confirmation Procedure" .
Is the CONTROL UNIT (RAM) or CONTROL UNIT (ROM) displayed again?
YES >> Replace TCM.
NO
>> INSPECTION END
AT
AT-199
http://vnx.su
DTC CONTROL UNIT(EEPROM)

[EURO-OBD]

Description
PFP:31036
ECS004SR
The TCM consists of a microcomputer and connectors for signal

input and output and for power supply. The unit controls the A/T.
SAT574J
ECS00CUX

: CONT UNIT (EEP ROM)

Possible Cause
TCM
ECS00CUY
TCM.
ECS00CUZ
NOTE:
WITH CONSULT-II
1.
2.

Start engine.
SAT014K
3.
4.
Run engine for at least 2 seconds at idle speed.

SCIA5358E
AT-200
http://vnx.su

[EURO-OBD]
ECS004SS
1. CHECK DTC
With CONSULT-II
1. Turn ignition switch ON and select SELF DIAGNOSIS mode for A/T with CONSULT-II.
3. Depress accelerator pedal (Full throttle position).
4. Touch ERASE.
5. Turn ignition switch OFF for 10 seconds.
6. Perform AT-200, "DTC Confirmation Procedure" .
Is the CONT UNIT (EEP ROM) displayed again?
YES >> Replace TCM.
NO
>> INSPECTION END
AT
AT-201
http://vnx.su
TROUBLE DIAGNOSES FOR SYMPTOMS

[EURO-OBD]

Wiring Diagram AT NONDTC
PFP:00100
ECS004ST
TCWA0238E
AT-202
http://vnx.su

[EURO-OBD]
A
AT
TCWA0239E
AT-203
http://vnx.su

[EURO-OBD]
O/D OFF Indicator Lamp Does Not Come On
ECS004SU
SYMPTOM:
O/D OFF indicator lamp does not come on for about 2 seconds
when turning ignition switch to ON.
SCIA4281E

1.
2.
Turn ignition switch to ON. (Do not start engine.)

Check voltage between TCM connector terminals 10, 19, 28 and ground.
Voltage:
3.
4.
Battery voltage

Check voltage between TCM connector terminal 28 and ground.
Voltage:
Battery voltage
OK or NG
OK
>> GO TO 2.
NG
>> Check the following items:
Harness for short or open between ignition switch and
TCM connector terminals 10, 19 and 28
Refer to AT-395, "Wiring Diagram AT MAIN" .
Ignition switch and fuse Refer to PG-2, "POWER SUPPLY ROUTING" .
SCIA0713E
2. CHECK TCM GROUND CIRCUIT

1.
2.
3.

Check continuity between TCM connector terminals 25, 48 and
ground.

OK or NG
OK
>> GO TO 3.
NG
in harness or connectors. Refer to AT-395, "Wiring Diagram AT MAIN" .
SCIA0766E
3. CHECK COMBINATION METERS SYSTEM

Check combination meters system. Refer to DI-12, "Combination Meter" .
OK or NG
OK
>> GO TO 4.
NG
AT-204
http://vnx.su

[EURO-OBD]
4. CHECK SYMPTOM
A
Check again. Refer to AT-71, "1. CHECK BEFORE ENGINE IS STARTED" .
OK or NG
B
OK
>> INSPECTION END
Terminals
and
Reference
NG
>> 1. Perform TCM input/output signal inspection. Refer to AT-94, "TCM
Value" .
AT
AT-205
http://vnx.su

[EURO-OBD]
Engine Cannot Be Started In P and N Position
ECS004SV
SYMPTOM:
Engine cannot be started with selector lever in P or N position.
Engine can be started with selector lever in D, 2, 1 or R position.
1. CHECK SELF-DIAGNOSIS RESULTS

Perform self-diagnosis. Refer to AT-45, "SELF-DIAGNOSTIC PROCEDURE (WITH CONSULT-II)" .
Do the self-diagnosis results indicate PNP switch circuit?
YES >> Check park/neutral position (PNP) switch circuit. Refer to AT-100, "DTC P0705 PARK/NEUTRAL
POSITION (PNP) SWITCH" .
NO
>> GO TO 2.
2. CHECK PNP SWITCH INSPECTION

Check for short or open of PNP switch harness connector terminals 1 and 2.
Refer to AT-237, "TCM Self-diagnosis Does Not Activate" .
OK or NG
OK
>> GO TO 3.
NG
SCIA0768E
3. ADJUST CONTROL CABLE

Check control cable. Refer to AT-409, "Control Cable Adjustment" .
OK or NG
OK
>> GO TO 4.
NG
>> Adjust control cable. Refer to AT-409, "Control Cable
Adjustment" .
SAT023JB

Check starting system. Refer to SC-22, "STARTING SYSTEM" .
OK or NG
OK
>> INSPECTION END
NG
AT-206
http://vnx.su

[EURO-OBD]
In P Position, Vehicle Moves Forward Or Backward When Pushed
ECS004SW
SYMPTOM:
Vehicle moves when it is pushed forward or backward with selector lever in P position.

OK or NG
OK
>> GO TO 2.
NG
Adjustment" .
AT
E
SAT023JB
2. CHECK PARKING COMPONENTS
Check parking components. Refer to AT-416, "OVERHAUL" .

OK or NG
OK
>> INSPECTION END
NG
I
SAT282F
AT-207
http://vnx.su

[EURO-OBD]
In N Position, Vehicle Moves
ECS004SX
SYMPTOM:
Vehicle moves forward or backward when selecting N position.

OK or NG
OK
>> GO TO 2.
NG
Adjustment" .
SAT023JB
2. CHECK A/T FLUID LEVEL

Check A/T fluid level. Refer to AT-16, "Checking A/T Fluid" .
OK or NG
OK
>> GO TO 3.
NG
>> Refill ATF.
SAT638A
3. CHECK A/T FLUID CONDITION

Remove oil pan. Refer to AT-404, "COMPONENTS" .
Check A/T fluid condition. Refer to AT-64, "FLUID CONDITION
CHECK" .
OK or NG
OK
>> GO TO 4.
NG
>> 1. Disassemble A/T. Refer to AT-424, "Disassembly" .
Forward clutch assembly. Refer to AT-475, "Forward
and Overrun Clutches" .
Overrun clutch assembly. Refer to AT-475, "Forward
Reverse clutch assembly. Refer to AT-464, "Reverse
Clutch" .
1.
2.
SAT171B
4. CHECK SYMPTOM
Check again. Refer to AT-72, "2. CHECK AT IDLE" .
OK or NG
OK
>> INSPECTION END
NG
Value" .
AT-208
http://vnx.su

[EURO-OBD]
Large Shock. N R Position
ECS004SY
SYMPTOM:
There is large shock when changing from N to R position.
1. CHECK SELF-DIAGNOSTIC RESULTS
Perform self-diagnosis. Refer to AT-45, "SELF-DIAGNOSTIC PROCEDURE (WITH CONSULT-II)" or AT-52,

Do the self-diagnosis results indicate A/T fluid temperature sensor, line pressure solenoid valve, accelerator AT
pedal position (APP) sensor circuit?
YES >> Check damaged circuit. Refer to the following items.
D
AT-154, "DTC P0745 LINE PRESSURE SOLENOID VALVE"
AT-173, "DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR"
AT-184, "DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM
E
POWER SOURCE)"
NO
>> GO TO 2
Check line pressure at idle with selector lever in D position. Refer to

AT-68, "Line Pressure Test" .
OK or NG
OK
>> GO TO 3.
NG
>> 1. Remove control valve assembly. Refer to AT-404,
"Control Valve Assembly and Accumulators" .
Valves to control line pressure (Pressure regulator
valve, pressure modifier valve, pilot valve and pilot filter)
Oil pump assembly. Refer to AT-443, "Oil Pump" .
I
SAT494G
3. CHECK SYMPTOM

OK or NG
OK
>> INSPECTION END
NG
Value" .
AT-209
http://vnx.su

[EURO-OBD]
Vehicle Does Not Creep Backward In R Position
ECS004SZ
SYMPTOM:
Vehicle does not creep backward when selecting R position.

OK or NG
OK
>> GO TO 2.
NG
>> Refill ATF.
SAT638A

Check line pressure at idle with selector lever in R position. Refer to
OK or NG
OK
>> GO TO 3.
NG
3. Disassemble A/T. Refer to AT-424, "Disassembly" .
4. Check the following item:
SAT494G
3. CHECK STALL TEST

Check stall revolution with selector lever in 1 and R positions.
Refer to AT-65, "Stall Test" .
OK or NG
OK
>> GO TO 4.
OK in 1 position, NG in R position>>1.Disassemble A/T. Refer to
AT-424, "Disassembly" .
Clutch" .
Low & reverse brake assembly. Refer to AT-483, "Low
& Reverse Brake" .
NG in both 1 and R positions>>GO TO 6.
AT-210
http://vnx.su
SAT493G

[EURO-OBD]

CHECK" .
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 6.
1.
2.
AT
D
SAT171B
5. CHECK SYMPTOM
OK or NG
OK
>> INSPECTION END
NG
Value" .
Disassemble A/T. Refer to AT-424, "Disassembly" .

Reverse clutch assembly. Refer to AT-464, "Reverse Clutch" .
High clutch assembly. Refer to AT-469, "High Clutch" .
Low & reverse brake assembly. Refer to AT-483, "Low & Reverse Brake" .
Forward clutch assembly. Refer to AT-475, "Forward and Overrun Clutches" .
Overrun clutch assembly. Refer to AT-475, "Forward and Overrun Clutches" .

OK or NG
OK
>> GO TO 5.
NG
1.
2.
AT-211
http://vnx.su

[EURO-OBD]
Vehicle Does Not Creep Forward In D, 2 Or 1 Position
ECS004T0
SYMPTOM:
Vehicle does not creep forward when selecting D, 2 or 1 position.

OK or NG
OK
>> GO TO 2.
NG
>> Refill ATF.
SAT638A

OK or NG
OK
>> GO TO 3.
NG
SAT494G
3. CHECK STALL TEST

Check stall revolution with selector lever in D position. Refer to AT65, "Stall Test" .
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 6.
SAT493G
AT-212
http://vnx.su

[EURO-OBD]

CHECK" .
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 6.
1.
2.
AT
D
SAT171B
5. CHECK SYMPTOM
OK or NG
OK
>> INSPECTION END
NG
Value" .

Forward one-way clutch. Refer to AT-475, "Forward and Overrun Clutches" .
Low one-way clutch. Refer to AT-424, "Disassembly" .
Torque converter. Refer to AT-424, "Disassembly" .

OK or NG
OK
>> GO TO 5.
NG
1.
2.
AT-213
http://vnx.su

[EURO-OBD]
Vehicle Cannot Be Started From D1
ECS004T1
SYMPTOM:
Vehicle cannot be started from D1 on Cruise Test Part 1.
1. SYMPTOM CHECK
Check symptom. Refer to AT-78, "Cruise Test Part 1" .
Is Vehicle does not creep backward in R position OK?
YES >> GO TO 2.
NO
>> Go to AT-210, "Vehicle Does Not Creep Backward In R Position" .

Do the self-diagnosis results indicate vehicle speed sensorA/T (revolution sensor), overrun clutch solenoid
valve, torque converter clutch solenoid valve, shift solenoid valve A,B or vehicle speed sensorMTR circuit?
AT-112, "DTC P0720 VEHICLE SPEED SENSORA/T (REVOLUTION SENSOR)"
AT-148, "DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE"
AT-161, "DTC P0750 SHIFT SOLENOID VALVE A"
AT-167, "DTC P0755 SHIFT SOLENOID VALVE B"
AT-178, "DTC P1760 OVERRUN CLUTCH SOLENOID VALVE"
AT-339, "DTC VEHICLE SPEED SENSOR MTR"
NO
>> GO TO 3.
3. CHECK ACCELERATOR PEDAL POSITION (APP) SENSOR

Check accelerator pedal position (APP) sensor. Refer to AT-173,
"DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR" .
OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace accelerator pedal position (APP) sensor.
PBIB0498E

Check line pressure at stall point with selector lever in D position.
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 8.
SAT494G
AT-214
http://vnx.su

[EURO-OBD]

CHECK" .
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 8.
1.
2.
AT
D
SAT171B

Shift valve A
Shift valve B
Pilot valve
Pilot filter
OK or NG
OK
>> GO TO 7.
NG
1.
2.
7. CHECK SYMPTOM
Check again. Refer to AT-78, "Cruise Test Part 1" .

OK or NG
OK
>> INSPECTION END
NG
Value" .
AT-215
http://vnx.su

[EURO-OBD]

Shift valve A
Shift valve B
Pilot valve
Pilot filter
Forward clutch. Refer to AT-475, "Forward and Overrun Clutches" .
Forward one-way clutch assembly. Refer to AT-424, "Disassembly" .
Low & reverse clutch assembly

OK or NG
OK
>> GO TO 7.
NG
1.
2.
AT-216
http://vnx.su

[EURO-OBD]
A/T Does Not Shift: D1 D2 Or Does Not Kickdown: D4 D2

SYMPTOM:
A/T does not shift from D1 to D2
ECS004T2
at the specified speed.

when depressing accelerator pedal fully at the specified speed.
B
1. CHECK SYMPTOM
Check symptom. Refer to AT-78, "Cruise Test Part 1" and AT-81, "Cruise Test Part 2" .
Are Vehicle Does Not Creep Ford In D, 2 Or 1 Position and Vehicle Cannot Be Started From D1 OK? AT
YES >> GO TO 2.
NO
>> GO TO AT-212, "Vehicle Does Not Creep Forward In D, 2 Or 1 Position" , AT-214, "Vehicle
D
Cannot Be Started From D1" .

E

OK or NG
OK
>> GO TO 3.
NG
Adjustment" .
H
SAT023JB
3. CHECK VEHICLE SPEED SENSORA/T (REVOLUTION SENSOR) AND CHECK VEHICLE SPEED
I
SENSORMTR CIRCUIT
Check vehicle speed sensorA/T (revolution sensor) and vehicle speed sensorMTR circuit. Refer to AT-112,
"DTC P0720 VEHICLE SPEED SENSORA/T (REVOLUTION SENSOR)" and AT-192, "DTC VEHICLE
SPEED SENSOR MTR" .
OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace vehicle speed sensorA/T (revolution sensor) and vehicle speed sensorMTR
circuits.
PBIB0498E
AT-217
Check accelerator pedal position (APP) sensor. Refer AT-173, "DTC

P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR" .
OK or NG
OK
>> GO TO 5
NG
http://vnx.su

[EURO-OBD]

CHECK" .
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 8.
1.
2.
SAT171B

Remove control valve. Refer to AT-404, "Control Valve Assembly and Accumulators" .
Shift valve A
Shift valve B
Pilot valve
Pilot filter
OK or NG
OK
>> GO TO 7.
NG
1.
2.
7. CHECK SYMPTOM
Check again. Refer to AT-78, "Cruise Test Part 1" and AT-81, "Cruise Test Part 2" .
OK or NG
OK
>> INSPECTION END
NG
Value" .
AT-218
http://vnx.su

[EURO-OBD]
Shift valve A
Shift valve B
Pilot valve
Pilot filter
Servo piston assembly
Brake band
OK or NG
OK
>> GO TO 7.
NG
1.
2.
AT
AT-219
http://vnx.su

[EURO-OBD]
A/T Does Not Shift: D2 D3

SYMPTOM:
ECS004T3
1. CHECK SYMPTOM
Are Vehicle Does Not Creep Ford In D, 2 Or 1 Position and Vehicle Cannot Be Started From D1 OK?
YES >> GO TO 2.
NO

OK or NG
OK
>> GO TO 3.
NG
Adjustment" .
SAT023JB
SENSORMTR CIRCUIT
SPEED SENSOR MTR" .
OK or NG
OK
>> GO TO 4.
NG
circuits.

"DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR" .
OK or NG
OK
>> GO TO 5.
NG
PBIB0498E
AT-220
http://vnx.su

[EURO-OBD]

CHECK" .
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 8.
1.
2.
AT
D
SAT171B

Shift valve B
Pilot valve
Pilot filter
OK or NG
OK
>> GO TO 7.
NG
1.
2.
7. CHECK SYMPTOM
OK or NG
OK
>> INSPECTION END
NG
Value" .
Shift valve B
Pilot valve
Pilot filter

OK or NG
OK
>> GO TO 7.
NG
1.
2.
AT-221
http://vnx.su

[EURO-OBD]
ECS004T4
SYMPTOM:
A/T does not shift from D3 to D4 at the specified speed.
A/T must be warm before D3 to D4 shift will occur.
1. CHECK SYMPTOM
YES >> GO TO 2.
NO

Do the self-diagnosis results indicate PNP switch, overdrive control switch, A/T fluid temperature sensor, vehicle speed sensorA/T (revolution sensor), shift solenoid valve A,B or vehicle speed sensorMTR circuit?
AT-184, "DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM
POWER SOURCE)"
AT-237, "TCM Self-diagnosis Does Not Activate"
NO
>> GO TO 3.

"DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR"
OK or NG
OK
>> GO TO 4.
NG
PBIB0498E

CHECK" .
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 7.
1.
2.
SAT171B
AT-222
http://vnx.su

[EURO-OBD]
Shift valve A
Pilot valve
Pilot filter
OK or NG
OK
>> GO TO 6.
NG
1.
2.
AT
6. CHECK SYMPTOM
OK or NG
OK
>> INSPECTION END
NG
Value" .
Shift valve A
Pilot valve
Pilot filter
Brake band
OK or NG
OK
>> GO TO 6
NG
1.
2.
AT-223
http://vnx.su

[EURO-OBD]
A/T Does Not Perform Lock-up
ECS004T5
SYMPTOM:
A/T does not perform lock-up at the specified speed.

Does self-diagnosis show damage to A/T fluid temperature sensor, vehicle speed sensorA/T (revolution sensor), engine speed signal, vehicle speed sensorMTR or torque converter clutch solenoid valve circuit after
cruise test?
YES >> Check damaged circuit. Refer to AT-148, "DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE" , AT-106, "DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT" , AT-112,
"DTC P0720 VEHICLE SPEED SENSORA/T (REVOLUTION SENSOR)" , AT-119, "DTC P0725
ENGINE SPEED SIGNAL" , AT-192, "DTC VEHICLE SPEED SENSOR MTR" .
NO
>> GO TO 2.

OK or NG
OK
>> GO TO 3.
NG
PBIB0498E

Torque converter clutch control valve
Pilot valve
Pilot filter
4. Check torque converter. Refer to AT-424, "Disassembly" .
OK or NG
OK
>> GO TO 4.
NG
1.
2.
4. CHECK SYMPTOM
OK or NG
OK
>> INSPECTION END
NG
Value" .
AT-224
http://vnx.su

[EURO-OBD]
A/T Does Not Hold Lock-up Condition
ECS004T6
SYMPTOM:
A/T does not hold lock-up condition for more than 30 seconds.
1. CHECK DIAGNOSTIC RESULTS

AT
Does self-diagnosis show damage to engine speed signal circuit after cruise test?
YES >> Check engine speed signal circuit. Refer to AT-119, "DTC P0725 ENGINE SPEED SIGNAL" .
NO
>> GO TO 2.
D
CHECK A/T FLUID CONDITION
2.

CHECK" .
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 5.
1.
2.
H
SAT171B
Pilot valve
Pilot filter
OK or NG
OK
>> GO TO 4.
NG
1.
2.
4. CHECK SYMPTOM

OK or NG
OK
>> INSPECTION END
NG
Value" .
AT-225
http://vnx.su

[EURO-OBD]

Pilot valve
Pilot filter
4. Check torque converter and oil pump assembly.
OK or NG
OK
>> GO TO 4.
NG
1.
2.
AT-226
http://vnx.su

[EURO-OBD]
Lock-up Is Not Released
ECS004T7
SYMPTOM:
Lock-up is not released when accelerator pedal is released.
1. CHECK ACCELERATOR PEDAL POSITION (APP) SENSOR CIRCUIT

AT
Do the self-diagnosis results indicate accelerator pedal position (APP) sensor circuit?
YES >> Check accelerator pedal position (APP) sensor circuit. Refer to AT-173, "DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR" .
D
NO
>> GO TO 2.
2. CHECK SYMPTOM
OK or NG
OK
>> INSPECTION END
NG
Value" .
AT-227
http://vnx.su

[EURO-OBD]
Engine Speed Does Not Return To Idle (Light Braking D4 D3 )
ECS004T8
SYMPTOM:
Engine speed does not smoothly return to idle when A/T shifts from D4 to D3 .

Does self-diagnosis show damage to overrun clutch solenoid valve circuit after cruise test?
YES >> Check overrun clutch solenoid valve circuit. Refer to AT-178, "DTC P1760 OVERRUN CLUTCH
SOLENOID VALVE" .
NO
>> GO TO 2.

OK or NG
OK
>> GO TO 3.
NG
PBIB0498E

CHECK" .
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 6.
1.
2.
SAT171B


OK or NG
OK
>> GO TO 5.
NG
1.
2.
AT-228
http://vnx.su

[EURO-OBD]
5. CHECK SYMPTOM
A
OK or NG
B
OK
>> INSPECTION END
Terminals
and
Reference
NG
>> 1. Perform TCM input/output signal inspection. Refer to AT-94, "TCM
Value" .
AT



OK or NG
OK
>> GO TO 5.
NG
1.
2.
AT-229
http://vnx.su

[EURO-OBD]
Vehicle Does Not Start From D1
ECS004T9
SYMPTOM:
Vehicle does not start from D1 on Cruise test Part 2.

Does self-diagnosis show damage to vehicle speed sensorA/T (revolution sensor), shift solenoid valve A, B or
vehicle speed sensorMTR after cruise test?
NO
>> GO TO 2.
2. CHECK SYMPTOM
OK or NG
OK
>> GO TO AT-214, "Vehicle Cannot Be Started From D1" .
NG
Value" .
AT-230
http://vnx.su

[EURO-OBD]
A/T Does Not Shift: D4 D3 , When Overdrive Control Switch ON OFF

ECS004TA
SYMPTOM:
when changing overdrive control switch to OFF position.
1. CHECK OVERDRIVE CONTROL SWITCH CIRCUIT
Check overdrive control switch circuit. Refer to AT-237, "TCM Self-diagnosis Does Not Activate" .
OK or NG
AT
OK
>> GO TO AT-220, "A/T Does Not Shift: D2 D3" .
NG
>> Check overdrive control switch circuit. Refer to AT-237, "TCM Self-diagnosis Does Not Activate" .
D
AT-231
http://vnx.su

[EURO-OBD]
A/T Does Not Shift: D3 22 , When Selector Lever D 2 Position

SYMPTOM:
A/T does not shift from D3 to 22
ECS004TB
when changing selector lever from D to 2 position.
1. CHECK PNP SWITCH CIRCUIT

Check PNP switch circuit. Refer to AT-100, "DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH" .
OK or NG
OK
>> GO TO AT-217, "A/T Does Not Shift: D1 D2 Or Does Not Kickdown: D4 D2" .
NG
>> Check PNP switch circuit. Refer to AT-100, "DTC P0705 PARK/NEUTRAL POSITION (PNP)
SWITCH" .
AT-232
http://vnx.su

[EURO-OBD]
A/T Does Not Shift: 22 11 , When Selector Lever 2 1 Position

SYMPTOM:
A/T does not shift from 22 to 11
ECS004TC
when changing selector lever from 2 to 1 position.

B
AT
OK or NG
OK
>> GO TO 2.
NG
>> Check PNP switch circuit. Refer to AT-100, "DTC P0705 PARK/NEUTRAL POSITION (PNP) D
SWITCH" .

OK or NG
OK
>> GO TO 3.
NG
Adjustment" .
H
SAT023JB
SENSORMTR CIRCUIT
SPEED SENSOR MTR" .
OK or NG
OK
>> GO TO 4.
NG
circuits.

CHECK" .
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.
1.
2.
SAT171B
AT-233
http://vnx.su

[EURO-OBD]

Shift valve A

Brake band
OK or NG
OK
>> GO TO 6.
NG
1.
2.
6. CHECK SYMPTOM
OK or NG
OK
>> INSPECTION END
NG
>> 1. Perform TCM input/output signal inspection. Refer to
AT-94, "TCM Terminals and Reference Value" .
2. If NG, recheck TCM pin terminals for damage or loose
connection with harness connector.
SAT778B
AT-234
http://vnx.su

[EURO-OBD]
Vehicle Does Not Decelerate By Engine Brake
ECS004TD
SYMPTOM:
Vehicle does not decelerate by engine brake when turning overdrive control switch OFF.
Vehicle does not decelerate by engine brake when shifting A/T from D to 2 position.
Vehicle does not decelerate by engine brake when shifting from 22 (12 ) to 11 .
AT
OK or NG
OK
>> GO TO 2.
NG
>> Check PNP switch circuit. Refer to AT-100, "DTC P0705 PARK/NEUTRAL POSITION (PNP)
SWITCH" .

OK or NG
OK
>> GO TO 3.
NG
Adjustment" .
SAT023JB
SENSORMTR CIRCUIT
SPEED SENSOR MTR" .
OK or NG
OK
>> GO TO 4.
NG
circuits.

M

CHECK" .
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.
1.
2.
SAT171B
AT-235
http://vnx.su

[EURO-OBD]

Shift valve A
Low & reverse bake assembly

OK or NG
OK
>> GO TO 6.
NG
1.
2.
6. CHECK SYMPTOM
OK or NG
OK
>> INSPECTION END
NG
SAT778B
AT-236
http://vnx.su

[EURO-OBD]
TCM Self-diagnosis Does Not Activate
ECS004TE
SYMPTOM:
O/D OFF indicator lamp does not come on in TCM self-diagnostic procedure even if the lamp circuit is
good.
DESCRIPTION
PNP switch
The PNP switch assembly includes a transaxle position switch.
The transaxle position switch detects the selector lever position
AT
E
SCIA0752E

Detects the overdrive control switch position (ON or OFF) and
sends a signal to the TCM.
I
SCIA0776E
Closed throttle position signal and wide open throttle position

signal
ECM judges throttle opening based on a signal from accelerator
pedal position sensor, and sends the signal via CAN communication to TCM.
PBIB0498E
AT-237
http://vnx.su

[EURO-OBD]

With CONSULT-II
3. Read out P/N, R, D, 2 and 1 position switches moving selector lever to each position.
properly.
OK or NG
OK
>> GO TO 3.
NG
PNP switch
(Refer to AT-240, "COMPONENT
INSPECTION" .)
PNP switch
Harness for short or open between PNP switch and
TCM
Diode (P, N positions)
SAT701J
2. CHECK PNP SWITCH CIRCUIT (WITHOUT CONSULT-II)

Without CONSULT-II
2. Check voltage between TCM terminals 26, 27, 34, 35, 36 and
Voltage:
B: Battery voltage
0: 0V
Terminal No.
Lever position
36
35
34
27
26
P, N
OK or NG
OK
>> GO TO 3.
NG
PNP switch
(Refer to AT-240, "COMPONENT
INSPECTION" .)
PNP switch
Harness for short or open between PNP switch and TCM
AT-238
http://vnx.su
SCIA0777E

[EURO-OBD]
With CONSULT-II
3. Read out OVERDRIVE SWITCH.
Check the signal of the overdrive control switch is indicated properly.
(Overdrive control switch ON displayed on CONSULT-II means
overdrive OFF.)
OK or NG
OK
>> GO TO 4.
NG
Overdrive control switch (Refer to AT-240, "COMPONENT INSPECTION" .)
Harness for short or open between Combination
meter and overdrive control switch
Harness of ground circuit for overdrive control switch
for short or open
Combination Meter (Refer to DI-4, "COMBINATION METERS" .)
AT
F
SAT645J
4. CHECK CLOSED THROTTLE POSITION AND WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT
(WITH CONSULT-II)
H
With CONSULT-II
3. Read out CLOSED THL/SW and W/O THRL-SW depressing and releasing accelerator pedal.
Check the signal of throttle position signal is indicated properly.
SAT646J
Accelerator pedal
condition
Data monitor
CLOSED THL/SW
W/O THRL-SW
Released
ON
OFF
Fully depressed
OFF
ON
OK or NG
OK
>> GO TO 5.
NG
>> Check the following items. If any items are damaged, repair or replace damaged parts.
Accelerator pedal position sensor Refer to AT-173, "DTC P1705 ACCELERATOR PEDAL
POSITION (APP) SENSOR" .
Harness for short or open between accelerator pedal position sensor and ECM
AT-239
http://vnx.su

[EURO-OBD]
(WITHOUT CONSULT-II)
Without CONSULT-II
Accelerator pedal position sensor Refer to AT-173, "DTC P1705 ACCELERATOR PEDAL POSITION
(APP) SENSOR" .
OK or NG
OK
>> GO TO 6.
NG
6. CHECK DTC
Perform AT-52, "TCM SELF-DIAGNOSTIC PROCEDURE (NO TOOLS)" .
OK or NG
OK
>> INSPECTION END
NG
>> Perform TCM input/output signal inspection. Refer to AT-94, "TCM Terminals and Reference
Value" .
If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
COMPONENT INSPECTION
Overdrive Control Switch
Check continuity between two terminals 1 and 2.

Switch position
Continuity
ON
No
OFF
Yes
SCIA4647E
AT-240
http://vnx.su

[EURO-OBD]
PNP Switch
1.
Check continuity between terminals 1 and 2, and between terminals 3 and 4, 5, 6, 7, 8, 9 while moving manual shaft through
each position.
Lever position
Terminal No.
37
38
39
36
35
34
12
AT
12
G
SCIA0754E
2.
3.
4.
5.
6.
If NG, check again with manual control cable disconnected from

manual shaft of A/T assembly. Refer to step 1.
If OK on step 2, adjust manual control cable. Refer to AT-409,
"Control Cable Adjustment" .
If NG on step 2, remove PNP switch from A/T and check continuity of PNP switch terminals. Refer to step 1.
If OK on step 4, adjust PNP switch. Refer to AT-409, "Control
Cable Adjustment" .
If NG on step 4, replace PNP switch.
K
SAT089JA
AT-241
http://vnx.su

[EXC.F/EURO-OBD]

CONSULT-II
[EXC.F/EURO-OBD]
PFP:00000
ECS004NW
After performing AT-242, "SELF-DIAGNOSTIC PROCEDURE (WITH CONSULT-II)" , place check marks for
results on the AT-252, "DIAGNOSTIC WORKSHEET" . Reference pages are provided following the items.
NOTICE:
1. The CONSULT-II electrically displays shift timing and lock-up timing (that is, operation timing of each solenoid).
Check for time difference between actual shift timing and the CONSULT-II display. If the difference is
noticeable, mechanical parts (except solenoids, sensors, etc.) may be malfunctioning. Check mechanical
parts using applicable diagnostic procedures.
2. Shift schedule (which implies gear position) displayed on CONSULT-II and that indicated in Service Manual may differ slightly. This occurs because of the following reasons:
Actual shift schedule has more or less tolerance or allowance,
Shift schedule indicated in Service Manual refers to the point where shifts start, and
Gear position displayed on CONSULT-II indicates the point where shifts are completed.
3. Shift solenoid valve A or B is displayed on CONSULT-II at the start of shifting. Gear position is displayed upon completion of shifting (which is computed by TCM).
4. Additional CONSULT-II information can be found in the Operation Manual supplied with the CONSULT-II
unit.
FUNCTION
Function
Reference page
Work support
This mode enables a technician to adjust some devices faster and more accurately by
following the indications on CONSULT-II.
Self-diagnostic results can be read and erased quickly.
AT-242
Data monitor
AT-244

monitor
Function test
Conducted by CONSULT-II instead of a technician to determine whether each system

is OK or NG.
DTC work support
Select the operating condition to confirm Diagnosis Trouble Codes.
TCM part number
TCM part number can be read.
AT-47
SELF-DIAGNOSTIC PROCEDURE (WITH CONSULT-II)

1.
Turn on CONSULT-II and touch A/T for TCM self-diagnosis.

If A/T is not displayed, check TCM power supply and ground circuit. Refer to AT-286, "TCM Terminals and Reference Value" . If
result is NG, refer to PG-2, "POWER SUPPLY ROUTING" .
SAT014K
AT-242
http://vnx.su

[EXC.F/EURO-OBD]
2.

Display shows malfunction experienced since the last erasing
operation.
CONSULT-II performs REAL TIME DIAG.
Also, any malfunction detected while in this mode will be displayed at real time.
AT
SAT987J
SELF-DIAGNOSTIC RESULT TEST MODE

No failure
(NO SELF DIAGNOSTIC FAILURE INDICATED FURTHER
TESTING MAY BE REQUIRED)
Remarks
No failure has been detected.
This is not a malfunction message (Whenever shutting off a power

supply to the TCM, this message appears on the screen.)
VHCL SPEED SENA/T
VHCL SPEED SENMTR
THROTTLE POSI SEN
TCM detects an improper voltage drop when it tries to operate the

solenoid valve.

solenoid valve.

solenoid valve.

solenoid valve.
BATT/FLUID TEMP SEN
ENGINE SPEED SIG
TCM does not receive the proper voltage signal from the ECM.

solenoid valve.
CAN COMM CIRCUIT
When malfunction is detected in CAN communication line.
CONTROL UNIT (RAM)
TCM memory (RAM) is malfunctioning
Refer to AT-286
CONTROL UNIT (ROM)
TCM memory (ROM) is malfunctioning
Refer to AT-286
CONT UNIT (EEP ROM)
Refer to AT-286
INITIAL START
SHIFT SOLENOID/V A
SHIFT SOLENOID/V B
OVERRUN CLUTCH S/V
T/C CLUTCH SOL/V
LINE PRESSURE S/V
J
To be displayed in case
of abnormality and when
no recording is made.
CAUTION:
If malfunction is detected in multiple systems including CAN communication line, CAN communication line trouble diagnosis
shall be performed first.
AT-243
http://vnx.su

[EXC.F/EURO-OBD]
DATA MONITOR MODE (A/T)
X: Standard, : Not applicable,
: Option
SELECT MONITOR ITEM

Monitor item (Unit)
SELECTION FROM
MENU
Remarks
TCM INPUT
SIGNALS
MAIN SIGNALS
When racing engine in N or P with vehicle stationary,

CONSULT-II data may not indicate 0 km/h (0 mph).
Vehicle speed display may not be accurate under

approx. 10 km/h (6 mph). It may not indicate 0 km/h (0
mph) when vehicle is stationary.
THRTL POS SEN

[V]
FLUID TEMP SE
[V]
BATTERY VOLT
[V]
OVERDRIVE SW
[ON/OFF]
PN POSI SW
[ON/OFF]
R POSITION SW
[ON/OFF]
D POSITION SW
[ON/OFF]
2 POSITION SW
[ON/OFF]
1 POSITION SW
[ON/OFF]
ASCDCRUISE
[ON/OFF]
ASCDOD CUT
[ON/OFF]
KICKDOWN SW
[ON/OFF]
CLOSED THL/SW
[ON/OFF]
W/O THRL/P-SW
[ON/OFF]
GEAR
VEHICLE SPEED
[km/h] or [mph]
TC SLIP
RATIO
[0.000]
TC SLIP
SPEED
[rpm]
VHCL/S SEA/T
[km/h] or [mph]
VHCL/S SEMTR
[km/h] or [mph]
ENGINE SPEED
[rpm]
SLCT LVR POSI
Engine speed display may not be accurate under

approx. 800 rpm. It may not indicate 0 rpm even when
engine is not running.
This is displayed even when no ASCD is mounted.
This is displayed even when no ASCD is mounted.
This is displayed even when no kick down switch is

equipped.
This means closed throttle position signal input via

CAN communication line.
This means wide open throttle position signal input

via CAN communication line.
A specific value used for control is displayed if failsafe is activated due to error.
Display doesn't indicate o rpm even if engine is

stopped.
But this isn't malfunction.
AT-244
http://vnx.su

[EXC.F/EURO-OBD]
SELECT MONITOR ITEM
Monitor item (Unit)
TCM INPUT
SIGNALS
MAIN SIGNALS
THROTTLE POSI
[/8]
BRAKE SW
[ON/OFF]
LINE PRES DTY

[%]
TCC S/V DUTY

[%]
SHIFT S/V A
[ON/OFF]
SHIFT S/V B
[ON/OFF]
OVERRUN/C S/V
[ON/OFF]
SELF-D DP LMP
[ON/OFF]
Voltage [V]
Frequency [Hz]
DUTY-HI [%]
DUTY-LOW [%]
PLS WIDTH-HI [msec]
PLS WIDTH-LOW [msec]
SELECTION FROM
MENU
Remarks
A specific value used for control is displayed if failsafe is activated due to error.
AT
D
Control value of solenoid is displayed even if solenoid
circuit is disconnected.
The OFF signal is displayed if solenoid circuit is
shorted.
2.
HOW TO ERASE SELF-DIAGNOSTIC RESULTS (WITH CONSULT-II)

1.
If the ignition switch stays ON after repair work, be sure to turn

ignition switch OFF once. Wait for at least 3 seconds and then
turn it ON again.
Turn CONSULT-II ON, and touch A/T.
M
SAT014K
3.
SCIA5358E
AT-245
http://vnx.su

[EXC.F/EURO-OBD]
4.
Touch ERASE. (The self-diagnostic results will be erased.)
SAT970J
Diagnostic Procedure Without CONSULT-II
ECS004NX
SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)

1.
2.
3.
4.
Selector lever in P position.

Wait 5 seconds.
Set overdrive control switch to ON.
SAT774B

YES >> GO TO 2.
NO
>> GO TO AT-291, "O/D OFF Indicator Lamp Does Not
Come On" .
SCIA5468E

1.
2.
3.
4.

Move selector lever to D.
Set overdrive control switch to OFF.
Wait more than 2 seconds after turning ignition switch ON.
>> GO TO 3.
SAT653E
AT-246
http://vnx.su

[EXC.F/EURO-OBD]

1.
2.

Set overdrive control switch to ON.
B
>> GO TO 4.
AT
D
SAT780B

1.
2.

Set overdrive control switch to OFF.
>> GO TO 5.
G
SAT781B

1.
Depress accelerator pedal fully and release it.

>> GO TO 6.
SAT981F
6. CHECK SELF-DIAGNOSIS CODE

Check O/D OFF indicator lamp. Refer to AT-248, "JUDGEMENT OF
SELF-DIAGNOSIS CODE" .
>> DIAGNOSIS END
SCIA5468E
AT-247
http://vnx.su

[EXC.F/EURO-OBD]
JUDGEMENT OF SELF-DIAGNOSIS CODE
O/D OFF indicator lamp:
All judgement flickers are the same.
1st judgement flicker is longer than others.
SCIA4672E
SCIA5591E
All circuits that can be confirmed by self-diagnosis are OK.
Revolution sensor circuit is short-circuited or disconnected.

Go to VEHICLE SPEED SENSORA/T (REVOLUTION SENSOR).
Refer to AT-332
2nd judgement flicker is longer than others.
3rd judgement flicker is longer than others.
SCIA5592E
SCIA5593E
Vehicle speed sensor circuit is short-circuited or disconnected.

Go to VEHICLE SPEED SENSORMTR.
Refer to AT-339
Accelerator pedal position (APP) sensor circuit is short-circuited

or disconnected.
Go to ACCELERATOR PEDAL POSITION (APP) SENSOR.
Refer to AT-345
SCIA5594E
SCIA5595E
Shift solenoid valve A circuit is short-circuited or disconnected.

Go to SHIFT SOLENOID VALVE A.
Refer to AT-350
Shift solenoid valve B circuit is short-circuited or disconnected.

Go to SHIFT SOLENOID VALVE B.
Refer to AT-356
AT-248
http://vnx.su

[EXC.F/EURO-OBD]
AT
D
SCIA5596E
SCIA5597E
E
Overrun clutch solenoid valve circuit is short-circuited or disconnected.
Go to OVERRUN CLUTCH SOLENOID VALVE.
Refer to AT-362
Torque converter clutch solenoid valve circuit is short-circuited or

disconnected.
Go to TORQUE CONVERTER CLUTCH SOLENOID VALVE.
Refer to AT-368
SCIA5598E
SCIA5599E
A/T fluid temperature sensor is disconnected or TCM power

source circuit is damaged.
Go to BATT/FLUID TEMP SEN(A/T FLUID TEMP SENSOR
CIRCUIT AND TCM POWER SOURCE).
Refer to AT-374
Engine speed signal circuit is short-circuited or disconnected.

Go to ENGINE SPEED SIGNAL.
Refer to AT-382
AT-249
http://vnx.su

[EXC.F/EURO-OBD]
SCIA5600E
SCIA4673E
Line pressure solenoid valve circuit is short-circuited or disconnected.

Go to LINE PRESSURE SOLENOID VALVE.
Refer to AT-387
CAN communication line is damaged.

Go to CAN COMMUNICATION LINE.
Refer to AT-329
Lamp comes OFF.
Flickers as shown below.
SCIA4674E
SCIA4675E
PNP switch, overdrive control switch, closed throttle position signal or wide-open throttle position signal circuit is disconnected or
TCM is damaged.
(Because closed throttle position signal and wide-open throttle
position signal are input via CAN communication line malfunction
may continue after self-diagnosis.)
Go to TCM Self-diagnosis Does Not Activate.
Refer to AT-324
t1 = 2.5 seconds
t2 = 2.0 seconds
t3 = 1.0 second
Battery power is low.

Battery has been disconnected for a long time.
Battery is connected conversely.
(When reconnecting TCM connectors.This is a problem.)
t4 = 1.0 second
HOW TO ERASE SELF-DIAGNOSTIC RESULTS (WITHOUT CONSULT-II)

1.
2.
3.
If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait for at least
3 seconds and then turn it ON again.
Perform SELF-DIAGNOSTIC PROCEDURE (Without CONSULT-II). Refer to AT-246, "Diagnostic Procedure Without CONSULT-II" .
Turn ignition switch OFF. (The self-diagnostic results will be erased.)
AT-250
http://vnx.su

[EXC.F/EURO-OBD]

Introduction
The TCM receives a signal from the vehicle speed sensor, throttle
position sensor or PNP switch and provides shift control or lock-up
control via A/T solenoid valves.
Input and output signals must always be correct and stable in the
operation of the A/T system. The A/T system must be in good operating condition and be free of valve seizure, solenoid valve malfunction, etc.
It is much more difficult to diagnose a problem that occurs intermittently rather than continuously. Most intermittent problems are
A visual check only, may not find the cause of the problems. A road
test with CONSULT-II or a circuit tester connected should be performed. Follow the Work Flow. Refer to AT-61 .
customer who approaches with a drive ability complaint. The customer can supply good information about such problems, especially
what conditions they occur. A Diagnostic Worksheet like the example (AT-58 ) should be used.
Start your diagnosis by looking for conventional problems first. This
will help troubleshoot drive ability problems on an electronically controlled engine vehicle.
Also check related Service bulletins for information.
PFP:00000
A
ECS004TF
AT
D
SAT631IA
H
SAT632I
K
SEF234G
AT-251
http://vnx.su

[EXC.F/EURO-OBD]
Information from Customer
KEY POINTS
WHAT..... Vehicle & A/T model
WHEN..... Date, Frequencies
WHERE..... Road conditions
HOW..... Operating conditions, Symptoms

Customer name
MR/MS
Model & Year
VIN
Trans. model
Engine
Mileage
Incident Date
Manuf. Date
In Service Date
Frequency
Continuous
Symptoms
Vehicle does not move.

No up-shift
Intermittent (
( Any position
( 1st 2nd
No down-shift
times a day)
2nd 3rd
( O/D 3rd
Particular position)
3rd O/D)
3rd 2nd
2nd 1st)
Lockup malfunction
Shift point too high or too low.
Shift shock or slip
( N D
Lockup
Any drive position)
Noise or vibration
No kick down
No pattern select
Others
(
Continuously lit
)
Not lit
AT-252
http://vnx.su

[EXC.F/EURO-OBD]
Diagnostic Worksheet
1.
Read the Fail-safe and listen to customer complaints.
AT-11,
AT-252
2.
Check A/T fluid
AT-256
Leakage (Follow specified procedure)

Fluid condition
Fluid level
3.
Perform Stall Test and Line Pressure Test.

Stall test Mark possible damaged components/others.
Torque converter one-way clutch
Reverse clutch
Forward clutch
Overrun clutch
AT-257,
AT-260
Low & reverse brake

Low one-way clutch
Engine
Line pressure is low
Clutches and brakes except high clutch and
brake band are OK
AT
Line Pressure test Suspected parts:

4.
Perform all Road Test and mark required procedures.
AT-262
4-1.
AT-263
Check before engine is started.

O/D OFF Indicator Lamp Does Not Come On, AT-291 .
SELF-DIAGNOSTIC CONFIRMATION PROCEDURE Mark detected items.

Accelerator pedal position (APP) sensor, AT-345 .
A/T fluid temperature sensor and TCM power source, AT-374 .
Battery
Others
4-2.
Check at idle
K
AT-264
Engine Cannot Be Started In P And N Position, AT-293 .

In P Position, Vehicle Moves Forward Or Backward When Pushed, AT-294 .
In N Position, Vehicle Moves, AT-295 .
Large Shock. N R Position, AT-296 .
Vehicle Does Not Creep Backward In R Position, AT-297 .
Vehicle Does Not Creep Forward In D, 2 Or 1 Position, AT-299 .
AT-253
http://vnx.su

[EXC.F/EURO-OBD]
4.
4-3.
Cruise test
AT-266,
AT-270
Part-1
Vehicle Cannot Be Started From D1 , AT-301 .
A/T Does Not Perform Lock-up,AT-311 .
A/T Does Not Hold Lock-up Condition, AT-312 .
Lock-up Is Not Released, AT-314 .
Engine Speed Does Not Return To Idle (Light Braking D4 D3 ), AT-315 .
Part-2
AT-273
Vehicle Does Not Start From D1 , AT-317 .

Part-3
AT-275
A/T Does Not Shift: D4 D3 When Overdrive Control Switch ON OFF, AT-318 .
Engine Speed Does Not Return To Idle (Engine Brake In D3 ), AT-315 .
A/T Does Not Shift: D3 22 , When Selector Lever D 2 Position, AT-319 .
Engine Speed Does Not Return To Idle (Engine Brake In 22 ),AT-315 .
A/T Does Not Shift: 22 11 , When Selector Lever 2 1 Position, AT-320 .
Vehicle Does Not Decelerate By Engine Brake, AT-322 .
TCM Self-diagnosis Does Not Activate (PNP & Overdrive Control Switches, and throttle position sensor
Circuit Checks), AT-324 .
SELF-DIAGNOSTIC PROCEDURE Mark detected items.
Accelerator pedal position (APP) sensor, AT-345 .
Batt/fluid temp sen (A/T fluid temperature sensor and TCM power source), AT-374 .
Battery
Others
5.
For self-diagnosis NG items, inspect each component. Repair or replace the damaged parts.
6.
Perform all Road Test and re-mark required procedures.
AT-262
7.
Perform the Diagnostic Procedures for all remaining items marked NG. Repair or replace the damaged parts.
Refer to the Symptom Chart when you perform the procedures. (The chart also shows some other possible
symptoms and the component inspection orders.)
AT-277
8.
Erase self-diagnosis code from TCM memories.
AT-245, AT250
AT-254
http://vnx.su
AT-246

[EXC.F/EURO-OBD]
Work Flow
ECS004TG
HOW TO PERFORM TROUBLE DIAGNOSES FOR QUICK AND ACCURATE REPAIR
A good understanding of the malfunction conditions can make troubleshooting faster and more accurate. In
general, each customer feels differently about a problem. It is important to fully understand the symptoms or
conditions for a customer complaint.
Make good use of the two sheets provided, INFORMATION FROM CUSTOMER (AT-252 ) and DIAGNOSTIC WORKSHEET (AT-253 ), to perform the best troubleshooting possible.
WORK FLOW CHART
AT
SAT097KC
*1
AT-252
*2
AT-253
*3
AT-10
*4
AT-256
*5
AT-257
*6
AT-260
*7
AT-262
*8
AT-246
*9
AT-242
*10 AT-242
*11 AT-332
*12 AT-329
*13 AT-291
*14 AT-322
:15 AT-277
*16 AT-245
*17 AT-250
*18 AT-332
*19 AT-329
AT-255
http://vnx.su

[EXC.F/EURO-OBD]

A/T Fluid Check
PFP:00000
ECS004VR
FLUID LEAKAGE CHECK

1.
2.
3.
Clean area suspected of leaking. for example, mating surface

of converter housing and transaxle case.
Start engine, apply foot brake, place selector lever in D position
and wait a few minutes.
Stop engine.
SAT767B
4.
Check for fresh leakage.
SAT288G
FLUID CONDITION CHECK

Fluid color
Suspected problem
Dark or black with burned odor
Wear of frictional material
Milky pink
Water contamination Road water

entering through filler tube or breather
Varnished fluid, light to dark brown and

tacky
Oxidation Over or under filling,

Overheating
FLUID LEVEL CHECK

Refer to AT-16, "Checking A/T Fluid" .
SAT638A
AT-256
http://vnx.su

[EXC.F/EURO-OBD]
Stall Test
ECS004VS
STALL TEST PROCEDURE

1.
2.
Check A/T fluid and engine oil levels. If necessary, add.

Drive vehicle for approx. 10 minutes or until fluid and oil reach
operating temperature. Refer to AT-17, "Changing A/T Fluid" .
AT
D
SAT647B
3.
4.

Install a tachometer where it can be seen by driver during test.
It is good practice to mark the point of specified engine
rpm on indicator.
SAT513G
5.
6.
7.
Start engine, apply foot brake, and place selector lever in D

position.
Accelerate to wide open throttle gradually while applying foot
brake.
Quickly note the engine stall revolution and immediately release
throttle.
During test, never hold throttle wide open for more than 5
seconds.
Stall revolution:
QR20DE:
QR25DE:
2,450 - 2,950 rpm

2,300 - 2,750 rpm
K
SAT514G
8.
9.
Move selector lever to N position.

Cool off ATF.
Run engine at idle for at least one minute.
10. Repeat steps 5 through 9 with selector lever in 2, 1 and R positions.
SAT771B
AT-257
http://vnx.su

[EXC.F/EURO-OBD]
JUDGEMENT OF STALL TEST
The test result and possible damaged components relating to each result are shown in the illustrations on next
page.
In order to pinpoint the possible damaged components, follow the WORK FLOW shown in AT-255, "Work
Flow" (EXCEPT FOR EURO-OBD).
NOTE:
Stall revolution is too high in D, 2 or 1 position:
Slippage occurs in 1st gear but not in 2nd and 3rd gears...... Low one-way clutch slippage
Slippage occurs in the following gears:

1st through 3rd gears in D position and engine brake functions with overdrive control switch set to OFF.
1st and 2nd gears in 2 position and engine brake functions with accelerator pedal released (fully closed
throttle)...... Forward clutch or forward one-way clutch slippage
Stall revolution is too high in R position:
Engine brake does not function in 1 position...... Low & reverse brake slippage
Engine brake functions in 1 position...... Reverse clutch slippage

Stall revolution within specifications:
Vehicle does not achieve speed of more than 80 km/h (50 MPH)...... One-way clutch seizure in torque
converter housing
CAUTION:
Be careful since automatic fluid temperature increases abnormally.
Slippage occurs in 3rd and 4th gears in D position...... High clutch slippage
Slippage occurs in 2nd and 4th gear in D position...... Brake band slippage
Engine brake does not function in 2nd and 3rd gears in D position, 2nd gear in 2 position, and 1st gear in
1 position with overdrive control switch set to OFF...... Overrun clutch slippage
Stall revolution less than specifications:
Poor acceleration during starts...... One-way clutch slippage in torque converter
AT-258
http://vnx.su

[EXC.F/EURO-OBD]
A
AT
SCIA0707E
AT-259
http://vnx.su

[EXC.F/EURO-OBD]
Line Pressure Test
ECS004VT
LINE PRESSURE TEST PORTS

Location of line pressure test ports are shown in the illustration.
Always replace pressure plugs as they are self-sealing

bolts.
SCIA0709E
LINE PRESSURE TEST PROCEDURE

1.
2.
Check A/T fluid and engine oil levels. If necessary, add fluid or
oil.
Drive vehicle for approx. 10 minutes or until engine oil and ATF
reach operating temperature. Refer to AT-17, "Changing A/T
Fluid" .
SAT647B
3.
Install pressure gauge to corresponding line pressure port.
UAT008
4.

Continue to depress brake pedal fully while line pressure
test is being performed at stall speed.
SAT513G
AT-260
http://vnx.su

[EXC.F/EURO-OBD]
5.
Start engine and measure line pressure at idle and stall speed.
When measuring line pressure at stall speed, follow the
stall test procedure.
AT
SAT493G
LINE PRESSURE
Line pressure
Check lock-up hold.
R position
Idle
500 (5.00, 5.1, 73)
778 (7.78, 7.9, 113)
Stall
1,233 (12.33, 12.6, 179)
1,918 (19.18, 19.6, 278)
JUDGEMENT OF LINE PRESSURE TEST

Judgement
Line pressure is low in all positions.
Line pressure is low in particular position.
Suspected parts
Oil pump wear
Control piston damage
Spring for pressure regulator valve damaged
Fluid pressure leakage between oil strainer and pressure regulator valve
Clogged strainer
Fluid pressure leakage between manual valve and particular clutch
For example, line pressure is:

Low in R and 1 positions, but
Normal in D and 2 positions.
Therefore, fluid leakage exists at or around low and reverse brake circuit.
At idle
Refer to AT-23 .
Line pressure is high.
Line pressure is low.
At stall
speed
A/T fluid temperature sensor damaged
Open in dropping resistor circuit
Pilot valve sticking
AT-261
http://vnx.su

[EXC.F/EURO-OBD]
Road Test
ECS004VU
DESCRIPTION
1.
2.
The purpose of the test is to determine overall performance of A/

T and analyze causes of problems.
The road test consists of the following three parts:
Check before engine is started
Check at idle
SAT786A
3.
Cruise test
Before road test, familiarize yourself with all test procedures and
items to check.
Conduct tests on all items until specified symptom is found.
Troubleshoot items which check out No Good after road test.
Refer to the following items.
Except for
Euro-OBD
TROUBLE DIAGNOSES FOR

SYMPTOMS
AT-242 to AT-246
AT-291 to AT-324
SAT496G
AT-262
http://vnx.su

[EXC.F/EURO-OBD]
1. CHECK BEFORE ENGINE IS STARTED
A

1.
2.
3.
4.
5.

Wait 5 seconds.
AT
E
SAT774B

YES >> 1. Turn ignition switch to OFF position.
2. Perform self-diagnosis and note NG items.
Refer to AT-246, "SELF-DIAGNOSTIC PROCEDURE
(WITHOUT CONSULT-II)" .
3. GO TO 2. CHECK AT IDLE, AT-264 .
NO
>> Stop road test. GO TO O/D OFF indicator Lamp Does
Not Come On. AT-291 .
H
SCIA5468E
AT-263
http://vnx.su

[EXC.F/EURO-OBD]
2. CHECK AT IDLE

1. Park vehicle on flat surface.
2. Move selector lever to P or N position.
3. Turn ignition switch to OFF position.
4. Turn ignition switch to START position.
Is engine started?
YES >> GO TO 2.
NO
>> Stop Road Test. Mark the box on the DIAGNOSTIC
WORKSHEET. Refer to AT-252, "DIAGNOSTIC
WORKSHEET" .
N Position" .
SAT769B

1. Turn ignition switch to ON position. (Do not start engine.)
2. Move selector lever to D, 1, 2 or R position.
3. Turn ignition switch to START.
Is engine started?
YES >> Stop Road Test. Mark the box on the DIAGNOSTIC
WORKSHEET. Refer to AT-252, "DIAGNOSTIC
WORKSHEET" .
N Position" .
Continue Road Test. Refer to AT-262, "Road Test" .
NO
>> GO TO 3.
SAT770B

1.
2.
3.

Release parking brake.
SAT768B
4. Push vehicle forward or backward.

Does vehicle move when it is pushed forward or backward?
Refer to AT-252, "DIAGNOSTIC WORKSHEET" .
GO TO AT-294, "In P Position, Vehicle Moves Forward Or Backward When Pushed" .
Continue Road Test.
NO
>> GO TO 4.
SAT796A
AT-264
http://vnx.su

[EXC.F/EURO-OBD]
A
1. Apply parking brake.
2. Start engine.
B
3. Move selector lever to N position.
4. Release parking brake.
Does vehicle move forward or backward?
AT
YES >> Mark the box on the DIAGNOSTIC WORKSHEET. Refer to AT-252, "DIAGNOSTIC WORKSHEET" .
GO TO AT-295, "In N Position, Vehicle Moves" .
D
Continue Road Test.
NO
>> GO TO 5.
E
5. CHECK SHIFT SHOCK

1.
Apply foot brake.

F
H
SAT797A

Is there large shock when changing from N to R position?
GO TO AT-296, "Large Shock. N R Position" .
Continue Road Test.
NO
>> GO TO 6.
L
SAT772B
Release foot brake for several seconds.

Does vehicle creep backward when foot brake is released?
YES >> GO TO 7.
NO
GO TO AT-297, "Vehicle Does Not Creep Backward
In R Position" .
Continue Road Test.
SAT799A
AT-265
http://vnx.su

[EXC.F/EURO-OBD]

1.
Move selector lever to D, 2 and 1 positions and check if vehicle

creeps forward.
Does vehicle creep forward in all three position?
YES >> GO TO AT-266, "3. CRUISE TEST" .
NO
GO TO AT-299, "Vehicle Does Not Creep Forward In
D, 2 Or 1 Position" .
Continue Road Test.
SAT773B
3. CRUISE TEST
Check all items listed in Parts 1 through 3.
SAT601J
With CONSULT-II
Using CONSULT-II, conduct a cruise test and record the result.

Print the result and ensure that shifts and lock-ups take place as per Shift Schedule.

1.
2.

link connector, which is located in instrument lower panel on
driver side.
SCIA0691E
SCIA0692E
AT-266
http://vnx.su

[EXC.F/EURO-OBD]
3.
4.

AT
SAIA0450E
5.
Touch A/T.
G
SAT014K
6.
Touch DATA MONITOR.
SCIA5358E
7.
8.
Touch MAIN SIGNALS or TCM INPUT SIGNALS.

Select Numerical Display, Barchart Display or Line Graph
Display.
SAT175K
AT-267
http://vnx.su

[EXC.F/EURO-OBD]
9.
Touch SETTING to recording condition (AUTO TRIG or

MANU TRIG) and touch BACK.
10. Touch Start.
SAT973J
11. When performing cruise test, touch RECORD.
SAT134K
12. After finishing cruise test part 1, touch STOP.
SAT135K
13. Touch STORE and touch BACK.
SAT987J
AT-268
http://vnx.su

[EXC.F/EURO-OBD]
A
AT
SAT974J
14.
15.
16.
17.
Touch DISPLAY.
Touch PRINT.
Check the monitor data printed out.
Continue cruise test part 2 and 3.
G
SAT975J
Without CONSULT-II
Throttle position sensor can be checked by voltage across terminals 41 and 42 of TCM.
SCIA0710E
AT-269
http://vnx.su

[EXC.F/EURO-OBD]
Cruise Test Part 1

1.
Drive vehicle for approximately 10 minutes to warm engine oil and ATF up to operating temperature.
ATF operating temperature:
2.
3.
4.
5.
50 - 80C (122 - 176F)

Start engine.
SAT774B
6.
SAT775B
7.
Accelerate vehicle by constantly depressing accelerator pedal

halfway.

MODE (A/T)" .
YES >> GO TO 2.
NO
GO TO AT-301, "Vehicle Cannot Be Started From D1"
.
Continue Road Test.
AT-270
http://vnx.su
SAT495G

[EXC.F/EURO-OBD]
TO D2 )
A
B
AT
YES >> GO TO 3.
NO
D
Continue Road Test.
E
SAT954I
TO D3 )

YES >> GO TO 4.
NO
Continue Road Test.
J
SAT955I
TO D4 )

YES >> GO TO 5.
NO
Continue Road Test.
SAT956I
AT-271
http://vnx.su

[EXC.F/EURO-OBD]
5. CHECK LOCK-UP (D4
TO D4 L/U)
Check lock-up (D4 to D4 L/U).

Specified speed when lock-up occurs. Refer to AT-530, "VEHICLE SPEED WHEN PERFORMING LOCK-UP"
.
Read vehicle speed, throttle opening when lock-up duty
becomes 94%. Refer to AT-244, "DATA MONITOR MODE (A/T)" .
Does A/T perform lock-up at the specified speed?
YES >> GO TO 6.
NO
GO TO AT-311, "A/T Does Not Perform Lock-up" .
Continue Road Test.
SAT957I
6. CHECK HOLD LOCK-UP

Continue Road Test.
When lock-up duty becomes 94%. Refer to AT-244, "DATA MONITOR MODE (A/T)" .
Does A/T hold lock-up condition for more than 30 seconds?
YES >> GO TO 7.
NO
GO TO AT-312, "A/T Does Not Hold Lock-up Condition" .
Continue Road Test.
7. CHECK SHIFT DOWN (D4
L/U TO D4 )

When lock-up duty becomes 4%. Refer to AT-244, "DATA
Is lock-up released when accelerator pedal is released?
YES >> GO TO 8.
NO
GO TO AT-314, "Lock-up Is Not Released" .
Continue Road Test.
SAT958I
TO D3 )
Decelerate vehicle by applying foot brake lightly.

Read gear position and engine speed. Refer to AT-244,
Does engine speed return to idle smoothly when A/T is shifted from
D4 to D3 ?
2. GO TO AT-273, "Cruise Test Part 2" .
NO
GO TO AT-315, "Engine Speed Does Not Return To
Idle (Light Braking D4 D3 )" .
Continue Road Test.
AT-272
http://vnx.su
SAT959I

[EXC.F/EURO-OBD]
Cruise Test Part 2
A

1.
2.
Confirm selector lever is in D.

Accelerate vehicle by half throttle again.

(A/T)" .
YES >> GO TO 2.
NO
GO TO AT-317, "Vehicle Does Not Start From D1" .
Continue Road Test.
AT
E
SAT495G
2. CHECK SHIFT UP AND SHIFT DOWN (D3

1.
2.
TO D4 TO D2 )
F
Accelerate vehicle to 80 km/h (50 MPH) as shown in illustration.

Release accelerator pedal and then quickly depress it fully.
Read gear position and throttle position. Refer to AT-244,

Does A/T shift from D4 to D2 as soon as accelerator pedal is
depressed fully?
YES >> GO TO 3.
NO
Continue Road Test.
I
SAT404H
TO D3 )
Check shift-up (D2 to D3 )

Specified speed when shifting from D2 to D3 . Refer to AT-530, "VEHICLE SPEED WHEN SHIFTING GEARS
YES >> GO TO 4.
NO
Continue Road Test.
SAT960I
AT-273
http://vnx.su

[EXC.F/EURO-OBD]
TO D4 ) AND ENGINE BRAKE
Release accelerator pedal after shifting from D2 to D3 .

Read gear position, throttle position and vehicle speed.
Does A/T shift from D3 to D4 and does vehicle decelerate by engine
brake?
2. GO TO AT-275, "Cruise Test Part 3" .
NO
Continue Road Test.
AT-274
http://vnx.su
SAT405H

[EXC.F/EURO-OBD]
Cruise Test Part 3

1.
2.
3.
TO D3 )
Confirm overdrive control switch is in ON.

Confirm selector lever is in D position.
Accelerate vehicle using half-throttle to D4 .
AT
E
SAT812A
4.
I
SAT813A
5.
Set overdrive control switch to OFF while driving in D4 .
Read gear position and vehicle speed. Refer to AT-244,

Does A/T shift from D4 to D3 (O/D OFF)?
YES >> GO TO 2.
NO
GO TO AT-318, "A/T Does Not Shift: D4 D3 , When
Overdrive Control Switch ON OFF" .
Continue Road Test.
SAT776BA

Check engine brake.
YES >> GO TO 3.
NO
Engine Brake" .
Continue Road Test.
SAT776BA
AT-275
http://vnx.su

[EXC.F/EURO-OBD]
TO 22 )
Move selector lever from D to 2 position while driving in D3 (O/D OFF).

(A/T)" .
Does A/T shift from D3 (O/D OFF) to 22 ?
YES >> GO TO 4.
NO
GO TO AT-319, "A/T Does Not Shift: D3 22 , When
Selector Lever D 2 Position" .
Continue Road Test.
SAT791GA

Check engine brake.
YES >> GO TO 5.
NO
Engine Brake" .
Continue Road Test.
SAT791GA
5. CHECK SHIFT DOWN

Move selector lever from 2 to 1 position while driving in 22 .
(A/T)" .
Does A/T shift from 22 to 11 position?
YES >> GO TO 6.
NO
GO TO AT-320, "A/T Does Not Shift: 22 11 , When
Selector Lever 2 1 Position" .
Continue Road Test.
SAT778B

Check engine brake.
2. Perform self-diagnosis.
Except for Euro-OBD: Refer to AT-246, "SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)" ,
NO
Engine Brake" .
Stop Road Test.
AT-276
http://vnx.su
SAT778B

[EXC.F/EURO-OBD]

Symptom Chart
Numbers are arranged in order of inspection.
Perform inspections starting with number one and work up.
Symptom
Condition
Engine cannot start in P and N
positions.
AT-293
Engine starts in position other than
N and P positions.
AT-293
AT-409
3. PNP switch
AT-324
AT-409
2. PNP switch
AT-324
1. Fluid level
AT-256
AT-260
AT-345

AT-332,
AT-339
5. Oil pump
AT-443
6. Torque converter
AT-423
ON vehicle
AT-409
OFF vehicle
AT-416,
AT-440
ON vehicle
AT-409
2. Forward clutch
AT-475
3. Reverse clutch
AT-464
4. Overrun clutch
AT-475
AT-409
2. Stall test
AT-257
AT-260
AT-387
AT-404
6. Reverse clutch
AT-464
7. High clutch
AT-469
8. Forward clutch
AT-475
9. Overrun clutch
AT-475
AT-483
1. Fluid level
AT-256
AT-260
AT-387
AT-404
5. High clutch
AT-469
6. Brake band
AT-497
7. Forward clutch
AT-475
8. Overrun clutch
AT-475
ON vehicle
ON vehicle
OFF vehicle
Vehicle will not run in R position (but

runs in D, 2 and 1 positions).
Clutch slips.
AT-297
Vehicle will not run in R position (but

runs in D, 2 and 1 positions).
Clutch slips.
AT-297
Reference Page
PG-2,
SC-22
ON vehicle
Vehicle runs in N position.

AT-295
A
ECS004VV
1. Ignition switch and starter
Transaxle noise in P and N positions.
Vehicle moves when changing into P

position, or parking gear does not disengage when shifted out of P position.
AT-294
Diagnostic Item
PFP:00000
OFF vehicle
ON vehicle
OFF vehicle
ON vehicle
Vehicle braked when shifting into R
position.
OFF vehicle
AT-277
http://vnx.su
AT

[EXC.F/EURO-OBD]
Symptom
Sharp shock in shifting from N to D

position.
Vehicle will not run in D and 2 positions (but runs in 1 and R positions).
Vehicle will not run in D, 1, 2 positions (but runs in R position). Clutch

slips. Very poor acceleration.
AT-299
Vehicle will not run in D, 1, 2 positions (but runs in R position). Clutch

slips. Very poor acceleration.
AT-299
Condition
Reference Page
EC-555
AT-345
AT-260
4. A/T fluid temp sen circ and TCM pow

sour
AT-374
AT-382
AT-387
AT-404
8. Accumulator N-D
AT-404
OFF vehicle
9. Forward clutch
AT-475
ON vehicle
AT-409
OFF vehicle
AT-416,
AT-423
1. Fluid level
AT-256
2. Stall test
AT-257
AT-260
AT-387
AT-404
6. Accumulator N-D
AT-404
7. Reverse clutch
AT-464
8. High clutch
AT-469
9. Forward clutch
AT-475
AT-416
AT-416,
AT-423
1. Fluid level
AT-256
AT-409
AT-345
AT-260
AT-387
AT-404
7. Accumulator N-D
AT-404
AT-350
AT-356
AT-362
AT-368
12. Forward clutch
AT-475
13. Reverse clutch
AT-464
AT-483
15. Oil pump
AT-443
AT-423
EC-555
ON vehicle
ON vehicle
OFF vehicle
ON vehicle
Clutches or brakes slip somewhat in

starting.
OFF vehicle
Excessive creep.
Diagnostic Item
ON vehicle
AT-278
http://vnx.su

[EXC.F/EURO-OBD]
Symptom
Condition
ON vehicle
No creep at all.
AT-297 and AT-299
OFF vehicle

D2 .
ON vehicle
ON vehicle
D3 .
ON vehicle
OFF vehicle
Too high a gear change point from D1
to D2 , from D2 to D3 , from D3
to D4 .
AT-304 and AT-309
Gear change directly from D1 to D3

occurs.
ON vehicle
ON vehicle
OFF vehicle
Engine stops when shifting lever into

R, D, 2 and 1.
AT-256
AT-387
AT-404
4. Forward clutch
AT-475
5. Oil pump
AT-443
6. Torque converter
AT-423
AT-409
AT-350
AT-404
ON vehicle
OFF vehicle
AT-332, AT-339
AT-345
6. Brake band
AT-497
AT-409
AT-356
AT-404

OFF vehicle
Reference Page
1. Fluid level

OFF vehicle

D4 .
Diagnostic Item
AT-345
6. High clutch
AT-469
7. Brake band
AT-497
1. PNP switch
AT-324
AT-362
AT-350

AT-332, AT-339

sour
AT-374
6. Brake band
AT-497
AT-345
AT-350
AT-356
1. Fluid level
AT-256
AT-404
3. Brake band
AT-497
EC-555
2. Fluid level
AT-256
AT-368
AT-404
5. Torque converter
AT-423
AT-279
AT
AT-332, AT-339
http://vnx.su
AT-332, AT-339


[EXC.F/EURO-OBD]
Symptom
Too sharp a shock in change from D1

to D2 .
Condition
ON vehicle
OFF vehicle
ON vehicle
to D3 .
OFF vehicle
ON vehicle
to D4 .
OFF vehicle
Almost no shock or clutches slipping

in change from D1 to D2 .
ON vehicle
OFF vehicle
ON vehicle
Almost no shock or slipping in change
from D2 to D3 .
OFF vehicle
Almost no shock or slipping in change

from D3 to D4 .

D1 to D2 .
ON vehicle
Diagnostic Item
Reference Page
AT-345
AT-260
AT-404
AT-404

sour
AT-374
6. Brake band
AT-497
AT-345
AT-260
AT-404

sour
AT-374
5. High clutch
AT-469
6. Brake band
AT-497
AT-345
AT-260
AT-404

sour
AT-374
5. Brake band
AT-497
6. Overrun clutch
AT-475
AT-416
1. Fluid level
AT-256
AT-345
AT-260
AT-404
AT-404
6. Brake band
AT-497
1. Fluid level
AT-256
AT-345
AT-260
AT-404
5. High clutch
AT-469
6. Brake band
AT-497
1. Fluid level
AT-256
AT-345
AT-260
AT-404
OFF vehicle
5. Brake band
AT-497
ON vehicle
1. Fluid level
AT-256
2. Reverse clutch
AT-464
AT-483
4. High clutch
AT-469
AT-416,
AT-423
OFF vehicle
AT-280
http://vnx.su

[EXC.F/EURO-OBD]
Symptom
D2 to D3 .

D3 to D4 .
Condition
Diagnostic Item
Reference Page
ON vehicle
1. Fluid level
AT-256
OFF vehicle
2. Brake band
AT-497
ON vehicle
1. Fluid level
AT-256
2. Overrun clutch
AT-362
AT-416
4. Reverse clutch
AT-464
1. Fluid level
AT-256
2. PNP switch
AT-324
AT-324
AT-345
AT-350
AT-356
AT-404
8. Reverse clutch
AT-464
9. High clutch
AT-469
10. Brake band
AT-497
AT-483
12. Oil pump
AT-443
AT-423
1. Fluid level
AT-256
AT-345
AT-362
AT-350
AT-387
AT-404
7. Brake band
AT-497
8. Overrun clutch
AT-475
1. Fluid level
AT-256
AT-345
AT-350
AT-356
AT-404
6. High clutch
AT-469
7. Brake band
AT-497
1. Fluid level
AT-256
AT-345
AT-350
AT-356
AT-404
AT-416,
AT-423
7. High clutch
AT-469
8. Brake band
AT-497
OFF vehicle
ON vehicle
Maximum speed not attained. Acceleration poor.
OFF vehicle
ON vehicle
D3 .
OFF vehicle
ON vehicle
OFF vehicle
ON vehicle
OFF vehicle
AT-281
http://vnx.su
AT

[EXC.F/EURO-OBD]
Symptom
Gear change shock felt during deceleration by releasing accelerator pedal.
Too high a change point from D4 to

D3 , from D3 to D2 , from D2 to
D1 .
Condition
ON vehicle
ON vehicle
Diagnostic Item
Reference Page
AT-345
AT-260
AT-362
AT-404
AT-345

Kickdown does not operate when

depressing pedal in D4 within kick
down vehicle speed.
Kickdown operates or engine overruns when depressing pedal in D4

beyond kick down vehicle speed limit.

depressing pedal.
ON vehicle
ON vehicle
ON vehicle
ON vehicle
depressing pedal.
OFF vehicle
ON vehicle
OFF vehicle
AT-345
AT-332, AT-339
AT-350
AT-356

OFF vehicle

depressing pedal.

AT-332, AT-339
AT-332, AT-339
AT-345
AT-350
AT-356
1. Fluid level
AT-256
AT-345
AT-260
AT-387
AT-350
AT-404
7. Brake band
AT-497
8. Forward clutch
AT-475
1. Fluid level
AT-256
AT-345
AT-260
AT-387
AT-350
AT-356
AT-404
8. Brake band
AT-497
9. High clutch
AT-469
10. Forward clutch
AT-475
1. Fluid level
AT-256
AT-345
AT-260
AT-387
AT-404
AT-356
7. Brake band
AT-497
8. High clutch
AT-469
AT-282
http://vnx.su

[EXC.F/EURO-OBD]
Symptom
Condition
AT-256
AT-345
AT-260
AT-387
AT-350
AT-356
AT-404
8. Forward clutch
AT-475
AT-416
AT-416,
AT-423
1. Fluid level
AT-256
AT-409
AT-260
AT-387
5. Oil pump
AT-443
6. Torque converter
AT-423
AT-416
ON vehicle
1. Fluid level
AT-256
OFF vehicle
2. Torque converter
AT-423
AT-345
AT-356
AT-404
AT-409
5. Brake band
AT-497
1. PNP switch
AT-324
AT-409
1. PNP switch
AT-324
AT-409

changing from D4 or D3 to D1
when depressing pedal.
OFF vehicle
ON vehicle
Vehicle will not run in any position.
OFF vehicle

AT-319
ON vehicle
OFF vehicle
position.
Engine brake does not operate in 1

position.
AT-317
ON vehicle
ON vehicle

OFF vehicle
position.
Reference Page
1. Fluid level
ON vehicle
Transaxle noise in D, 2, 1 and R

positions.
Diagnostic Item
ON vehicle
ON vehicle
Does not change from 12 to 11 in
1 position.
OFF vehicle
AT-404
AT-362
AT-475
AT-483
1. PNP switch
AT-324
AT-409
1. PNP switch
AT-324
AT-332, AT-339
AT-350
AT-404
AT-416,
AT-423
6. Brake band
AT-497
AT-483
AT-283
http://vnx.su
AT
AT-332, AT-339
6. Overrun clutch


[EXC.F/EURO-OBD]
Symptom
Large shock changing from 12 to 11
in 1 position.
Condition
AT-404
OFF vehicle
AT-483
1. Fluid level
AT-256
EC-555
AT-345
AT-260
AT-387
AT-404
7. Oil pump
AT-443
8. Reverse clutch
AT-464
9. High clutch
AT-469
10. Brake band
AT-497
11. Forward clutch
AT-475
12. Overrun clutch
AT-475
AT-483
AT-423
1. Fluid level
AT-256
2. Reverse clutch
AT-464
3. High clutch
AT-469
4. Brake band
AT-497
5. Forward clutch
AT-475
6. Overrun clutch
AT-475
AT-483
1. Fluid level
AT-256
2. Torque converter
AT-423
3. Oil pump
AT-443
4. Reverse clutch
AT-464
5. High clutch
AT-469
6. Brake band
AT-497
7. Forward clutch
AT-475
8. Overrun clutch
AT-475
AT-483
AT-345
ON vehicle
OFF vehicle
OFF vehicle
ON vehicle
Offensive smell at fluid charging pipe.

OFF vehicle

Reference Page
ON vehicle
ON vehicle
ATF shoots out during operation.

White smoke emitted from exhaust
pipe during operation.
Diagnostic Item
ON vehicle
OFF vehicle
AT-332, AT-339
AT-382

sour
AT-374
AT-260
AT-368
AT-404
8. Torque converter
AT-423
AT-284
http://vnx.su

[EXC.F/EURO-OBD]
Symptom
Torque converter clutch piston slip.
Condition
ON vehicle
OFF vehicle
Lock-up point is extremely high or low.

AT-311
ON vehicle
Diagnostic Item
1. Fluid level
AT-256
AT-345
AT-260
AT-368
AT-387
AT-404
7. Torque converter
AT-423
AT-345

AT-332, AT-339
AT-368
AT-404
AT-345
2. PNP switch
AT-324
AT-324

A/T does not shift to D4 when driving with overdrive control switch ON.
A/T does not shift to D4 when driving with overdrive control switch ON.
Engine is stopped at R, D, 2 and

1 positions.
ON vehicle
OFF vehicle
ON vehicle
Reference Page
AT-332, AT-339
AT-350
AT-362
AT-404

sour
AT-374
AT-260
10. Brake band
AT-497
11. Overrun clutch
AT-475
1. Fluid level
AT-256
AT-368
AT-350
AT-356
AT-404
AT
AT-285
http://vnx.su

[EXC.F/EURO-OBD]
TCM Terminals and Reference Value
ECS004VW
PREPARATION
Measure voltage between each terminal and terminal 25 or 48

by following TCM INSPECTION TABLE.
SAT216J
TCM HARNESS CONNECTOR TERMINAL LAYOUT
SCIA0495E
TCM INSPECTION TABLE

(Data are reference values.)
Terminal No.
Wire color
R/W
P/B
GY/R
Item
Condition

1.5 - 3.0V

0V
Line pressure
solenoid valve
(with dropping
resistor)

5 - 14V

0V
Torque converter
clutch solenoid
valve
8 - 15V
0V
Line pressure
solenoid valve
G/R
CAN-H
GY/R
CAN-L
10
BR/W
Power source
or
AT-286
http://vnx.su
Battery voltage

OFF.
0V

[EXC.F/EURO-OBD]
Terminal No.
11
12
Wire color
L/W
L/Y
Item
Condition
Shift solenoid
valve A
Shift solenoid
valve B

Battery voltage

operate.
0V

Battery voltage

operate.
AT
D
0V
E
19
BR/W
Power source
Same as No. 10
or
20
25
26
27
28
L/B
BR/Y
Overrun clutch
solenoid valve
Ground
PNP switch 1
position
PNP switch 2
position
and
Power source
(Memory back-up)

operates.
Battery voltage

does not operate.
0V
Always
0V

position.
Battery voltage

positions.
0V

position.
Battery voltage

positions.
0V
Always
Battery voltage
450 Hz
When vehicle parks.
Under 1.3V or
over 4.5V
29
W/R
Revolution sensor
30 *2
G/B
CONSULT- II (RX)
31 *2
CONSULT- II (TX)
32 *1
Throttle position
sensor
(Power source)
or
AT-287
http://vnx.su
4.5 - 5.5V

OFF.
0V

[EXC.F/EURO-OBD]
Terminal No.
34
35
Wire color
W/G
Y/G
Item
Condition
PNP switch D
position
PNP switch R
position
and
36
39 *1
L/OR
PNP switch N or
P position
Engine speed signal
and

position.
Battery voltage

positions.
0V

position.
Battery voltage

positions.
0V
When setting selector lever to N or

P position.
Battery voltage

positions.
0V
Refer to EC-94, "ECM INSPECTION

TABLE" .
L/B
Vehicle speed
sensor

Voltage varies
between less
than 0V and
more than 4.5V
41
G/Y
Throttle position
sensor

Fully-closed
throttle: 0.5V
42
Sensor ground
Always
0V

(68F).
1.5V

(176F).
0.5V
Always
0V
40
47
48
BR

Ground
*1: These terminals are connected to the ECM.

*2: These terminals are connected to the data link connector.
AT-288
http://vnx.su

[EXC.F/EURO-OBD]

Wiring Diagram AT NONDTC
PFP:00100
A
ECS004V1
AT
TCWA0238E
AT-289
http://vnx.su

[EXC.F/EURO-OBD]
TCWA0239E
AT-290
http://vnx.su

[EXC.F/EURO-OBD]
O/D OFF Indicator Lamp Does Not Come On
ECS00EBE
SYMPTOM:
O/D OFF indicator lamp does not come on for about 2 seconds
when turning ignition switch to ON.
AT
D
SCIA4281E

1.
2.
Voltage:
3.
4.

Check voltage between TCM connector terminals 10, 19, 28 and ground.
Battery voltage

Check voltage between TCM connector terminal 28 and ground.
Voltage:
Battery voltage
OK or NG
OK
>> GO TO 2.
NG
TCM connector terminals 10, 19 and 28
Refer to AT-395, "Wiring Diagram AT MAIN" .
Ignition switch and fuse Refer to PG-2, "POWER SUPPLY ROUTING" .
SCIA0713E

1.
2.
3.

Check continuity between TCM connector terminals 25, 48 and
ground.

OK or NG
OK
>> GO TO 3.
NG
in harness or connectors. Refer to AT-395, "Wiring Diagram AT MAIN" .
SCIA0766E
3. CHECK COMBINATION METERS SYSTEM

Check combination meters system. Refer to DI-12, "Combination Meter" .
OK or NG
OK
>> GO TO 4.
NG
AT-291
http://vnx.su

[EXC.F/EURO-OBD]
4. CHECK SYMPTOM
Check again. Refer to AT-263, "1. CHECK BEFORE ENGINE IS STARTED" .
OK or NG
OK
>> INSPECTION END
NG
Value" .
AT-292
http://vnx.su

[EXC.F/EURO-OBD]
Engine Cannot Be Started In P and N Position
ECS00EBF
SYMPTOM:
Engine cannot be started with selector lever in P or N position.
Engine can be started with selector lever in D, 2, 1 or R position.
1. CHECK SELF-DIAGNOSIS RESULTS

Perform self-diagnosis. Refer to AT-242, "SELF-DIAGNOSTIC PROCEDURE (WITH CONSULT-II)" .
AT
Do the self-diagnosis results indicate PNP switch circuit?
YES >> Check park/neutral position (PNP) switch circuit. Refer to AT-324, "TCM Self-diagnosis Does Not
Activate" .
D
NO
>> GO TO 2.
2. CHECK PNP SWITCH INSPECTION
Check for short or open of PNP switch harness connector terminals 1 and 2.
Refer to AT-324, "TCM Self-diagnosis Does Not Activate" .
OK or NG
OK
>> GO TO 3.
NG
H
SCIA0768E

OK or NG
OK
>> GO TO 4.
NG
Adjustment" .
SAT023JB

Check starting system. Refer to SC-22, "STARTING SYSTEM" .
OK or NG
OK
>> INSPECTION END
NG
AT-293
http://vnx.su

[EXC.F/EURO-OBD]
In P Position, Vehicle Moves Forward Or Backward When Pushed
ECS00EBG
SYMPTOM:
Vehicle moves when it is pushed forward or backward with selector lever in P position.

OK or NG
OK
>> GO TO 2.
NG
Adjustment" .
SAT023JB
2. CHECK PARKING COMPONENTS

Check parking components. Refer to AT-416, "OVERHAUL" .
OK or NG
OK
>> INSPECTION END
NG
SAT282F
AT-294
http://vnx.su

[EXC.F/EURO-OBD]
In N Position, Vehicle Moves
ECS00EBH
SYMPTOM:
Vehicle moves forward or backward when selecting N position.

OK or NG
OK
>> GO TO 2.
NG
Adjustment" .
AT
E
SAT023JB

OK or NG
OK
>> GO TO 3.
NG
>> Refill ATF.
I
SAT638A

CHECK" .
OK or NG
OK
>> GO TO 4.
NG
>> 1. Disassemble A/T. Refer to AT-424, "Disassembly" .
Forward clutch assembly. Refer to AT-475, "Forward
Overrun clutch assembly. Refer to AT-475, "Forward
Clutch" .
1.
2.
SAT171B
4. CHECK SYMPTOM
OK or NG
OK
>> INSPECTION END
NG
Value" .
AT-295
http://vnx.su

[EXC.F/EURO-OBD]
Large Shock. N R Position
ECS00EBI
SYMPTOM:
There is large shock when changing from N to R position.

Perform self-diagnosis. Refer to AT-242, "SELF-DIAGNOSTIC PROCEDURE (WITH CONSULT-II)" or AT246, "Diagnostic Procedure Without CONSULT-II" .
Do the self-diagnosis results indicate A/T fluid temperature sensor, line pressure solenoid valve, accelerator
pedal position (APP) sensor circuit?
AT-387, "LINE PRESSURE SOLENOID VALVE"
AT-345, "ACCELE RATOR PEDAL POSITION (APP) SENSOR"
AT-374, "BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER
SOURCE)"
NO
>> GO TO 2

OK or NG
OK
>> GO TO 3.
NG
SAT494G
3. CHECK SYMPTOM
OK or NG
OK
>> INSPECTION END
NG
Value" .
AT-296
http://vnx.su

[EXC.F/EURO-OBD]
Vehicle Does Not Creep Backward In R Position
ECS00EBJ
SYMPTOM:
Vehicle does not creep backward when selecting R position.

OK or NG
OK
>> GO TO 2.
NG
>> Refill ATF.
AT
E
SAT638A
Check line pressure at idle with selector lever in R position. Refer to

OK or NG
OK
>> GO TO 3.
NG
I
SAT494G
3. CHECK STALL TEST

Check stall revolution with selector lever in 1 and R positions.
Refer to AT-257, "Stall Test" .
OK or NG
OK
>> GO TO 4.
OK in 1 position, NG in R position>>1.Disassemble A/T. Refer to
AT-424, "Disassembly" .
Clutch" .
Low & reverse brake assembly. Refer to AT-483, "Low
& Reverse Brake" .
NG in both 1 and R positions>>GO TO 6.
AT-297
http://vnx.su
SAT493G

[EXC.F/EURO-OBD]

CHECK" .
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 6.
1.
2.
SAT171B
5. CHECK SYMPTOM
OK or NG
OK
>> INSPECTION END
NG
Value" .

Low & reverse brake assembly. Refer to AT-483, "Low & Reverse Brake" .

OK or NG
OK
>> GO TO 5.
NG
1.
2.
AT-298
http://vnx.su

[EXC.F/EURO-OBD]
Vehicle Does Not Creep Forward In D, 2 Or 1 Position
ECS00EBK
SYMPTOM:
Vehicle does not creep forward when selecting D, 2 or 1 position.

OK or NG
OK
>> GO TO 2.
NG
>> Refill ATF.
AT
E
SAT638A

OK or NG
OK
>> GO TO 3.
NG
I
SAT494G
3. CHECK STALL TEST

L
Check stall revolution with selector lever in D position. Refer to AT257, "Stall Test" .
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 6.
SAT493G
AT-299
http://vnx.su

[EXC.F/EURO-OBD]

CHECK" .
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 6.
1.
2.
SAT171B
5. CHECK SYMPTOM
OK or NG
OK
>> INSPECTION END
NG
Value" .

Forward one-way clutch. Refer to AT-475, "Forward and Overrun Clutches" .
Low one-way clutch. Refer to AT-424, "Disassembly" .

OK or NG
OK
>> GO TO 5.
NG
1.
2.
AT-300
http://vnx.su

[EXC.F/EURO-OBD]
Vehicle Cannot Be Started From D1
ECS00EBL
SYMPTOM:
Vehicle cannot be started from D1 on Cruise Test Part 1.
1. SYMPTOM CHECK
Check symptom. Refer to AT-270, "Cruise Test Part 1" .

Is Vehicle does not creep backward in R position OK?
YES >> GO TO 2.
NO
>> Go to AT-297, "Vehicle Does Not Creep Backward In R Position" .
AT
Do the self-diagnosis results indicate vehicle speed sensorA/T (revolution sensor), overrun clutch solenoid
valve, torque converter clutch solenoid valve, shift solenoid valve A,B or vehicle speed sensorMTR circuit?
AT-332, "VEHICLE SPEED SENSORA/T (REVOLUTION SENSOR)"
AT-368, "TORQUE CONVERTER CLUTCH SOLENOID VALVE"
AT-350, "SHIFT SOLENOID VALVE A"
AT-356, "SHIFT SOLENOID VALVE B"
AT-362, "OVERRUN CLUTCH SOLENOID VALVE"
NO
>> GO TO 3.

"ACCELE RATOR PEDAL POSITION (APP) SENSOR" .
OK or NG
OK
>> GO TO 4.
NG
L
PBIB0498E
Check line pressure at stall point with selector lever in D position.

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 8.
SAT494G
AT-301
http://vnx.su

[EXC.F/EURO-OBD]

CHECK" .
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 8.
1.
2.
SAT171B

Shift valve A
Shift valve B
Pilot valve
Pilot filter
OK or NG
OK
>> GO TO 7.
NG
1.
2.
7. CHECK SYMPTOM
OK or NG
OK
>> INSPECTION END
NG
Value" .
AT-302
http://vnx.su

[EXC.F/EURO-OBD]
Shift valve A
Shift valve B
Pilot valve
Pilot filter
Forward clutch. Refer to AT-475, "Forward and Overrun Clutches" .
Forward one-way clutch assembly. Refer to AT-424, "Disassembly" .
Low & reverse clutch assembly

OK or NG
OK
>> GO TO 7.
NG
1.
2.
AT
AT-303
http://vnx.su

[EXC.F/EURO-OBD]
A/T Does Not Shift: D1 D2 Or Does Not Kickdown: D4 D2

SYMPTOM:
ECS00EBM

when depressing accelerator pedal fully at the specified speed.
1. CHECK SYMPTOM
YES >> GO TO 2.
NO

OK or NG
OK
>> GO TO 3.
NG
Adjustment" .
SAT023JB
SENSORMTR CIRCUIT
"VEHICLE SPEED SENSORA/T (REVOLUTION SENSOR)" and AT-339, "DTC VEHICLE SPEED SENSOR
MTR" .
OK or NG
OK
>> GO TO 4.
NG
circuits.

Check accelerator pedal position (APP) sensor. Refer AT-345,
OK or NG
OK
>> GO TO 5
NG
PBIB0498E
AT-304
http://vnx.su

[EXC.F/EURO-OBD]

CHECK" .
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 8.
1.
2.
AT
D
SAT171B

Shift valve A
Shift valve B
Pilot valve
Pilot filter
OK or NG
OK
>> GO TO 7.
NG
1.
2.
7. CHECK SYMPTOM
OK or NG
OK
>> INSPECTION END
NG
Value" .
AT-305
http://vnx.su

[EXC.F/EURO-OBD]

Shift valve A
Shift valve B
Pilot valve
Pilot filter
Brake band
OK or NG
OK
>> GO TO 7.
NG
1.
2.
AT-306
http://vnx.su

[EXC.F/EURO-OBD]

SYMPTOM:
ECS00EBN
1. CHECK SYMPTOM
AT
YES >> GO TO 2.
NO
D
ADJUST CONTROL CABLE
2.

OK or NG
OK
>> GO TO 3.
NG
Adjustment" .
SAT023JB
SENSORMTR CIRCUIT
MTR" .
OK or NG
OK
>> GO TO 4.
NG
circuits.
PBIB0498E
AT-307

OK or NG
OK
>> GO TO 5.
NG
http://vnx.su

[EXC.F/EURO-OBD]

CHECK" .
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 8.
1.
2.
SAT171B

Shift valve B
Pilot valve
Pilot filter
OK or NG
OK
>> GO TO 7.
NG
1.
2.
7. CHECK SYMPTOM
OK or NG
OK
>> INSPECTION END
NG
Value" .

Shift valve B
Pilot valve
Pilot filter

OK or NG
OK
>> GO TO 7.
NG
1.
2.
AT-308
http://vnx.su

[EXC.F/EURO-OBD]
ECS00EBO
SYMPTOM:
A/T does not shift from D3 to D4 at the specified speed.
A/T must be warm before D3 to D4 shift will occur.
1. CHECK SYMPTOM
AT
YES >> GO TO 2.
NO
>> GO TO AT-299, "Vehicle Does Not Creep Forward In D, 2 Or 1 Position" , AT-301, "Vehicle D
Do the self-diagnosis results indicate PNP switch, overdrive control switch, A/T fluid temperature sensor, vehicle speed sensorA/T (revolution sensor), shift solenoid valve A,B or vehicle speed sensorMTR circuit?
AT-374, "BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER
SOURCE)"
AT-324, "TCM Self-diagnosis Does Not Activate"
NO
>> GO TO 3.

"ACCELE RATOR PEDAL POSITION (APP) SENSOR"
OK or NG
OK
>> GO TO 4.
NG
M
PBIB0498E

CHECK" .
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 7.
1.
2.
SAT171B
AT-309
http://vnx.su

[EXC.F/EURO-OBD]

Shift valve A
Pilot valve
Pilot filter
OK or NG
OK
>> GO TO 6.
NG
1.
2.
6. CHECK SYMPTOM
OK or NG
OK
>> INSPECTION END
NG
Value" .

Shift valve A
Pilot valve
Pilot filter
Brake band
OK or NG
OK
>> GO TO 6
NG
1.
2.
AT-310
http://vnx.su

[EXC.F/EURO-OBD]
A/T Does Not Perform Lock-up
ECS00EBP
SYMPTOM:
A/T does not perform lock-up at the specified speed.
Does self-diagnosis show damage to A/T fluid temperature sensor, vehicle speed sensorA/T (revolution sen- AT
sor), engine speed signal, vehicle speed sensorMTR or torque converter clutch solenoid valve circuit after
cruise test?
YES >> Check damaged circuit. Refer to AT-368, "TORQUE CONVERTER CLUTCH SOLENOID VALVE" D
, AT-374, "BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER
SOURCE)" , AT-332, "VEHICLE SPEED SENSORA/T (REVOLUTION SENSOR)" , AT-382,
"ENGINE SPEED SIGNAL" , AT-339, "DTC VEHICLE SPEED SENSOR MTR" .
E
NO
>> GO TO 2.

OK or NG
OK
>> GO TO 3.
NG
I
PBIB0498E
Pilot valve
Pilot filter
4. Check torque converter. Refer to AT-424, "Disassembly" .
OK or NG
OK
>> GO TO 4.
NG
1.
2.
4. CHECK SYMPTOM
OK or NG
OK
>> INSPECTION END
NG
Value" .
AT-311
http://vnx.su

[EXC.F/EURO-OBD]
A/T Does Not Hold Lock-up Condition
ECS00EBQ
SYMPTOM:
A/T does not hold lock-up condition for more than 30 seconds.
1. CHECK DIAGNOSTIC RESULTS

Does self-diagnosis show damage to engine speed signal circuit after cruise test?
YES >> Check engine speed signal circuit. Refer to AT-382, "ENGINE SPEED SIGNAL" .
NO
>> GO TO 2.

CHECK" .
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 5.
1.
2.
SAT171B

Pilot valve
Pilot filter
OK or NG
OK
>> GO TO 4.
NG
1.
2.
4. CHECK SYMPTOM
OK or NG
OK
>> INSPECTION END
NG
Value" .
AT-312
http://vnx.su

[EXC.F/EURO-OBD]
Pilot valve
Pilot filter
4. Check torque converter and oil pump assembly.
OK or NG
OK
>> GO TO 4.
NG
1.
2.
AT
AT-313
http://vnx.su

[EXC.F/EURO-OBD]
Lock-up Is Not Released
ECS00EBR
SYMPTOM:
Lock-up is not released when accelerator pedal is released.
1. CHECK ACCELERATOR PEDAL POSITION (APP) SENSOR CIRCUIT

Do the self-diagnosis results indicate accelerator pedal position (APP) sensor circuit?
YES >> Check accelerator pedal position (APP) sensor circuit. Refer to AT-345, "ACCELE RATOR
PEDAL POSITION (APP) SENSOR" .
NO
>> GO TO 2.
2. CHECK SYMPTOM
OK or NG
OK
>> INSPECTION END
NG
Value" .
AT-314
http://vnx.su

[EXC.F/EURO-OBD]
Engine Speed Does Not Return To Idle (Light Braking D4 D3 )
ECS00EBS
SYMPTOM:
Engine speed does not smoothly return to idle when A/T shifts from D4 to D3 .
AT
Does self-diagnosis show damage to overrun clutch solenoid valve circuit after cruise test?
YES >> Check overrun clutch solenoid valve circuit. Refer to AT-362, "OVERRUN CLUTCH SOLENOID
VALVE" .
D
NO
>> GO TO 2.

E

OK or NG
OK
>> GO TO 3.
NG
H
PBIB0498E

I

CHECK" .
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 6.
1.
2.
L
SAT171B


OK or NG
OK
>> GO TO 5.
NG
1.
2.
AT-315
http://vnx.su

[EXC.F/EURO-OBD]
5. CHECK SYMPTOM
OK or NG
OK
>> INSPECTION END
NG
Value" .



OK or NG
OK
>> GO TO 5.
NG
1.
2.
AT-316
http://vnx.su

[EXC.F/EURO-OBD]
Vehicle Does Not Start From D1
ECS00EBT
SYMPTOM:
Vehicle does not start from D1 on Cruise test Part 2.
Does self-diagnosis show damage to vehicle speed sensorA/T (revolution sensor), shift solenoid valve A, B or AT
vehicle speed sensorMTR after cruise test?
D
E
NO
>> GO TO 2.
2. CHECK SYMPTOM

OK or NG
OK
>> GO TO AT-301, "Vehicle Cannot Be Started From D1" .
NG
Value" .
AT-317
http://vnx.su

[EXC.F/EURO-OBD]
A/T Does Not Shift: D4 D3 , When Overdrive Control Switch ON OFF

ECS00EBU
SYMPTOM:
when changing overdrive control switch to OFF position.

Check overdrive control switch circuit. Refer to AT-324, "TCM Self-diagnosis Does Not Activate" .
OK or NG
OK
>> GO TO AT-307, "A/T Does Not Shift: D2 D3" .
NG
>> Check overdrive control switch circuit. Refer to AT-324, "TCM Self-diagnosis Does Not Activate" .
AT-318
http://vnx.su

[EXC.F/EURO-OBD]
A/T Does Not Shift: D3 22 , When Selector Lever D 2 Position

SYMPTOM:
A/T does not shift from D3 to 22
ECS00EBV
when changing selector lever from D to 2 position.
Check PNP switch circuit. Refer to AT-324, "TCM Self-diagnosis Does Not Activate" .
OK or NG
OK
>> GO TO AT-304, "A/T Does Not Shift: D1 D2 Or Does Not Kickdown: D4 D2" .
NG
>> Check PNP switch circuit. Refer to AT-324, "TCM Self-diagnosis Does Not Activate" .
AT
AT-319
http://vnx.su

[EXC.F/EURO-OBD]
A/T Does Not Shift: 22 11 , When Selector Lever 2 1 Position

SYMPTOM:
A/T does not shift from 22 to 11
ECS00EBW
when changing selector lever from 2 to 1 position.

OK or NG
OK
>> GO TO 2.
NG

OK or NG
OK
>> GO TO 3.
NG
Adjustment" .
SAT023JB
SENSORMTR CIRCUIT
MTR" .
OK or NG
OK
>> GO TO 4.
NG
circuits.

CHECK" .
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.
1.
2.
SAT171B
AT-320
http://vnx.su

[EXC.F/EURO-OBD]
Shift valve A

Brake band
OK or NG
OK
>> GO TO 6.
NG
1.
2.
AT
6. CHECK SYMPTOM
OK or NG
OK
>> INSPECTION END
NG
SAT778B
AT-321
http://vnx.su

[EXC.F/EURO-OBD]
Vehicle Does Not Decelerate By Engine Brake
ECS00EBX
SYMPTOM:
Vehicle does not decelerate by engine brake when turning overdrive control switch OFF.
Vehicle does not decelerate by engine brake when shifting A/T from D to 2 position.
Vehicle does not decelerate by engine brake when shifting from 22 (12 ) to 11 .

OK or NG
OK
>> GO TO 2.
NG

OK or NG
OK
>> GO TO 3.
NG
Adjustment" .
SAT023JB
SENSORMTR CIRCUIT
MTR" .
OK or NG
OK
>> GO TO 4.
NG
circuits.

CHECK" .
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.
1.
2.
SAT171B
AT-322
http://vnx.su

[EXC.F/EURO-OBD]
Shift valve A
Low & reverse bake assembly

OK or NG
OK
>> GO TO 6.
NG
1.
2.
AT
6. CHECK SYMPTOM
F

OK or NG
OK
>> INSPECTION END
NG
SAT778B
AT-323
http://vnx.su

[EXC.F/EURO-OBD]
TCM Self-diagnosis Does Not Activate
ECS00EBY
SYMPTOM:
O/D OFF indicator lamp does not come on in TCM self-diagnostic procedure even if the lamp circuit is
good.
DESCRIPTION
PNP switch
The PNP switch assembly includes a transaxle position switch.
The transaxle position switch detects the selector lever position
SCIA0752E

Detects the overdrive control switch position (ON or OFF) and
sends a signal to the TCM.
SCIA0776E
Closed throttle position signal and wide open throttle position

signal
ECM judges throttle opening based on a signal from accelerator
pedal position sensor, and sends the signal via CAN communication to TCM.
PBIB0498E
AT-324
http://vnx.su

[EXC.F/EURO-OBD]
A

With CONSULT-II
3. Read out P/N, R, D, 2 and 1 position switches moving selector lever to each position.
properly.
OK or NG
OK
>> GO TO 3.
NG
PNP switch (Refer to AT-327, "COMPONENT
INSPECTION" .)
PNP switch
Harness for short or open between PNP switch and
TCM
AT
F
SAT701J
2. CHECK PNP SWITCH CIRCUIT (WITHOUT CONSULT-II)

H
Without CONSULT-II
2. Check voltage between TCM terminals 26, 27, 34, 35, 36 and
Voltage:
B: Battery voltage
0: 0V
Terminal No.
Lever position
36
35
34
27
26
P, N
OK or NG
OK
>> GO TO 3.
NG
PNP switch (Refer to AT-327, "COMPONENT
INSPECTION" .)
PNP switch
Harness for short or open between PNP switch and TCM
AT-325
http://vnx.su
SCIA0777E

[EXC.F/EURO-OBD]

With CONSULT-II
3. Read out OVERDRIVE SWITCH.
Check the signal of the overdrive control switch is indicated properly.
(Overdrive control switch ON displayed on CONSULT-II means
overdrive OFF.)
OK or NG
OK
>> GO TO 4.
NG
Overdrive control switch (Refer to AT-327, "COMPONENT INSPECTION" .)
Harness for short or open between Combination
meter and overdrive control switch
Harness of ground circuit for overdrive control switch
for short or open
Combination Meter (Refer to DI-4, "COMBINATION METERS" .)
SAT645J
(WITH CONSULT-II)
With CONSULT-II
3. Read out CLOSED THL/SW and W/O THRL-SW depressing and releasing accelerator pedal.
Check the signal of throttle position signal is indicated properly.
SAT646J
Accelerator pedal
condition
Data monitor
CLOSED THL/SW
W/O THRL-SW
Released
ON
OFF
Fully depressed
OFF
ON
OK or NG
OK
>> GO TO 5.
NG
>> Check the following items. If any items are damaged, repair or replace damaged parts.
Accelerator pedal position sensor Refer to AT-345, "ACCELE RATOR PEDAL POSITION
(APP) SENSOR" .
AT-326
http://vnx.su

[EXC.F/EURO-OBD]
(WITHOUT CONSULT-II)
Without CONSULT-II
B
Accelerator pedal position sensor Refer to AT-345, "ACCELE RATOR PEDAL POSITION (APP) SENSOR" .
AT
OK or NG
OK
>> GO TO 6.
D
NG
6. CHECK DTC
Perform self-diagnosis. Refer to AT-246, "Diagnostic Procedure Without CONSULT-II" .

OK or NG
OK
>> INSPECTION END
NG
>> Perform TCM input/output signal inspection. Refer to AT-286, "TCM Terminals and Reference
Value" .
If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
COMPONENT INSPECTION
Overdrive Control Switch
Continuity
ON
No
OFF
Yes
Check continuity between two terminals 1 and 2.

Switch position
K
SCIA4647E
AT-327
http://vnx.su

[EXC.F/EURO-OBD]
PNP Switch
1.
Check continuity between terminals 1 and 2, and between terminals 3 and 4, 5, 6, 7, 8, 9 while moving manual shaft through
each position.
Lever position
Terminal No.
37
38
39
36
35
34
12
12
SCIA0754E
2.
3.
4.
5.
6.
If NG, check again with manual control cable disconnected from

manual shaft of A/T assembly. Refer to step 1.
If OK on step 2, adjust manual control cable. Refer to AT-409,
"Control Cable Adjustment" .
If NG on step 2, remove PNP switch from A/T and check continuity of PNP switch terminals. Refer to step 1.
If OK on step 4, adjust PNP switch. Refer to AT-409, "Control
Cable Adjustment" .
If NG on step 4, replace PNP switch.
SAT089JA
AT-328
http://vnx.su
CAN COMMUNICATION LINE

[ALL]

Description
[ALL]
PFP:31940
A
ECS004UJ
CAN (Control Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many elec- B
AT
ECS004UK

: CAN COMM CIRCUIT

When a malfunction is detected in CAN
communication line.
Possible Cause
shorted.)
E
ECS00CT9
(CAN communication line is open or shorted.)
ECS004UL
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

Wait at least 6 seconds or start engine and wait for at least 6
seconds.
SAT014K
WITHOUT CONSULT-II
1.
2.
3.
4.

Wait at least 6 seconds or start engine and wait at least 6 seconds.
SCIA4673E
AT-329
http://vnx.su

[ALL]
Wiring Diagram AT CAN
ECS004UM
TCWA0234E
AT-330
http://vnx.su

[ALL]
Terminal No.
Wire color
Item
Condition
Judgement
standard
(Approx.)
G/R
CAN-H
GY/R
CAN-L
ECS004UN
1. CHECK CAN COMMUNICATION CIRCUIT

With CONSULT-II
Turn ignition switch ON and start engine.
Select SELF-DIAG RESULTS mode for A/T with CONSULTII.
Is any malfunction of the CAN COMM CIRCUIT indicated?
YES >> Print out CONSULT-II screen, GO TO LAN section.
Refer to LAN-4, "CAN Communication Unit" .
NO
>> INSPECTION END
AT
1.
2.
G
PCIA0061E
AT-331
http://vnx.su
VEHICLE SPEED SENSORA/T (REVOLUTION SENSOR)

[ALL]

Description
PFP:32702
ECS004TJ
The revolution sensor detects the revolution of the idler gear parking
pawl lock gear and emits a pulse signal. The pulse signal is sent to
the TCM which converts it into vehicle speed.
SCIA0715E
CONSULT-II Reference Value
ECS00CS5

Monitor item
Condition
VHCL/S SEA/T (km/h)
Display value
Approximately matches the speedometer
reading.
During driving
ECS00CS6

: VHCL SPEED SENAT
Revolution sensor

: 1st judgement flicker
Possible Cause
ECS00CS7
Revolution sensor
ECS00CS8
CAUTION:
NOTE:
If DTC Confirmation Procedure has been previously performed, always turn ignition switch OFF and wait at
least 10 seconds before performing the next test.
WITH CONSULT-II
1.

SAT014K
AT-332
http://vnx.su

[ALL]
A
AT
SCIA5358E
2.
3.
4.
5.
Drive vehicle and check for an increase of VHCL/S SEMTR value.

SLCT LVR POSI: D position
SAT014K
ENGINE SPEED: 3,500 rpm or more
Driving location: Driving the vehicle uphill (increased engine load) will help maintain the driving
conditions required for this test.
WITHOUT CONSULT-II
1.
2.
3.
4.
Start engine.
SCIA5591E
AT-333
http://vnx.su

[ALL]
Wiring Diagram AT VSSA/T
ECS004TK
TCWA0231E
AT-334
http://vnx.su

[ALL]
Terminal No.
29
42
Wire color
W/R
Item
Condition
Revolution sensor
Sensor ground
Judgement standard
(Approx.)
450 Hz
When vehicle parks.
Under 1.3V or
over 4.5V
Always
0V
AT
ECS004TL
1. CHECK INPUT SIGNAL (WITH CONSULT-II)

E
With CONSULT-II
1. Start engine.
3. Read out the value of VHCL/S SEA/T while driving.
SAT014K

J
L
SAT614J
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 2.
AT-335
http://vnx.su

[ALL]
2.
1.
2.
CHECK REVOLUTION SENSOR
With CONSULT-II
Start engine.
Check power supply to revolution sensor by voltage between TCM connector terminals. Refer to AT-395,
"Wiring Diagram AT MAIN" and AT-334, "Wiring Diagram AT VSSA/T" .
Item
Connector
No.
TCM
F46, F47
Terminal No. (Wire color)
Data (Approx.)
10 (BR/W) - 42 (B)
Battery voltage
19 (BR/W) - 42 (B)
3.
If OK check the pulse when vehicle cruises.

Name
Condition
When moving at 20 km/h (12 MPH), use the CONSULT-II
pulse frequency measuring function.
Revolution sensor
CAUTION:
Connect the diagnosis data link cable to the data link
connector.
Item
Connector
No.
Terminal
No. (Wire
color)
Name
Data
(Approx.)
TCM
F47
29 (W/R)
Revolution sensor
450 Hz
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 3.
SCIA2344E
AT-336
http://vnx.su

[ALL]
3.
1.
2.
3.
4.
CHECK POWER AND SENSOR GROUND

Disconnect the revolution sensor harness connector.
terminals.
AT
Item
Connector No.
Terminal No.
(Wire color)
Data
(Approx.)
Revolution sensor
F15
1 (BR/W) - 3 (B)
Battery voltage
E
SCIA2614E
5.

terminal and ground.
Item
Connector No.
Terminal No.
(Wire color)
Data
(Approx.)
Revolution sensor
F15
1 (BR/W) ground
Battery voltage

OK or NG
SCIA2615E
OK
>> GO TO 4.
NG - 1 >> Battery voltage is not supplied between terminals 1 and 3, terminals 1 and ground.:GO TO 6.
NG - 2 >> Battery voltage is not supplied between terminals 1 and 3 only.: GO TO 7.
4.
1.
2.
3.
CHECK HARNESS BETWEEN TCM AND REVOLUTION SENSOR

Check continuity between TCM connector and revolution sensor
harness connector.
Item
Connector No.
Terminal No.
(Wire color)
TCM
F47
29 (W/R)
Revolution sensor
F15
Continuity
2 (W/R)
M
Yes

OK or NG
OK
>> GO TO 5.
NG
5. CHECK TCM
2. If NG, re-check TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> GO TO 8.
NG
AT-337
http://vnx.su
SCIA2616E

[ALL]
6.
1.
2.
3.
CHECK HARNESS BETWEEN TCM AND REVOLUTION SENSOR (POWER)

harness connector. Refer to AT-21, "Circuit Diagram" and AT395, "Wiring Diagram AT MAIN" .
Item
Connector No.
Terminal No.
(Wire color)
TCM
F46
10 (BR/W)
Revolution sensor
F15
1 (Y)
Item
Connector No.
Terminal No.
(Wire color)
TCM
F46
19 (BR/W)
Revolution sensor
F15
1 (Y)
Continuity
Yes
Continuity
SCIA2617E
Yes

OK or NG
OK
>> Fuse or ignition switch are malfunctioning.
NG
7.
1.
2.
3.
CHECK HARNESS BETWEEN TCM AND REVOLUTION SENSOR (SENSOR GROUND)

harness connector.
Item
Connector No.
Terminal No.
(Wire color)
TCM
F47
42 (B)
Revolution sensor
F15
3 (B)
Continuity
Yes

OK or NG
OK
>> GO TO 5.
NG
8. CHECK DTC
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 5.
AT-338
http://vnx.su
SCIA2618E

[ALL]

Description
PFP:24814
A
ECS004TM
The vehicle speed sensorMTR is built into the speedometer assembly. The sensor functions as an auxiliary device to the revolution sensor when it is malfunctioning. The TCM will then use a signal sent
from the vehicle speed sensorMTR.
AT
D
SCIA0716E
ECS00CSH

Monitor item
Condition
VHCL/S SEMTR (km/h)
Display value
Approximately matches the speedometer
reading.
During driving
ECS00CSA
: VHCL SPEED SENMTR

: 2nd judgement flicker

Possible Cause
Combination meter
4WD/ABS control unit
I
ECS00CSB
ECS00CSC
CAUTION:
WITH CONSULT-II
1.

SAT014K
AT-339
http://vnx.su

[ALL]
2.
3.
Start engine and accelerate vehicle from 0 to 25 km/h (0 to 16

MPH).
SCIA5358E
WITHOUT CONSULT-II
1.
2.
3.
4.
Start engine.
Selector lever in D and vehicle speed higher than 25 km/h (16 MPH).
SCIA5592E
AT-340
http://vnx.su

[ALL]
Wiring Diagram AT VSSMTR
ECS004TN
LHD models
AT
TCWA0236E
AT-341
http://vnx.su

[ALL]
RHD models
TCWA0237E
AT-342
http://vnx.su

[ALL]
Terminal No.
Wire color
Item
Condition
Judgement standard
(Approx.)
B
40
Vehicle speed
sensor
L/W

Voltage varies
between less
than 0V and
more than 4.5V
AT
ECS004TO

With CONSULT-II
1. Start engine.
3. Read out the value of VHCL/S SEMTR while driving.
LCIA0090E
1.
2.
Without CONSULT-II
Start engine.
Check voltage between TCM connector and ground.
Name
Vehicle
speed sensor
Connector No.
F47
Condition
x.)
When moving vehicle at

2 to 3 km/h (1 to 2 MPH)
for 1 m (3 ft) or more.
Voltage
varies
between
less than
0V and
more than
4.5V
Terminal
No. (Wire
color)
40(L/W) Ground
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
L
SCIA3246E

Combination meters. Refer to DI-4, "COMBINATION METERS" .
Harness for short or open between TCM and unified combination meter.
OK or NG
OK
>> GO TO 3.
NG
AT-343
http://vnx.su

[ALL]
3. CHECK DTC
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 4.
4. CHECK TCM
OK or NG
OK
>> INSPECTION END
NG
AT-344
http://vnx.su
ACCELE RATOR PEDAL POSITION (APP) SENSOR

[ALL]

Description
PFP:22620
A
ECS004TP

acceleration pedal position sensor, throttle position sensor, etc.
The actuator sends a signal to the ECM.
AT
D
PBIB0498E
CONSULT-II REFERENCE VALUE

Monitor item
(THRTL POS SEN)
Condition
Specification
Fully-closed throttle
Approximately 0.5V
Fully-open throttle
Approximately 4V
ECS00CSD

: THROTTLE POSI SEN*

: 3rd judgement flicker

*:This code means Accelerator pedal position (APP) sensor in reality.
Possible Cause
I
ECS00CSE
ECS00CSF
CAUTION:
NOTE:
WITH CONSULT-II
1.
2.
3.
Turn ignition switch ON and select DATA MONITOR mode for A/T with CONSULT-II.
Touch TCM INPUT SIGNALS.
Touch START
Accelerator pedal condition
THRTL POS SEN
Fully released
Approx. 0.5V
Partially depressed
0.5 - 4V
Fully depressed
Approx. 4V

SAT014K
AT-345
http://vnx.su

[ALL]
4.
5.
6.
7.
8.

Touch SELECTION FROM MENU
Touch VHCL SPEED SE and THRTL POS SEN.
Touch START.
consecutive seconds. Then release accelerator pedal completely.
THRTL POS SEN: Approximately 3V or less
SCIA5358E
Maintain the following conditions for at least 3 consecutive seconds. Then release accelerator pedal completely.
THROTTLE POSI: 8.0/8
SAT014K
WITHOUT CONSULT-II
1.
2.
3.
4.
Start engine.
SCIA5593E
AT-346
http://vnx.su

[ALL]
Wiring Diagram AT TPS
ECS004TQ
AT
TCWA0233E
AT-347
http://vnx.su

[ALL]
Terminal No.
Wire color
32
Item
Throttle position
sensor
(Power source)
41
G/Y
Throttle position
sensor
42
Sensor ground
Condition
or
When turning ignition switch ON.
4.5 - 5.5V
When turning ignition switch OFF.
0V

Fully-closed throttle:
0.5V
Fully-open throttle:
4V
Always
Judgement standard
(Approx.)
0V
ECS00CSG

Check P code with CONSULT-II ENGINE.
Turn ignition switch ON and select SELF DIAGNOSTIC RESULTS mode for ENGINE with CONSULT-II.
Refer to EC-63, "Malfunction Indicator (MI)" (WITH EURO-OBD) or EC-565, "Malfunction Indicator (MI)"
(WITHOUT EURO-OBD).
OK or NG
OK
>> GO TO 2.
NG
>> Check accelerator pedal position (APP) sensor circuit for engine control. Refer to EC-408, "DTC
P2122, P2123 APP SENSOR" , EC-415, "DTC P2127, P2128 APP SENSOR" , EC-431, "DTC
P2138 APP SENSOR" . If CAN communication line is detected, GO TO LAN-4, "CAN COMMUNICATION" .
AT-348
http://vnx.su

[ALL]
With CONSULT-II
3. Read out the value of THRTL POS SEN.
Monitor item
Condition
Display value
Fully-closed throttle: 0.5V
THRTL POS SEN (V)

warming up engine.
(Voltage rises gradually in
response to throttle position.)
AT
D
LCIA0090E
Without CONSULT-II
2. Check voltage between TCM connector terminals.
Name
Accelerator
pedal position (APP)
sensor
Connector No.
F47
Terminal
No. (Wire
color)
Condition
x.)
41(G/Y) 42(B)

warming up engine.
(Voltage rises gradually
in response to throttle
position.)
Fullyclosed
throttle:
0.5V
Fully-open
throttle: 4V
J
SCIA3247E
OK or NG
OK
>> GO TO 3.
NG
>> Check harness for short or open between ECM and TCM regarding throttle position sensor circuit.
3. CHECK DTC

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 5.
4. CHECK TCM
OK or NG
OK
>> INSPECTION END
NG
AT-349
http://vnx.su

[ALL]

Description
PFP:31940
ECS004TS

position.
SCIA0718E
Gear position
ON (Closed)
OFF (Open)
OFF (Open)
ON (Closed)
ON (Closed)
ON (Closed)
OFF (Open)
OFF (Open)
ECS00CSI

Monitor item
Condition
Display value

ON

OFF
ECS00CSJ

: SHIFT SOLENOID/VA

Possible Cause
ECS00CSK
ECS00CSL
CAUTION:
AT-350
http://vnx.su

[ALL]
WITH CONSULT-II
1.
2.
3.
4.

Start engine.
(GEAR).
AT
SAT014K
WITHOUT CONSULT-II
1.
2.
3.
4.
Start engine.
Drive vehicle in D1 D2 position.
SCIA5594E
AT-351
http://vnx.su

[ALL]
Wiring Diagram AT SSV/A
ECS004TT
TCWA0040E
AT-352
http://vnx.su

[ALL]
Terminal No.
Wire color
11
Item
Condition
Shift solenoid
valve A
L/W
Judgement standard
(Approx.)

Battery voltage

operate.
0V
AT
ECS004TU

E
With CONSULT-II
1. Start engine.
3. Read out the value of SHIFT S/V A while driving.
Monitor item
SHIFT S/V A
Condition
Display value

ON

OFF
I
SCIA3251E
Without CONSULT-II
1. Start engine.
Name
Connector No.
F46
Terminal
No. (Wire
color)
11 (L/W) Ground
Condition
x.)

A operates.
D4 .)
Battery
voltage

A does not operate.
D3 .)
0V
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 2.
AT-353
http://vnx.su
SCIA3248E

[ALL]
2. CHECK SHIFT SOLENOID VALVE A CIRCUIT

1.
2.
3.

Solenoid Valve
Connector No.
Terminal No.
(Wire color)
Resistance
(Approx.)
F46
11 (L/W) Ground
20 - 30
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.
SCIA3249E
3.
1.
2.
3.
Check continuity between terminal cord assembly harness connector and TCM connector.
Item
Connector No.
Terminal No.
(Wire color)
TCM
F46
11 (L/W)

harness connector
F23
2 (L/W)
Continuity
Yes

OK or NG
OK
>> GO TO 4.
NG
SCIA3250E

1.
2.
3.

Check resistance between terminal cord assembly harness connector F23 terminal 2 (L/W) and ground.
Resistance:
20 - 30
OK or NG
OK
>> GO TO 5.
NG
SCIA3453E
5. CHECK DTC
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 6.
AT-354
http://vnx.su

[ALL]
6. CHECK TCM
OK or NG
OK
>> INSPECTION END
NG
AT
ECS004TV
Resistance Check
Check resistance between two terminal 2 and ground.

E
Solenoid valve
Shift solenoid
valve A
Resistance
(Approx.)
Terminal No.
2
Ground
20 - 30
G
SCIA2049E
Operation Check

K
SCIA2052E
AT-355
http://vnx.su

[ALL]

Description
PFP:31940
ECS004TW

position.
SCIA0718E
Gear position
ON (Closed)
OFF (Open)
OFF (Open)
ON (Closed)
ON (Closed)
ON (Closed)
OFF (Open)
OFF (Open)
ECS00CSN

Monitor item
Condition
Display value

ON

OFF
ECS00CSM

: SHIFT SOLENOID/VB

ECS00CSO
CAUTION:
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

Start engine.
3 (GEAR).
SAT014K
AT-356
http://vnx.su

[ALL]
WITHOUT CONSULT-II
1.
2.
3.
4.
Start engine.
Drive vehicle in D1 D2 D3 position.
AT
SCIA5595E
AT-357
http://vnx.su

[ALL]
Wiring Diagram AT SSV/B
ECS004TX
TCWA0041E
AT-358
http://vnx.su

[ALL]
Terminal No.
Wire color
12
Item
Condition
Shift solenoid
valve B
L/Y
Judgement standard
(Approx.)

Battery voltage

operate.
0V
AT
ECS004TY

E
With CONSULT-II
1. Start engine.
3. Read out the value of SHIFT S/V B while driving.
Monitor item
SHIFT S/V B
Condition
Display value

ON

OFF
I
SCIA3251E
Without CONSULT-II
1. Start engine.
Name
Connector No.
F46
Terminal
No. (Wire
color)
12 (L/Y) Ground
Condition
x.)

B operates.
D2 .)
Battery
voltage

B does not operate.
D4 .)
0V
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 2.
AT-359
http://vnx.su
SCIA3253E

[ALL]
2. CHECK SHIFT SOLENOID VALVE B CIRCUIT

1.
2.
3.

Solenoid Valve
Connector No.
Terminal No.
(Wire color)
Resistance
(Approx.)
F46
12 (L/Y) Ground
5 - 20
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.
SCIA3254E
3.
1.
2.
3.
Item
Connector No.
Terminal No.
(Wire color)
TCM
F46
12 (L/Y)

harness connector
F23
1 (L/Y)
Continuity
Yes

OK or NG
OK
>> GO TO 4.
NG
SCIA3255E

1.
2.
3.

Check resistance between terminal cord assembly harness connector F23 terminal 1(L/Y) and ground.
Resistance:
5 - 20
OK or NG
OK
>> GO TO 5.
NG
SCIA3454E
5. CHECK DTC
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 6.
AT-360
http://vnx.su

[ALL]
6. CHECK TCM
OK or NG
OK
>> INSPECTION END
NG
AT
ECS004TZ
Resistance Check

E
Solenoid valve
Shift solenoid
valve B
Resistance
(Approx.)
Terminal No.
1
Ground
5 - 20
G
SCIA2055E
Operation Check

K
SCIA2058E
AT-361
http://vnx.su

[ALL]

Description
PFP:31940
ECS004U0
The overrun clutch solenoid valve is activated by the TCM in

response to signals sent from the inhibitor switch, overdrive control
switch, vehicle speed and throttle position sensors. The overrun
clutch operation will then be controlled.
SCIA0718E
ECS00CSR

Monitor item
Condition
OVERRUN/C S/V (ON/OFF)
Display value
ON
When overrun clutch solenoid valve does not operate.
OFF
ECS00CSS

: OVERRUN CLUTCH S/V
Possible Cause

ECS00CST
ECS00CSU
CAUTION:
NOTE:
TESTING CONDITION:
Always drive vehicle on a level road to improve accuracy of test.
WITH CONSULT-II
1.
2.
3.
4.
5.

Start engine.
Accelerate vehicle to a speed of more than 10 km/h (6 MPH)
with selector lever in D position.
Release accelerator pedal completely with selector lever in 3rd
position.
SAT014K
AT-362
http://vnx.su

[ALL]
WITHOUT CONSULT-II
1.
2.
3.
4.
Start engine.
Selector lever in 3rd position, vehicle speed higher than 10 km/h
(6 MPH).
AT
D
SCIA5596E
AT-363
http://vnx.su

[ALL]
Wiring Diagram AT OVRCSV
ECS004U1
TCWA0042E
AT-364
http://vnx.su

[ALL]
Terminal No.
Wire color
20
Item
Condition
Overrun clutch
solenoid valve
L/B
Judgement standard
(Approx.)

operates.
Battery voltage

does not operate.
0V
ECS004U2
With CONSULT-II
1. Start engine.
3. Read out the value of OVERRUN/C S/V while driving.
OVERRUN/C S/
V
Condition
Display value
ON
When overrun clutch solenoid valve does

not operate.
OFF
AT
Monitor item
I
SCIA3257E
Without CONSULT-II
1. Start engine.
K
Name
Overrun
clutch solenoid valve
Connector No.
F46
Terminal
No. (Wire
color)
20 (L/B) Ground
x.)
Condition
When overrun clutch

solenoid valve operates.
Battery
voltage
When overrun clutch

solenoid valve does not
operate.
0V
M
SCIA3258E
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 2.
AT-365
http://vnx.su

[ALL]
2. CHECK OVERRUN CLUTCH SOLENOID VALVE CIRCUIT

1.
2.
3.

Solenoid Valve
Connector No.
Terminal No.
(Wire color)
Resistance
(Approx.)
Overrun clutch solenoid

valve
F46
20 (L/B) Ground
20 - 30
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.
SCIA3259E
3.
1.
2.
3.
Item
Connector No.
Terminal No.
(Wire color)
TCM
F46
20 (L/B)

harness connector
F23
3 (L/B)
Continuity
Yes

OK or NG
OK
>> GO TO 4.
NG
SCIA3260E

1.
2.
3.

Check resistance between terminal cord assembly harness connector F23 terminal 3 (L/B) and ground.
Resistance:
20 - 30
OK or NG
OK
>> GO TO 5.
NG
SCIA3455E
5. CHECK DTC
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 6.
AT-366
http://vnx.su

[ALL]
6. CHECK TCM
OK or NG
OK
>> INSPECTION END
NG
AT
ECS004U3
For removal, refer toAT-404, "Control Valve Assembly and Accumulators" .
Resistance Check

E
Solenoid valve
Overrun clutch
solenoid valve
Resistance
(Approx.)
Terminal No.
3
Ground
20 - 30
G
SCIA2059E
Operation Check

K
SCIA2062E
AT-367
http://vnx.su

[ALL]

Description
PFP:31940
ECS004U4
The torque converter clutch solenoid valve is activated, with the gear
in D4 , by the TCM in response to signals sent from the vehicle
speed and throttle position sensors. Lock-up piston operation will
then be controlled.
Lock-up operation, however, is prohibited when A/T fluid temperature is too low.
When the accelerator pedal is depressed (less than 2/8) in lock-up
condition, the engine speed should not change abruptly. If there is a
big jump in engine speed, there is no lock-up.
SCIA0718E
ECS00CSV

Monitor item
duty
Condition
Specification
Lock-up OFF
Lock-up ON
Approximately 4%
Approximately 94%
ECS00CSW

: T/C CLUTCH SOL/V
T/C clutch solenoid valve

Possible Cause
ECS00CW8
Torque converter clutch solenoid valve.
Harness or connector.
ECS00CSX
CAUTION:
NOTE:
WITH CONSULT-II
1.
2.
3.
4.

Select DATA MONITOR mode for A/T with CONSULT-II and
wait at least 1 second.
Start engine and maintain the following condition for at least 5
THROTTLE POSI: 0.5/8 - 1.0/8
AT-368
http://vnx.su
SAT014K

[ALL]
WITHOUT CONSULT-II
1.
2.
3.
4.
Start engine.
Drive vehicle in D1 D2 D3 D4 D4 lock-up position.
AT
SCIA5597E
AT-369
http://vnx.su

[ALL]
Wiring Diagram AT TCV
ECS004U5
TCWA0043E
AT-370
http://vnx.su

[ALL]
Terminal No.
Wire color
GY/R
Item
Condition
Torque converter
clutch solenoid
valve
Judgement standard
(Approx.)
8 - 15V
0V
AT
ECS004U6

With CONSULT-II
1. Start engine.
3. Read out the value of TCC S/V DUTY while driving.
Monitor item
TCC S/V
DUTY (%)
Condition
Display value
Lock-up OFF
Lock-up ON
Approx. 4%
Approx. 94%
I
SCIA3257E
Without CONSULT-II
1. Start engine.
K
Name

solenoid
valve
Connector No.
Terminal
No. (Wire
color)
F46
3 (GY/R) Ground
Judgement standard
(Approx.)
Condition
When A/T performs lockup.
8 - 15V
0V
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 2.
M
SCIA3261E
AT-371
http://vnx.su

[ALL]
2. CHECK TORQUE CONVERTER CLUTCH SOLENOID VALVE CIRCUIT

1.
2.
3.

Solenoid Valve
Connector No.
Terminal No.
(Wire color)
Resistance
(Approx.)

solenoid valve
F46
3 (GY/R) Ground
5 - 20
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.
SCIA3262E
3.
1.
2.
3.
Item
Connector No.
Terminal No.
(Wire color)
TCM
F46
3 (GY/R)

harness connector
F23
5 (GR/Y)
Continuity
Yes

OK or NG
OK
>> GO TO 4.
NG
SCIA3263E

1.
2.
3.

Check resistance between terminal cord assembly harness connector F23 terminal 5 (GY/R) and ground.
Resistance:
5 - 20
OK or NG
OK
>> GO TO 5.
NG
SCIA3456E
5. CHECK DTC
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 6.
AT-372
http://vnx.su

[ALL]
6. CHECK TCM
OK or NG
OK
>> INSPECTION END
NG
AT
ECS004U7
Resistance Check

E
Solenoid valve
Torque converter
clutch solenoid
valve
Resistance
(Approx.)
Terminal No.
Ground
5 - 20
G
SCIA2063E
Operation Check

K
SCIA2066E
AT-373
http://vnx.su
BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE)
[ALL]
BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER
PFP:31940
SOURCE)
Description
ECS004U8
SCIA0735E
SAT021J
ECS00CSY

Monitor item
Condition
Cold [20C (68F)]
Hot [80C (176F)]
1.5V
0.5V
2.5 k
0.3 k

: BATT/FLUID TEMP SEN
ECS00CSZ

Possible Cause
ECS00CT0
AT-374
http://vnx.su
[ALL]
ECS00CT1
CAUTION:
WITH CONSULT-II
1.
2.
AT
Start engine.
D
F
SAT014K
3.
4.

VHCL SPEED SE: higher than 20 km/h (12 MPH)
J
SCIA5358E
WITHOUT CONSULT-II
1.
2.
3.
4.
Start engine.
SCIA5598E
AT-375
http://vnx.su
[ALL]
Wiring Diagram AT BA/FTS
ECS004U9
TCWA0235E
AT-376
http://vnx.su
[ALL]
Terminal No.
Wire color
10
BR/W
Item
Judgement standard
(Approx.)
Condition
Power source
or
Battery voltage

OFF.
0V
BR/W
28
Power source
(Memory back-up)
Always
Battery voltage
42
Sensor ground
Always
0V

(68F).
1.5V

(176F).
0.5V
BR
Same as No. 10
ECS004UA

1.
2.

Name
Connector No.
Power source
F46
Power source
(Memory back-up)
F47
Terminal
No. (Wire
color)
10 (BR/W)
Battery voltage
19 (BR/W)
Battery voltage
28 (L)
Battery voltage
AT
19
47
Power source
J
SCIA2656E
3.
4.

Name
Connector No.
Power source
F46
Power source
(Memory back-up)
F47
Terminal
No. (Wire
color)
10 (BR/W)
0V
19 (BR/W)
0V
28 (L)
Battery voltage
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
SCIA2657E
AT-377
http://vnx.su
[ALL]

Harness for short or open between ignition switch and TCM terminal 10, 19
Harness for short or open between battery and TCM terminal 28
Fuse
Ignition switch. Refer to PG-2, "POWER SUPPLY ROUTING" .

OK or NG
OK
>> GO TO 9.
NG
3. CHECK INPUT SIGNAL OF A/T FLUID TEMPERATURE SENSOR

With CONSULT-II
1. Start engine.
Monitor item
Condition
Display value
FLUID TEMP
SE
1.5V
0.5V
LCIA0090E
Without CONSULT-II
1. Start engine.
2. Check voltage TCM connector while warming up A/T.
Name
A/T fluid
temperature
sensor
Connector No.
Terminal
No. (Wire
color)
F47
47 (BR) 42 (B)
Condition
Judgement standard
(Approx.)

is 20C (68F).
1.5V

is 80C (176F).
0.5V
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 4.
SCIA2658E

Harness for short or open between TCM, ECM and terminal cord assembly
Ground circuit for ECM

OK or NG
OK
>> GO TO 5.
NG
AT-378
http://vnx.su
[ALL]
5.
CHECK FLUID TEMPERATURE SENSOR CIRCUIT
1.
2.
3.

Disconnect the TCM connector.
Check resistance between terminals.
Connector
No.
Name
A/T fluid
temperature sensor
F47
Terminal No.
(Wire color)
B
Temperature C (F)
Resistance
(K) (Approx.)
20 (68)
2.5
80 (176)
0.3
AT
47 (BR) - 42 (B)
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 6.
E
SCIA2338E
6.
1.
2.
3.

Item
Connector No.
Terminal No.
(Wire color)
TCM
F47
42 (B)

harness connector
F23
7 (B)
Item
Connector No.
Terminal No.
(Wire color)
TCM
F47
47 (BR)

harness connector
F23
6 (BR)
Continuity
Yes
Continuity
SCIA2660E
Yes

OK or NG
OK
>> GO TO 7.
NG
AT-379
http://vnx.su
[ALL]

1.
2.
3.

Check resistance between terminal cord assembly F23 terminals 6 (BR) and 7 (B) when A/T is cold.
Temperature C (F)
Resistance
20 (68)
Approx. 2.5 k
80 (176)
Approx. 0.3 k

OK or NG
OK
>> GO TO 8.
NG
LCIA0095E

1.
2.
Remove oil pan. Refer to AT-404, "Control Valve Assembly and Accumulators" .
Temperature C (F)
Resistance
20 (68)
Approx. 2.5 k
80 (176)
Approx. 0.3 k

OK or NG
OK
>> GO TO 9.
NG
9. CHECK DTC
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 10.
10. CHECK TCM

OK or NG
OK
>> INSPECTION END
NG
AT-380
http://vnx.su
SAT298F
[ALL]
ECS004UB
For removal, refer toAT-404, "Control Valve Assembly and Accumulators" .

Check resistance between two terminals while changing temperature as shown at left.
Temperature C (F)
Resistance
20 (68)
Approximately 2.5 k
80 (176)
Approximately 0.3 k
AT
D
SAT298F
AT-381
http://vnx.su
ENGINE SPEED SIGNAL

[ALL]
ENGINE SPEED SIGNAL

Description
PFP:24825
ECS004UC
The engine speed signal is sent from the ECM to the TCM.
ECS00CT2

Monitor item
Condition
ENGINE SPEED (rpm)
Display value
Approximately matches the tachometer
reading.
Engine running
ECS00CT3

: ENGINE SPEED SIG

signal from ECM.
ECS00CT4
CAUTION:
WITH CONSULT-II
1.
2.
3.

SAT014K
WITHOUT CONSULT-II
1.
2.
3.
4.
Start engine.
SCIA5599E
AT-382
http://vnx.su
ENGINE SPEED SIGNAL

[ALL]
Wiring Diagram AT ENGSS
ECS004UD
AT
TCWA0232E
AT-383
http://vnx.su
ENGINE SPEED SIGNAL

[ALL]
Terminal No.
39
Wire color
L/OR
Item
Engine speed
signal
Condition
and
Refer to EC-94, "ECM INSPECTION TABLE"

(WITH EURO-OBD) or EC-592, "ECM
INSPECTION TABLE" (WITHOUT EUROOBD).
Judgement standard
(Approx.)
ECS004UE

Perform diagnostic test mode II (self-diagnostic results) for engine control. Check ignition signal circuit condition.
OK or NG
OK
>> GO TO 2.
NG
>> Check ignition signal circuit for engine control. Refer to EC-439, "IGNITION SIGNAL" (WITH
EURO-OBD) or EC-870, "IGNITION SIGNAL" (WITHOUT EURO-OBD).
AT-384
http://vnx.su
ENGINE SPEED SIGNAL

[ALL]
With CONSULT-II
1. Start engine.
AT
E
SAT014K
3.
Read out the value of ENGINE SPEED.

Check engine speed changes according to throttle position.
SAT645J
Without CONSULT-II
1. Start engine.
2. Check voltage between TCM terminal 39 and ground.
Name
Connector No.
Terminal
No. (Wire
color)
Condition
Judgement standard
(Approx.)
Engine
speed signal
F47
39(L/OR) Ground
Refer to EC-592, "ECM

INSPECTION TABLE"
(WITHOUT EURO-OBD).
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.
M
SCIA3265E
AT-385
http://vnx.su
ENGINE SPEED SIGNAL

[ALL]
3.
CHECK HARNESS BETWEEN TCM AND ECM
1.
2.
3.

Disconnect ECM connector and TCM connector.
Check continuity between ECM connector and TCM connector.
Item
Connector No.
Terminal No.
(Wire color)
TCM
F47
39 (L/OR)
ECM
M118
103 (L/OR)
Continuity
Yes
4.
5.

If OK, check continuity between body ground and transaxle
assembly.
OK or NG
OK
>> GO TO 4.
NG
SCIA3269E
4. CHECK DTC
Perform Refer to AT-382, "DTC Confirmation Procedure" .
OK or NG
OK
>> INSPECTION END
NG
Value" .
2. GO TO 5.
5. CHECK TCM
OK or NG
OK
>> INSPECTION END
NG
AT-386
http://vnx.su

[ALL]

Description
PFP:31940
A
ECS004UF
The line pressure solenoid valve regulates the oil pump discharge
pressure to suit the driving condition in response to a signal sent
from the TCM.
The line pressure duty cycle value is not consistent when the
closed throttle position switch is ON. To confirm the line pressure duty cycle at low pressure, the accelerator (throttle)
should be open until the closed throttle position switch is OFF.
AT
D
SCIA0735E
ECS00CT5

Monitor item
Condition
Specification

(Low line pressure)

Approximately 24%
Approximately 95%
NOTE:
The line pressure duty cycle value is not consistent when the closed throttle position switch is ON. To confirm the line pressure duty
cycle at low pressure, the accelerator (throttle) should be open until the closed throttle position switch is OFF.
ECS00CT6

: LINE PRESSURE S/V
Possible Cause

ECS00CT7
ECS00CT8
NOTE:
WITH CONSULT-II
1.

SAT014K
AT-387
http://vnx.su

[ALL]
2.
3.
Depress accelerator pedal completely and wait at least 5 seconds.

If check result is NG, go to AT-390, "Diagnostic Procedure" .
SCIA5358E
WITHOUT CONSULT-II
1.
2.
3.
4.
Start engine.
With brake pedal depressed, shift the lever from P N D N P positions.
SCIA5600E
AT-388
http://vnx.su

[ALL]
Wiring Diagram AT LPSV
ECS004UG
AT
TCWA0046E
AT-389
http://vnx.su

[ALL]
Terminal No.
Wire color
R/W
Item
Condition
Line pressure
solenoid valve
Line pressure
solenoid valve
(with dropping
resistor)
P/B
Judgement standard
(Approx.)

1.5 - 3.0V

0V

5 - 14V

0V
ECS004UH

1.
2.
3.
With CONSULT-II
Read out the value of LINE PRES DTY while driving.
Monitor item
Condition
Display value
LINE PRES
DTY (%)
Line pressure low Line pressure high
24% 95%
SCIA3251E
1.
2.
Without CONSULT-II
Name

(with dropping resistor)
Connector No.
F46
F46
Terminal
No. (Wire
color)
1 (R/W) Ground
2 (P/B) Ground
Condition
Judgement standard
(Approx.)

up engine.
1.5 - 3.0V

warming up engine.
0V

up engine.
5 - 14V

warming up engine.
0V
SCIA3267E
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 2.
AT-390
http://vnx.su

[ALL]
2. CHECK DROPPING RESISTOR

1.
2.
3.

Disconnect dropping resistor harness connector in engine room.
Resistance:
Approx.12
AT
OK or NG
OK
>> GO TO 3.
NG
SCIA3276E

1.
2.
3.

Check resistance between terminal cord assembly harness connector F23 terminal 4 (R/W) and ground.
Resistance:
2.5 - 5
H
OK or NG
OK
>> GO TO 4.
NG
SCIA3457E
AT-391
http://vnx.su

[ALL]
4.
1.
2.
3.
Item
Connector No.
Terminal No.
(Wire color)
TCM
F46
1 (R/W)

harness connector
F23
4 (R/W)
Continuity
Yes
SCIA3272E
4.
Check continuity between terminal cord assembly harness connector and dropping resistor harness connector.
Item
Connector No.
Terminal No.
(Wire color)

connector
E49
1 (R/W)

harness connector
Continuity
Yes
F23
4 (R/W)
SCIA3273E
5.
Check continuity between dropping resistor harness connector

and TCM connector.
Item
Connector No.
Terminal No.
(Wire color)
TCM
F46
2 (P/B)

connector
E49
2 (P/B)
Continuity
Yes

OK or NG
OK
>> GO TO 5.
NG
5. CHECK DTC
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 6.
6. CHECK TCM
OK or NG
OK
>> INSPECTION END
NG
AT-392
http://vnx.su
SCIA3274E

[ALL]
ECS004UI
Resistance Check
Check resistance between terminal 4 and ground.

Solenoid valve
Line pressure
solenoid valve
Resistance
(Approx.)
Terminal No.
4
Ground
AT
2.5 - 5
E
SCIA3457E
Operation Check

SCIA3275E
DROPPING RESISTOR

Resistance:
Approx.12
K
SCIA3276E
AT-393
http://vnx.su
MAIN POWER SUPPLY AND GROUND CIRCUIT

[ALL]

Description
PFP:00100
ECS00CS1
When the power supply to the TCM is cut OFF, for example because the battery is removed, and the self-diagnostics memory function stops, malfunction is detected.
ECS00CS2
Diagnostic trouble code INITIAL START with CONSULT-II is detected when TCM dose not receive the
voltage signal from the battery power supply.
This is not a malfunction message. (Whenever shutting OFF a power supply to the TCM, this message
appears on the screen.)
Possible Cause
ECS00CS3
(Battery or ignition switch and TCM circuit is open or shorted.)
ECS00CS4
NOTE:
If DTC Confirmation Procedure has been previously performed, always turn ignition switch OFF
and wait at least 10 seconds before performing the next test.
WITH CONSULT-II
1.
2.
3.
4.

Wait for at least 2 consecutive seconds.
SAT014K
AT-394
http://vnx.su

[ALL]
Wiring Diagram AT MAIN
ECS004TH
AT
TCWA0240E
AT-395
http://vnx.su

[ALL]
Terminal No.
Wire color
10
BR/W
Item
Power source
or
19
BR/W
25
B/W
28
48
B/W
Judgement standard
(Approx.)
Condition
Battery voltage

OFF.
0V
Power source
Same as No. 10
Ground
Always
0V
Power source
(Memory back-up)
Always
Battery voltage
Ground
Always
0V
ECS004TI

1.
2.

Check voltage between TCM terminals 10, 19, 28 and ground.
Name
Connector No.
Power source
F46
Power source
(Memory back-up)
F47
Terminal
No. (Wire
color)
10 (BR/W)
Battery voltage
19 (BR/W)
Battery voltage
28 (L)
Battery voltage
SCIA0713E
3.
4.

Check voltage between TCM terminal 10, 19, 28 and ground.
Name
Connector No.
Power source
F46
Power source
(Memory back-up)
F47
Terminal No.
(Wire color)
Judgement standard
(Approx.)
10 (BR/W)
0V
19 (BR/W)
0V
28 (L)
Battery voltage
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.
SCIA2657E

Harness for short or open between ignition switch and TCM terminals 10, 19 and 28
Fuse
Ignition switch
Refer to PG-2, "POWER SUPPLY ROUTING" , POWER SUPPLY ROUTING.
OK or NG
OK
>> GO TO 4
NG
AT-396
http://vnx.su

[ALL]

1.
2.
3.

Disconnect TCM harness connector.
Check continuity between TCM terminals 25, 48 and ground.
Name
Connector No.
Terminal No.
(Wire color)
Continuity
Ground
F47
25 (B), 48 (B)
-Ground
Yes
AT
OK or NG
OK
>> GO TO 4.
NG
SCIA2671E
4. CHECK DTC
F

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 5.
5. CHECK TCM
OK or NG
OK
>> INSPECTION END
NG
AT-397
http://vnx.su
A/T SHIFT LOCK SYSTEM

[ALL]

Description
PFP:34950
ECS00405
The mechanical key interlock mechanism also operates as a shift lock:

With the ignition switch turned to ON, the selector lever cannot be shifted from P (parking) to any other
position unless the brake pedal is depressed.
With the key removed, the selector lever cannot be shifted from P to any other position.
The key cannot be removed unless the selector lever is placed in P.
The shift lock and key interlock mechanisms are controlled by the ON-OFF operation of the shift lock solenoid and by the operation of the rotator and slider located inside the key cylinder.
Shift Lock System Electrical Parts Location
ECS00406
SCIA4597E
AT-398
http://vnx.su

[ALL]
Wiring Diagram SHIFT
ECS00407
AT
TCWA0241E
AT-399
http://vnx.su

[ALL]
ECS00408
SYMPTOM 1:
Selector lever cannot be moved from P position with key in ON position and brake pedal
applied.
Selector lever can be moved from P position with key in ON position and brake pedal released.
Selector lever can be moved from P position when key is removed from key cylinder.
SYMPTOM 2:
Ignition key cannot be removed when selector lever is set to P position.
Ignition key can be removed when selector lever is set to any position except P.
1. CHECK KEY INTERLOCK CABLE

Check key interlock cable for damage.
OK or NG
OK
>> GO TO 2.
NG
>> Repair key interlock cable. Refer to AT-402, "KEY INTERLOCK CABLE" .
2. CHECK SELECTOR LEVER POSITION

Check selector lever position for damage.
OK or NG
OK
>> GO TO 3.
NG
>> Check selector lever. Refer to AT-409, "Park/Neutral Position (PNP) Switch Adjustment" .
3. CHECK SHIFT LOCK SOLENOID AND PARK POSITION SWITCH

1.
2.
3.

Selector lever is set in P position.
Check operation sound.
Condition
Brake pedal
Operation sound
When ignition switch is turned to

ON position and selector lever
is set in P position.
Depressed
Yes
Released
No
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 4.
4. CHECK POWER SOURCE

1.
2.

Check voltage between A/T device harness connector M58 terminal 5 (P) and ground.
Voltage:
Brake pedal depressed:
Battery voltage
Brake pedal released:
0V
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 5.
SCIA5337E
AT-400
http://vnx.su

[ALL]

1.
2.
3.

Check continuity between stop lamp switch harness connector M12 terminals 3 (G) and 4 (P).
AT
E
SCIA1796E
Check stop lamp switch after adjusting brake pedal refer to BR-6, "BRAKE PEDAL" .
OK or NG
OK
>> GO TO 6.
NG

Check the following items. If any items are damaged, repair or replace damaged parts.
1. Harness for short or open between battery and stop lamp switch harness connector 3 (G)
2. Harness for short or open between stop lamp switch harness connector 4 (P) and A/T device harness
connector 5 (P)
3. 15A fuse [No.22, located in the fuse block (J/B)]
4. Ignition switch (Refer to PG-2, "POWER SUPPLY ROUTING" .)
OK or NG
OK
>> INSPECTION END
NG
7. CHECK GROUND CIRCUIT

1.
2.
3.

Disconnect A/T device harness connector.
Check continuity between A/T device harness connector M58
terminal 6 (B) and ground.

4. Connect A/T device harness connector.
OK or NG
OK
>> Replace shift lock solenoid or park position switch.
NG
SCIA4284E
AT-401
http://vnx.su
KEY INTERLOCK CABLE

[ALL]
KEY INTERLOCK CABLE

Components
PFP:34908
ECS00409
SAT996J
CAUTION:
Install key interlock cable in such a way that it will not be damaged by sharp bends, twists or interference with adjacent parts.
After installing key interlock cable to control device, make sure that casing cap and bracket are
firmly secured in their positions.
Removal
1.
ECS0040A
Unlock slider by squeezing lock tabs on slider from adjuster

holder and remove interlock rod from cable.
SAT853J
AT-402
http://vnx.su
KEY INTERLOCK CABLE

[ALL]
2.
Remove lock plate from steering lock assembly and remove key
interlock cable.
AT
SAT854J
Installation
1.
2.
3.
4.
ECS0040B
Turn ignition key to lock position.

Set A/T selector lever to P position.
Set key interlock cable to steering lock assembly and install lock
plate.
Clamp cable to steering column and fix to control cable with
band.
G
SAT854J
5.
Insert interlock rod into adjuster holder.

I
K
SAT804E
6.
7.
Install casing cap to bracket.

Move slider in order to fix adjuster holder to interlock rod.
SAT805E
AT-403
http://vnx.su
ON-VEHICLE SERVICE
[ALL]
ON-VEHICLE SERVICE
Control Valve Assembly and Accumulators
PFP:00000
ECS0040C
COMPONENTS
SCIA4320E
1.
Transaxle
2.
Lip seal
3.
O-ring
4.
Servo release accumulator piston
5.
O-ring
6.
Return spring
7.
Control valve assembly
8.
Oil pan gasket
9.
Drain plug gasket
10. Drain plug
11. Magnet
13. Oil pan fitting bolt
14. Snap ring
12. Oil pan

15. O-ring
16. O-ring
17. N-D accumulator piston
18. O-ring
19. Return spring
AT-404
http://vnx.su
ON-VEHICLE SERVICE
[ALL]
REMOVAL AND INSTALLATION
Removal
1.
2.
3.
Disconnect negative battery terminal.

Drain ATF from transaxle. Refer to MA-41, "Changing A/T Fluid"
.
Remove oil pan and gasket.
AT
SAT992C
4.
Disconnect terminal cord assembly harness connector.

F
H
SCIA4853E
5.
6.
Remove snap ring from terminal body.

Remove terminal cord assembly by pushing terminal body into
transaxle case.
SCIA0789E
AT-405
http://vnx.su
ON-VEHICLE SERVICE
[ALL]
7.
Remove control valve assembly by removing fixing bolts A, B

and C .
CAUTION:
Be careful not to drop manual valve and servo release accumulator return springs.
AAT260A
Bolt length, number and location:

Bolt symbol
Bolt length
mm (in)
Number of bolts
8.
40.0 mm
(1.575 in)
33.0 mm
(1.299 in)
43.5 mm
(1.713 in)
Remove manual valve from control valve assembly.

CAUTION:
Be careful not to drop manual valve.
SCIA3150E
Disassemble and inspect control valve assembly if necessary. Refer to AT-448, "Control Valve Assembly"
AT-457, "Control Valve Upper Body" and AT-461, "Control Valve Lower Body" .
10. Remove servo release accumulator and N-D accumulator by
applying compressed air if necessary.
Hold each piston with a paper towel.
9.
SAT935J
AT-406
http://vnx.su
ON-VEHICLE SERVICE
[ALL]
11. Blow air into the oil hole as shown in the figure and remove
servo release accumulator piston from transaxle case.
CAUTION:
Strong flow of air will push the accumulator piston out
along with a splash of oil. Cover the area with paper towels and blow air little by little to avoid this.
Wrap the removed accumulator piston in a paper towel.
12. Remove O-ring from servo release accumulator piston.
AT
SAT019DA
13. Blow air into the oil hole shown in the figure and remove N-D
accumulator piston and return spring from transaxle case.
CAUTION:
along with a splash of oil. Cover the area with paper towels and blow air little by little to avoid this.
14. Remove O-ring from N-D accumulator piston.
15. Remove lip seals from oil groove for band servo.
G
SAT020D
INSTALLATION
Set manual shaft in Neutral position, then align manual

plate with groove in manual valve.
After installing control valve assembly to transaxle case,

make sure that selector lever can be moved to all positions.
After completing installation, check for leakage, and fluid

level. Refer to AT-16, "Checking A/T Fluid".
CAUTION:
Do not reuse O-ring and lip seal.
Do not reuse oil pan gasket and oil pan fixing bolt.
K
SAT497H
AT-407
http://vnx.su
ON-VEHICLE SERVICE
[ALL]
Park/Neutral Position (PNP) Switch
ECS00CRB
COMPONENTS
SCIA4855E
1.
Transaxle assembly
2.
PNP switch

Removal
1.
2.
3.
4.
Set select lever in N position.

Remove front tire LH from vehicle.
Remove LH splash guard. (Front fender side) Refer to EI-21, "Removal and Installation" .
Remove engine under cover.
5.
Remove control cable end from manual shaft.
SCIA3156E
6.
7.
Remove PNP switch fixing bolts.

Remove PNP switch from transaxle assembly.
SCIA3154E
Installation
Align PNP switch position when installing.
AT-408
http://vnx.su
ON-VEHICLE SERVICE
[ALL]
After installation is completed, adjust and check A/T position. Refer to AT-409, "Control Cable Adjustment"
, AT-409, "Park/Neutral Position (PNP) Switch Adjustment" .
After installation is completed, check continuity of PNP switch. Refer to AT-100, "DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH" .
CONTROL CABLE ADJUSTMENT

Move selector lever from the P position to the 1 position. You should
be able to feel the detents in each position. If the detents cannot be
felt or if the pointer indicating the position is improperly aligned, the
control cable needs adjustment.
1. Place selector lever in P position.
2. Loosen control cable lock nut and place manual shaft in P position.
3. Pull control cable, by specified force, in the direction of the arrow
shown in the illustration.
AT
Specified force: 6.9N (0.7 kg, 1.5 lb)

4.
5.
6.
7.
Return control cable in the opposite direction of the arrow for 1.0
mm (0.039 in).
Tighten control cable lock nut.
Move selector lever from P to 1 position again. Make sure that
selector lever moves smoothly.
Apply grease to contacting areas of selector lever and control
cable. Install any part removed.
AAT980
PARK/NEUTRAL POSITION (PNP) SWITCH ADJUSTMENT

1.
2.
Set select lever and manual shaft in N position.

Remove control cable end from manual shaft.
M
SCIA3156E
3.
4.
a.
b.
5.
6.
7.
8.
9.
Loosen PNP switch fixing bolts.

Use a 3 mm (0.12 in) pin for this adjustment.
Insert the pin straight into the manual shaft adjustment hole.
Rotate PNP switch until the pin can also be inserted straight into
hole in PNP switch.
Tighten PNP switch fixing bolts.
Remove pin from adjustment hole after adjusting PNP switch.
Reinstall any part removed.
Adjust control cable. Refer to AT-409, "Control Cable Adjustment" .
Check continuity of PNP switch. Refer to AT-237 (EUR-OBD) or AT-324 (Except EUR-OBD).
AT-409
http://vnx.su
SCIA3154E
ON-VEHICLE SERVICE
[ALL]
Differential Side Oil Seal Replacement
ECS0040F
COMPONENTS
SCIA4970E
1.
1.
2.
3.
4.
transaxle assembly
2.
LH differential side oil seal
3.
RH differential side oil seal
Remove exhaust front tube. Refer to EX-2, "Removal and Installation"

Remove left side drive shaft assemblies. Refer to FAX-11, "FRONT DRIVE SHAFT" .
Remove transfer from right side of transaxle.
Refer to TF-57, "Removal and Installation" .
Remove differential side oil seal using a flat-bladed screwdriver.
CAUTION:
Be careful not to scratch transaxle case.
SCIA2792E
Installation
1.
As shown below, use a drift to drive the differential side oil seals
into the case until it is flush. Refer to dimensions A.
Unit: mm (in)
A
-0.5 to 0.5 (-0.020 to 0.020)
0.5 to 0.5 (0.020 to 0.020)
NOTE:
The differential side oil seal pulling direction is used as the reference.
SCIA0791E
AT-410
http://vnx.su
ON-VEHICLE SERVICE
[ALL]
Drift to be used:
Transaxle case side:
Converter housing side:
ST33400001
KV40100621
AT
SCIA4739E
2.
CAUTION:
Apply ATF to differential side oil seal.
Do not reuse differential side oil seal.
Reinstall any part removed.
CAUTION:
If lubricant leak has occurred, after finishing work, check A/T fluid level.
AT-411
http://vnx.su
ON-VEHICLE SERVICE
[ALL]
Revolution Sensor Replacement
ECS0040G
COMPONENTS
SCIA4864E
1.
1.
2.
3.
4.
5.
transaxle assembly
2.
Revolution sensor
3.
O-ring
Remove front tire LH from vehicle.

Remove LH splash guard.(Front fender side) Refer toEI-21, "Removal and Installation" .
Disconnect revolution sensor harness connector.
Remove harness bracket from transaxle assembly.
Remove revolution sensor from transaxle assembly.
SCIA2788E
Installation
CAUTION:
Apply petroleum jelly to O-ring.
AT-412
http://vnx.su

[ALL]

Removal
PFP:00000
A
ECS004NC
COMPONENTS
B
AT
SCIA6893E
1.
Transfer assembly
2.
A/T fluid level gauge
3.
A/T fluid charging pipe
4.
O-ring
5.
Center member
6.
7.
Grommet
8.
Fluid cooler tube
9.
Fluid cooler tube
10. Copper washer
11. Copper washer
13. Stopper
14. LH engine mounting insulator
AT-413
12. Transaxle assembly
CAUTION:
Before separating transaxle from engine, remove the crankshaft position sensor (Euro-OBD) from
transaxle. Be careful not to damage sensor.
1. Remove battery and bracket, air cleaner and air duct.
2. Remove air breather hose.
3. Disconnect terminal cord assembly harness connector, PNP switch harness connector and revolution
sensor harness connector.
4. Remove crankshaft position sensor (Euro-OBD) from transaxle.
5. Disconnect control cable from transaxle.
6. Remove front exhaust tube. Refer to EX-2, "Removal and Installation"
7. Disconnect A/T fluid cooler hoses.
8. Remove drive shafts. Refer to FAX-11, "FRONT DRIVE SHAFT" , RAX-10, "REAR DRIVE SHAFT" .
9. Remove transfer assembly. Refer to TF-57, "Removal and Installation" .
10. Remove starter motor from transaxle. Refer to SC-26, "Removal and Installation" .
11. Support transaxle with a transmission jack.
http://vnx.su

[ALL]
12. Remove center member, engine insulator and engine mounting
bracket.
Center member fixing bolts to specified torque, Refer to AT413, "Components" .
13. Remove suspension member. Refer to FSU-12, "FRONT SUSPENSION MEMBER" .
SCIA0794E
14. Remove dust cover from converter housing part.

15. Turn crankshaft, and remove the four tightening bolts for drive
plate and torque converter.
CAUTION:
The crankshaft should be rotated clockwise, viewed from
the front of engine.
AAT259A
16. Support engine with a transmission jack.

17. Remove bolts fixing transaxle to engine.
18. Lower transaxle while supporting it with a transmission jack.
ATM0479D
19. Disconnect harness connector and wire harness.

20. Remove A/T fluid charging pipe.
SCIA5885E
AT-414
http://vnx.su

[ALL]
21. Remove fluid cooler tube.
A
AT
SCIA2596E
INSPECTION
Installation and inspection of torque converter
After inserting a torque converter to a transaxle, be sure to

check distance A to ensure it is within the reference value limit.
Distance A
QR20DE models:
QR25DE models:
19.0 mm (0.75 in) or more

SAT573D
Installation
ECS004ND
Install the removed parts in the reverse order of the removal, while paying attention to the following work.
When installing transaxle to the engine, attach the fixing bolts in

accordance with the following standard.
Bolt No.
Tightening torque
Nm (kg-m, ft-lb)
1
2
Bolt length L
mm (in)
45 (1.77)
40 (1.57)
43 (4.4, 32)
5
6
49 (1.93)
75 (7.7, 55)
3
4
30 (1.18)
40 (1.57)
36 (3.7, 27)
L
SCIA0795E
45 (1.97)
Align the positions of tightening bolts for drive plate with those of
the torque converter, and temporarily tighten the bolts. Then,
tighten the bolts to the specified torque. Refer to AT-416, "Components" .
CAUTION:
When turning crankshaft, turn it clockwise as viewed from

the front of the engine.
When tightening the tightening bolts for the torque converter after fixing the crankshaft pulley bolts, be sure to
confirm the tightening torque of the crankshaft pulley
SCIA3138E
mounting bolts.
After converter is installed to drive plate, rotate crankshaft

several turns and check to be sure that transaxle rotates freely without binding.
After completing installation, check for fluid leakage, fluid level, and the positions of A/T. Refer to AT-16,
"Checking A/T Fluid" , AT-409, "Control Cable Adjustment" .
AT-415
http://vnx.su
OVERHAUL
[ALL]
OVERHAUL
Components
PFP:00000
ECS004LW
SCIA4426E
AT-416
http://vnx.su
OVERHAUL
[ALL]
1.
2.
Pinion mate gear thrust washer
3.
Pinion mate gear
4.
Pinion mate shaft
5.
Lock pin
6.
Side gear
7.
Side gear thrust washer
8.
9.
Differential case
10. Final gear
11. Differential side bearing adjusting

shim
12. RH differential side oil seal
14. Converter housing
15. Differential lubricant tube
16. Clip
17. O-ring
18. Oil pump housing oil seal
19. Oil pump housing
20. O-ring
21. Outer gear
22. Inner gear
23. Oil pump cover
24. Oil pump assembly
25. Seal ring
26. Gasket
AT
AT-417
http://vnx.su
OVERHAUL
[ALL]
SCIA4911E
1.
Snap ring
2.
Retaining plate
3.
Driven plate
4.
Dish plate
5.
Snap ring
6.
Spring retainer
7.
Return spring
8.
Reverse clutch piston
9.
Seal ring
AT-418
http://vnx.su
OVERHAUL
[ALL]
10. D-ring
11. Reverse clutch drum
12. Thrust washer
13. Reverse clutch assembly
14. Drive plate
15. Needle bearing
16. Bearing race
17. Front sun gear
18. Needle bearing
19. High clutch hub
20. Needle bearing
21. Snap ring
22. Retaining plate
23. Driven plate
24. Snap ring
25. Spring retainer
26. D-ring
27. D-ring
28. High clutch piston
29. High clutch drum
30. Seal ring
31. Needle bearing
32. Bearing race
33. High clutch assembly
34. Return spring
35. Drive plate
36. Needle bearing
37. Overrun clutch hub
38. Thrust washer
39. Bearing race
41. Bearing race
42. Forward clutch hub
43. Thrust washer
44. Rear internal gear
45. Needle bearing
46. Rear planetary carrier
47. Rear sun gear
48. Front planetary carrier
49. Spring retainer
50. D-ring
51. D-ring
52. Low & reverse brake piston
53. Retainer
54. Snap ring
56. Snap ring
57. Needle bearing
58. Needle bearing
59. Forward clutch drum
60. Forward clutch piston
61. Seal ring
62. D-ring
63. Spring retainer
64. Snap ring
65. Dish plate
66. Driven plate
67. Retaining plate
68. Snap ring
69. Dish plate
70. Driven plate
71. Retaining plate
72. Retaining plate
73. Snap ring
74. Forward clutch assembly and overrun clutch assembly
75. Drive plate
76. Drive plate
77. Return spring
78. overrun clutch piston
79. D-ring
80. seal ring
81. Retaining plate
82. Driven plate
83. Low & reverse brake assembly
84. snap ring
85. Retaining plate
86. Dish plate
87. Drive plate
AT
AT-419
http://vnx.su
OVERHAUL
[ALL]
SCIA4862E
1.
Side cover fitting bolt
2.
Output shaft bearing
3.
Output shaft
4.
Seal ring
5.
Needle bearing
6.
Parking actuator support
7.
LH differential side oil seal
8.
O-ring
9.
Revolution sensor
AT-420
http://vnx.su
OVERHAUL
[ALL]
10. Bracket
11. Anchor end pin
12. Lock nut
13. Transaxle case
14. Brake band
15. Bearing retainer
16. Seal ring
17. Radial needle bearing
18. Snap ring
19. Reduction pinion gear
20. Reduction pinion gear bearing inner

race
21. Reduction pinion gear bearing outer

race
22. Strut
23. O-ring
24. O-ring
25. Servo release accumulator piston
26. O-ring
27. Return spring
29. Oil pan gasket
30. Drain plug gasket
31. Drain plug
32. Magnet
33. Oil pan
34. Oil pan fitting bolt
35. Low & reverse brake tube
36. Oil sleeve
37. O-ring
38. Snap ring
39. O-ring
40. N-D accumulator piston
41. Return spring
42. Lip seal
43. Parking rod
44. Retaining pin
45. Manual shaft oil seal
46. Detent spring
47. Manual shaft
48. Retaining pin
49. Manual plate
50. Parking rod plate
51. O/D servo piston
52. O/D servo piston retainer
53. O/D servo piston retainer fitting bolt
54. O-ring
55. D-ring
56. Servo piston retainer
57. O-ring
58. E-ring
59. Spring retainer
60. O/D servo return spring
61. D-ring
62. Band servo piston
63. Band servo thrust washer
64. Band servo piston stem
65. 2nd servo return spring
66. Parking pawl

69. Paring pawl spacer
67. Parking shaft
68. Return spring
70. PNP switch
71. Idler gear bearing
72. Idler gear
73. Idler gear lock nut
74. Reduction pinion gear adjusting

shim
75. Output shaft adjusting shim
AT
76. Side cover
AT-421
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OVERHAUL
[ALL]
Oil Channel
ECS004LX
SCIA5650E
AT-422
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OVERHAUL
[ALL]
Locations of Adjusting Shims, Needle Bearings, Thrust Washers and Snap

Rings
ECS004LY
AT
SCIA0799E
AT-423
http://vnx.su
DISASSEMBLY
[ALL]
DISASSEMBLY
Disassembly
1.
PFP:31020
ECS004LZ
Drain ATF through drain plug.
SCIA0003E
2.
Remove torque converter.
SAT008D
3.
a.
b.
c.
Check torque converter one-way clutch using check tool as

shown in the right figure.
Insert check tool into the groove of bearing support built into
one-way clutch outer race.
When fixing bearing support with check tool, rotate one- way
clutch spline using screwdriver.
Check that inner race rotates clockwise only. If not, replace
torque converter assembly.
SAT009D
AT-424
http://vnx.su
DISASSEMBLY
[ALL]
4.
5.
6.
7.
8.
Set manual shaft to position P.

Remove park/neutral position (PNP) switch.
Remove bracket from transaxle case.
Remove revolution sensor from transaxle case.
Remove O-ring from revolution sensor.
AT
SCIA3154E
9.
Remove oil pan and oil pan gasket.

Do not reuse oil pan bolts.
10. Check foreign materials in oil pan to help determine causes of
malfunction. If the fluid is very dark, smells burned, or contains
foreign particles, the frictional material (clutches, band) may
need replacement. A tacky film that will not wipe clean indicates
varnish build up. Varnish can cause valves, servo, and clutches
to stick and can inhibit pump pressure.
If frictional material is detected, replace radiator after
repair of A/T. Refer to CO-12, "RADIATOR" .
11. Remove magnets from oil pan.
G
SCIA3476E
12. Remove control valve assembly according to the following procedures.

a. Remove snap ring from terminal body.
K
SCIA4866E
b.
Push terminal body into transaxle case and draw out terminal
cord assembly.
SCIA0801E
AT-425
http://vnx.su
DISASSEMBLY
[ALL]
c.
Remove control valve assembly mounting bolts A, B and C .

Bolt symbol
Bolt length
mm (in)
Number of bolts
40.0 mm
(1.575 in)
33.0 mm
(1.299 in)
43.5 mm
(1.713 in)
AAT260A
d.
Remove control valve assembly from transaxle case.
13. Remove manual valve from control valve assembly.

CAUTION:
Be careful not to drop manual valve and servo release accumulator return springs.
14. Remove O-ring from terminal body.
SAT005F
15. Remove return spring from servo release accumulator piston.
SCIA4741E
AT-426
http://vnx.su
DISASSEMBLY
[ALL]
16. Remove servo release accumulator piston with compressed air.
CAUTION:
along with a splash of oil.Cover the area with paper towels and blow air little by little to avoid this.
17. Remove O-rings from servo release accumulator piston.
AT
SAT019DA
18. Remove N-D accumulator piston and return spring with compressed air.
CAUTION:
along with a splash of oil.Cover the area with paper towels and blow air little by little to avoid this.
19. Remove O-rings from N-D accumulator piston.
G
SAT020D
20. Check accumulator pistons and contact surface of transaxle

case for damage.
21. Check accumulator return springs for damage and free length.
SAT023DA
22. Remove lip seals.

L
SCIA4867E
23. Remove low & reverse brake tube and oil sleeve.
SCIA3478E
AT-427
http://vnx.su
DISASSEMBLY
[ALL]
24. Remove converter housing according to the following procedures.
a. Remove converter housing mounting bolts.
b. Remove converter housing by tapping it lightly.
ATM0024D
c.
Remove O-ring from differential oil port.
SCIA3281E
25. Remove final drive assembly from transaxle case.
SAT228F
26. Remove differential side bearing outer race.
SAT010FC
27. Remove differential side bearing adjusting shim from transaxle

case.
SCIA4742E
AT-428
http://vnx.su
DISASSEMBLY
[ALL]
28. Remove differential side bearing outer race from converter
housing.
AT
SAT011FC
29. Remove RH differential side oil seal with flat-bladed screwdriver

from converter housing.
CAUTION:
Be careful not to damage converter housing.
G
SCIA3283E
30. Remove differential lubricant tube from converter housing.
SAT063K
31. Remove oil pump assembly according to the following procedures.

a. Remove O-ring from input shaft assembly (high clutch drum).
SCIA2979E
AT-429
http://vnx.su
DISASSEMBLY
[ALL]
b.
Remove oil pump assembly and gasket from transaxle case.
SCIA3282E
c.
Remove thrust washer and bearing race from oil pump assembly.
SCIA3629E
32. Remove brake band according to the following procedures.

a. Loosen lock nut, then back off anchor end pin.
CAUTION:
Do not reuse anchor end pin.
SCIA4324E
b.
Remove brake band and strut from transaxle case.
SAT196F
AT-430
http://vnx.su
DISASSEMBLY
[ALL]
To prevent brake linings from cracking or peeling, do not

stretch the flexible band unnecessarily. When removing
the brake band, always secure it with a clip as shown in
the right figure.
Leave the clip in position after removing the brake band.
AT
SAT039D
c.
Check brake band facing for damage, cracks, wear or burns.

E
G
SAT040D
33. Remove input shaft assembly (high clutch assembly) and reverse clutch assembly according to the following procedures.
a. Remove input shaft assembly (high clutch assembly) with
reverse clutch assembly.
K
SCIA4009E
b.
Remove input shaft assembly (high clutch assembly) from

reverse clutch.
SCIA4010E
AT-431
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DISASSEMBLY
[ALL]
c.
Remove needle bearing from input shaft assembly (high clutch

drum) and check for damage or wear.
SCIA4872E
d.
Remove high clutch hub (with front sun gear) and needle bearing from input shaft assembly (high clutch drum) and check for
damage or wear.
SCIA5195E
e.
f.
Remove front sun gear and needle bearing from high clutch hab
and check for damage or wear.
Remove bearing race from front sun gear and check for damage
or wear.
SCIA4013E
34. Remove needle bearing from transaxle case and check for damage or wear.
SCIA4014E
35. Apply compressed air and check to see that low and reverse
brake operates.
SAT138F
AT-432
http://vnx.su
DISASSEMBLY
[ALL]
36. Remove low one-way clutch and front planetary carrier assembly according to the following procedures.
a. Remove snap ring with flat-bladed screwdriver.
AT
D
SCIA4743E
b.
c.
Remove low one-way clutch with a hook made of wire.

Check low one-way clutch for damage or wear.
K
AAT889
d.
Remove snap ring with flat-bladed screwdriver.
SCIA4744E
AT-433
http://vnx.su
DISASSEMBLY
[ALL]
e.
Remove front planetary carrier with low & reverse brake piston
and retainer.
SAT023F
f.
Remove low and reverse brake spring retainer.

CAUTION:
Do not remove return springs from spring retainer.
SAT148F
g.
Check that low one-way clutch rotates in the direction of the

clockwise arrow and locks in the opposite direction.
SAT048D
h.
i.
Remove needle bearing, low and reverse brake piston and

retainer from front planetary carrier.
Check front planetary carrier, low & reverse brake piston,
retainer and needle bearing for damage or wear.
SCIA3636E
j.
k.
Check front planetary carrier, low one-way clutch and needle

bearing for damage or wear.
Check clearance between planetary gears and planetary carrier
with feeler gauge.
Standard clearance: 0.20 - 0.70 mm (0.0079 - 0.0276 in)
Allowable limit: 0.80 mm (0.0315 in)
Replace front planetary carrier if the clearance exceeds
allowable limit.
SAT025F
AT-434
http://vnx.su
DISASSEMBLY
[ALL]
37. Remove rear planetary carrier and rear sun gear according to
the following procedures.
a. Remove rear planetary carrier (with rear sun gear) from transaxle case.
AT
SAT026F
b.
Remove rear sun gear from rear planetary carrier.

E
G
SAT027F
c.
d.
Remove needle bearings from rear planetary carrier.

Check rear planetary carrier, rear sun gear and needle bearings
for damage or wear.
SCIA4016E
e.
Check clearance between pinion washer and rear planetary carrier with feeler gauge.

M
Replace rear planetary carrier if the clearance exceeds allowable limit.
SAT054D
38. Remove rear internal gear and forward clutch hub from transaxle case.
SAT029F
AT-435
http://vnx.su
DISASSEMBLY
[ALL]
39. Remove overrun clutch hub from transaxle case.
SAT030F
40. Remove needle bearing from overrun clutch hub and check for
damage or wear.
SCIA4017E
41. Remove forward clutch assembly and overrun clutch assembly

SCIA4878E
42. Remove needle bearing from transaxle case and check for damage or wear.
SCIA4019E
43. Remove output shaft assembly according to the following procedures.

a. Remove side cover bolts.
CAUTION:
Do not mix bolts A and B.
Always replace bolts A as they are self-sealing bolts.
AAT850
AT-436
http://vnx.su
DISASSEMBLY
[ALL]
b.
Remove side cover by lightly tapping it with a soft hammer.

CAUTION:
Be careful not to drop output shaft assembly. It might
come out when removing side cover.
Be careful not to damage side cover.
AT
SAT434D
c.
Remove adjusting shim.

E
G
SAT440D
d.
Remove output shaft assembly.
SAT035F
If output shaft assembly came off with side cover, tap cover
with a soft hammer to separate.
CAUTION:
Be careful not to damage side cover.
SAT435D
e.
Remove needle bearing.
SCIA4327E
AT-437
http://vnx.su
DISASSEMBLY
[ALL]
f.
Remove bearing retainer from transaxle case.
ATM0315D
44. Disassemble reduction pinion gear according to the following

procedures.
a. Set manual shaft to position P to fix idler gear.
b. Unlock idler gear lock nut using a pin punch.
SAT037F
c.
Remove idler gear lock nut.

CAUTION:
Do not reuse idler gear lock nut.
SAT061D
d.
Remove idler gear with puller.
SAT841DC
e.
f.
Remove reduction pinion gear.

Remove reduction pinion gear adjusting shim from reduction
pinion gear.
SCIA3669E
AT-438
http://vnx.su
DISASSEMBLY
[ALL]
45. Remove return spring and parking pawl spacer with flat-bladed
screwdriver from parking shaft.
46. Draw out parking shaft and remove parking pawl from transaxle
case.
47. Check parking pawl and shaft for damage or wear.
AT
SCIA4881E
48. Remove parking actuator support from transaxle case.

49. Check parking actuator support for damage or wear.
E
G
SAT066D
50. Remove LH differential side oil seal with flat-bladed screwdriver

CAUTION:
SAT040F
AT-439
http://vnx.su
REPAIR FOR COMPONENT PARTS

[ALL]

Manual Shaft
PFP:00000
ECS00EBZ
COMPONENTS
SCIA3286E
1.
Manual shaft oil seal
2.
Parking rod
3.
Retaining pin
4.
Parking rod plate
5.
Retaining pin
6.
Manual plate
7.
Manual shaft
8.
Retaining pin
9.
Detent spring
REMOVAL
1.
Remove detent spring from transaxle case.
SAT042F
2.
Drive out manual plate retaining pin.
SAT842DC
AT-440
http://vnx.su

[ALL]
3.
4.
5.
6.
Drive and pull out parking rod plate retaining pin.

Remove parking rod plate (with parking rod) from manual shaft.
Draw out parking rod (with parking rod plate) from transaxle
case.
Remove parking rod from parking rod plate.
AT
SAT043FC
7.
8.
Pull out manual shaft retaining pin.

Remove manual shaft and manual plate from transaxle case.
E
G
SAT049F
9.
Remove manual shaft oil seal.

CAUTION:
K
SAT080D
INSPECTION
Check component parts for wear or damage. Replace if necessary.

M
INSTALLATION
1.
2.
Use a drift [commercial service tool 22 mm (0.87 in)] to drive

manual shaft oil seal into the transaxle case.
CAUTION:
Do not reuse manual shaft oil seal.
Apply ATF to outer surface of manual shaft oil seal.
Install parking rod to parking rod plate.
SAT081D
AT-441
http://vnx.su

[ALL]
3.
4.
Install manual shaft and manual plate.

Install parking rod plate (with parking rod) on manual shaft.
SCIA3627E
5.
6.
Align groove of manual shaft and hole of transaxle case.

Install manual shaft retaining pin up to bottom of hole.
CAUTION:
SAT045FC
7.
Set parking rod plate onto manual shaft and drive retaining pin.
CAUTION:
Both ends of pin should protrude.
SAT034JA
8.
Install manual plate retaining pin.

CAUTION:
Both ends of pin should protrude.
SAT047FC
9.
Install detente spring on transaxle case. Tighten detente spring

fitting bolt to the specified torque. Refer to AT-440, "COMPONENTS" .
SAT042F
AT-442
http://vnx.su

[ALL]
Oil Pump
ECS00EC0
COMPONENTS
AT
SCIA3341E
1.
Oil pump housing oil seal
2.
Oil pump housing
3.
O-ring
4.
Outer gear
5.
Inner gear
6.
Oil pump cover
7.
Seal ring
DISASSEMBLY
1.
Remove seal rings.
ATM0090D
2.
Loosen bolts in a crisscross pattern and remove oil pump cover.

M
SAT051F
AT-443
http://vnx.su

[ALL]
3.
Remove inner and outer gear from oil pump housing.
SAT092D
4.
Remove O-ring from oil pump housing.
SCIA2841E
5.
Remove oil pump housing oil seal.

CAUTION:
Be careful not to scratch oil pump housing.
SAT094D
AT-444
http://vnx.su

[ALL]
INSPECTION
Oil Pump Housing, Oil Pump Cover, Inner Gear and Outer Gear
Check for wear or damage.
Side Clearances
Measure the side clearance of inner and outer gears in at least

four places around each outside edge. Maximum measured values should be within specified positions.
AT
If the clearance is less than standard, select inner and outer

gear as a set so that clearance is within specifications. Refer to
AT-530, "SERVICE DATA AND SPECIFICATIONS (SDS)" .
If the clearance is more than standard, replace whole oil pump
assembly except oil pump cover.
SAT095D
Measure the clearance between outer gear and oil pump housing.
J

If not within allowable limit, replace whole oil pump assembly

except oil pump cover.
L
SAT096D
Seal Ring Clearance
Measure the clearance between seal ring and ring groove.

If not within allowable limit, replace oil pump cover assembly.
SAT097D
AT-445
http://vnx.su

[ALL]
ASSEMBLY
1.
Install oil pump housing oil seal on oil pump housing.

CAUTION:
Do not reuse oil pump housing oil seal.
Apply ATF to outer surface of oil pump housing oil seal.
SAT900DA
2.
Install O-ring on oil pump housing.

CAUTION:
Apply ATF to O-ring.
SCIA2841E
3.
Install inner and outer gears on oil pump housing.

CAUTION:
Be careful of the direction of inner gear.
SAT092D
4.
a.
b.
Install oil pump cover on oil pump housing.

Wrap masking tape around splines of oil pump cover assembly
to protect seal. Position oil pump cover assembly on oil pump
housing assembly, then remove masking tape.
Tighten bolts in a crisscross pattern. Tighten oil pump cover
bolts to the specified torque. Refer to AT-443, "COMPONENTS"
.
SAT051F
AT-446
http://vnx.su

[ALL]
5.
Install new seal rings carefully after packing ring groove with
petroleum jelly.
CAUTION:
Do not spread the gap of seal ring excessively while
installing. The ring may be deformed.
Do not reuse seal rings.
Apply petroleum jelly to seal rings.
AT
SCIA3638E
AT-447
http://vnx.su

[ALL]
Control Valve Assembly
ECS00EC1
COMPONENTS
SCIA4973E
1.
Oil strainer
2.
O-ring
3.
4.
Terminal body
5.
O-ring
6.
Solenoid valve assembly
7.
Control valve lower body
8.
Oil cooler relief valve spring
9.
Check ball
Support plate
12.
Steel ball
15.
Separating plate
10. Separating plate
11.
13. Control valve inter body
14. Pilot filter
16. Steel ball
17. Control valve upper body
AT-448
http://vnx.su
Snap ring

[ALL]
DISASSEMBLY
A
Disassemble upper, inter and lower bodies.

Bolt symbol
Bolt length
mm (in)
Number of bolts
13.5
(0.531)
58.0
(2.283)
40.0
(1.575)
66.0
(2.598)
33.0
(1.299)
78.0
(3.071)
18.0
(0.709)
11
AT
f: Reamer bolt and nut.
I
SCIA4974E
1.
Remove bolts a, d , reamer bolt f and nut and remove oil

strainer from control valve assembly.
SCIA4439E
2.
Remove bolts a, c, g , solenoid valve assembly and line pressure solenoid valve from control valve assembly.
SCIA4438E
AT-449
http://vnx.su

[ALL]
3.
Remove O-rings from solenoid valves and terminal body.
SCIA3693E
4.
Place control valve upper body facedown, and remove bolts b ,

and nut f .
CAUTION:
Remove bolts with control valve upper body facing down,
because control valve upper body and control valve inter
body may come off and steel ball may fall and be lost.
SCIA4437E
5.
Remove control valve lower body from control valve inter body.
SCIA4975E
6.
7.
Turn over control valve lower body.

Remove bolts e , separating plate and support plates from control valve lower body.
SCIA5637E
8.
Remove check balls and oil cooler relief valve springs from control valve lower body.
CAUTION:
Be careful not to lose check balls and oil cooler relief valve
springs.
SAT110DA
AT-450
http://vnx.su

[ALL]
9.
Remove control valve inter body from control valve upper body.
A
AT
SCIA4977E
10. Check to see that steel balls are properly positioned in control
valve inter body and then remove them.
CAUTION:
Be careful not to lose steel balls.
11. Remove pilot filter from control valve upper body.
12. Remove separating plate from control valve upper body.
G
SAT705J
13. Check to see that steel balls are properly positioned in control
valve upper body and then remove them.
CAUTION:
Be careful not to lose steel balls.
SAT771J
INSPECTION
Control Valve Lower Body and Upper Body
CAUTION:
Be careful not to lose these parts.
Check to see that retainer plates are properly positioned in control valve lower body.
SCIA4978E
AT-451
http://vnx.su

[ALL]
Check to see that retainer plates are properly positioned in control valve upper body.
SCIA4979E
Oil Strainer
Check wire netting of oil strainer for damage.
SCIA3291E
Shift Solenoid Valves A and B, Line Pressure Solenoid Valve, Torque Converter Clutch
Solenoid Valve and Overrun Clutch Solenoid Valve
Measure resistance.
Except for EURO-OBD:
For shift solenoid valve A, refer to AT-350, "SHIFT SOLENOID
VALVE A" .
For shift solenoid valve B, refer to AT-356, "SHIFT SOLENOID
VALVE B" .
For line pressure solenoid valve, refer to AT-387, "LINE PRESSURE SOLENOID VALVE" .
For torque converter clutch solenoid valve, refer to AT-368,
"TORQUE CONVERTER CLUTCH SOLENOID VALVE" .
SCIA0805E
For overrun clutch solenoid valve, refer to AT-362, "OVERRUN
CLUTCH SOLENOID VALVE" .
For A/T fluid temperature sensor, refer toAT-374, "BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR
CIRCUIT AND TCM POWER SOURCE)" .
EURO-OBD:
For shift solenoid valve A, refer to AT-161, "DTC P0750 SHIFT SOLENOID VALVE A" .
For shift solenoid valve B, refer to AT-167, "DTC P0755 SHIFT SOLENOID VALVE B" .
For line pressure solenoid valve, refer to AT-154, "DTC P0745 LINE PRESSURE SOLENOID VALVE" .
For torque converter clutch solenoid valve, refer to AT-148, "DTC P0740 TORQUE CONVERTER
CLUTCH SOLENOID VALVE" .
For overrun clutch solenoid valve, refer to AT-178, "DTC P1760 OVERRUN CLUTCH SOLENOID VALVE"
.
For A/T fluid temperature sensor, refer to AT-184, "DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE)" .
AT-452
http://vnx.su

[ALL]
Oil Cooler Relief Valve Spring
Check springs for damage or deformation.

Measure free length and outer diameter. Refer to AT-530, "SERVICE DATA AND SPECIFICATIONS (SDS)" .
AT
SAT138D
ASSEMBLY
1.
a.
Install control valve upper, inter and lower body.

Place oil circuit of control valve upper body face up. Install steel
balls in their proper positions.
SAT771J
b.
Install reamer bolts f from bottom of control valve upper body.

Using reamer bolts as guides, install separating plate as a set.
CAUTION:
Do not reuse separating plate.
K
SCIA4980E
c.
Install pilot filter.
SAT074F
AT-453
http://vnx.su

[ALL]
d.
Place control valve inter body as shown in the figure (side of

control valve lower body face up). Install steel balls in their
proper positions.
SAT705J
e.
Install control valve inter body on control valve upper body using
reamer bolts f as guides.
CAUTION:
Be careful not to dislocate or drop steel balls.
SCIA4981E
f.
Install check balls and oil cooler relief valve springs in their
proper positions in control valve lower body.
SAT110DA
g.
h.
Install bolts e from bottom of control valve lower body. Using

bolts e as guides, install separating plate as a set.
CAUTION:
Do not reuse separating plate.
Install support plates on control valve lower body.
SCIA4982E
i.
Install control valve lower body on control valve inter body using
reamer bolts f as guides and tighten reamer bolts f slightly.
SCIA5669E
AT-454
http://vnx.su

[ALL]
2.
Install O-rings to solenoid valves and terminal body.

CAUTION:
Do not reuse O-rings.
Apply ATF to O-rings.
AT
SCIA3693E
3.
Install and tighten bolts.

Bolt symbol
Bolt length
mm (in)
Number of bolts
13.5
(0.531)
58.0
(2.283)
40.0
(1.575)
66.0
(2.598)
33.0
(1.299)
78.0
(3.071)
18.0
(0.709)
11
Tightening torque
Nm (kg-m, in-lb)
7.8 (0.80, 69)
4.0
(0.41, 35)
7.8 (0.80, 69)
f: Reamer bolt and nut.
M
SCIA4974E
a.
Install and tighten bolts b and nut f to specified torque.

: 7.8 Nm (0.80 kg-m, 69 in-lb)
SCIA4437E
AT-455
http://vnx.su

[ALL]
b.
c.
Install solenoid valve assembly and line pressure solenoid valve

on control valve assembly.
Tighten bolts a , c and g to specified torque.
: 7.8 Nm (0.80 kg-m, 69 in-lb)
SCIA4438E
d.
Set oil strainer, then tighten bolts a , d and nut f to specified

torque.
: 7.8 Nm (0.80 kg-m, 69 in-lb)
SCIA3484E
e.
Tighten bolts e to specified torque.

: 4.0 Nm (0.41 kg-m, 35 in-lb)
SCIA3487E
AT-456
http://vnx.su

[ALL]
Control Valve Upper Body
ECS00EC2
COMPONENTS
AT
SCIA2960J
AT-457
http://vnx.su

[ALL]
1.
Retainer plate
2.
Plug
3.
Cooler check valve spring
4.
Cooler check valve
5.
Control valve upper body
6.
Pilot valve
7.
Pilot valve spring
8.
Retainer plate
9.
1-2 accumulator retainer plate
10. 1-2 accumulator piston spring
11.
1-2 accumulator piston
12. Plug
13. Retainer plate
14.
Retainer plate
15. Plug
16. 1st reducing valve
17.
1st reducing valve spring
18. Retainer plate
19. 3-2 timing valve spring
20.
3-2 timing valve
21. Retainer plate
22. Plug
23.
24. Overrun clutch reducing valve spring
25. Retainer plate
26.
Torque converter relief valve spring 27. Torque converter relief valve
28. Retainer plate
29.
Sleeve
30. Plug
31. Torque converter clutch control valve 32.

spring
Torque converter clutch control

valve
33. Retainer plate
34. Plug
1-2 accumulator valve spring
36. 1-2 accumulator valve
35.
DISASSEMBLY
1.
Remove valves at retainer plates.

CAUTION:
Do not use a magnetic pick-up tool.
SCIA4979E
a.
Use a screwdriver to remove retainer plates.
SAT553G
b.
Remove retainer plates while holding spring, plugs or sleeves.

CAUTION:
Remove plugs slowly to prevent internal parts from jumping
out.
SAT554G
AT-458
http://vnx.su

[ALL]
c.
Place mating surface of valve body face down, and remove

internal parts.
CAUTION:
If a valve is hard to remove, place valve body face down
and lightly tap it with a soft hammer.
Be careful not to drop or damage valves and sleeves.
AT
SAT137D
INSPECTION
Valve Spring
Measure free length and outer diameter of each valve spring.

Also check for damage or deformation. Refer to AT-530, "SERVICE DATA AND SPECIFICATIONS (SDS)" .
Replace valve springs if deformed or fatigued.
H
SAT138D
Control Valves
Check sliding surfaces of valves, sleeves and plugs.
ASSEMBLY
CAUTION:
Apply ATF to all components before installation.
Lay control valve body down when installing valves. Do not

stand control valve body upright.
SAT139D
Lubricate control valve body and all valves with ATF. Install control valves by sliding them carefully into their bores.
CAUTION:
Install each control valve one by one.
Install control valves after checking, because some of
them are similar.
Be careful not to scratch or damage valve body.
SAT140DA
AT-459
http://vnx.su

[ALL]
Wrap a small screwdriver with vinyl tape and use it to insert

valves into their proper positions.
SAT141D
1-2 Accumulator Valve
Install 1-2 accumulator valve. Align 1-2 accumulator retainer

plate from opposite side of control valve body.
Install 1-2 accumulator piston spring, 1-2 accumulator valve
spring, 1-2 accumulator piston and plugs.
SCIA5638E
Install retainer plates.

While pushing plugs (with 1-2 accumulator piston spring and 1-2
accumulator valve spring), install retainer plate.
SAT143D
Retainer Plate (Control Valve Upper Body)

Unit: mm (in)
Loca
tion
Name of control valve
L14
Pilot valve
L16
1st reducing valve
L17
3-2 timing valve
L19
L15
1-2 accumulator valve
Width A
Length B
21.5 (0.846)
6.0 (0.236)
40.5 (1.594)
1-2 accumulator piston
L18
L21
Cooler check valve
L20
SAT086F
24.0 (0.945)
28.0 (1.102)
Install proper retainer plates.

Refer to AT-457, "Control Valve Upper Body" .
AT-460
http://vnx.su

[ALL]
Control Valve Lower Body
ECS00EC3
COMPONENTS
AT
SCIA2959J
AT-461
http://vnx.su

[ALL]
1.
Retainer plate
2.
Pressure modifier piston spring
3.
Pressure modifier piston
4.
Parallel pin
5.
Sleeve
6.
Pressure modifier valve spring
7.
Pressure modifier valve
8.
Control valve lower body
9.
Manual valve
10. Pressure regulator valve
11. Pressure regulator valve spring
13. Plug
14. Retainer plate
12. Spring seat

15. Sleeve
16. Overrun clutch control valve spring
17. Overrun clutch control valve
18. Plug
19. Retainer plate
20. Accumulator control valve spring
21. Accumulator control valve
22. Plug
23. Retainer plate
24. Retainer plate
25. Shift valve A spring
26. Shift valve A
27. Retainer plate
28. Plug
29. Shuttle plug
30. Shuttle valve spring
31. Shuttle valve
32. Shift valve B spring
33. Shift valve B
34. Plug
35. Retainer plate
DISASSEMBLY
Remove valves at retainer plates.

For removal procedures, refer to AT-458, "DISASSEMBLY" .
SCIA4978E
INSPECTION
Valve Springs
Check each valve spring for damage or deformation. Also measure free length and outer diameter. Refer to AT-530, "SERVICE
DATA AND SPECIFICATIONS (SDS)" .
Replace valve springs if deformed or fatigued.
SAT138D
Control Valves
Check sliding surfaces of control valves, sleeves and plugs for damage.
ASSEMBLY
CAUTION:
Apply ATF to all components before installation.
Lay control valve body down when installing valves. Do not

stand control valve body upright.
SAT139D
AT-462
http://vnx.su

[ALL]
Install control valves.

For installation procedures, refer to AT-459, "ASSEMBLY" .
AT
SCIA4978E
Retainer Plate (Control Valve Lower Body)
Install proper retainer plates. Refer to AT-461, "COMPONENTS" .

Unit: mm (in)
Loca
tion
Name of control valve and plug
L3
Pressure regulator valve
L5
Accumulator control valve
L6
Shift valve A
L4
L13
Pressure modifier valve
L7
Shuttle valve
L12
Shift valve B
Width A
Length B
Type
6.0
(0.236)
28.0
(1.102)
SAT089F
17.0
(0.669)
24.0
(0.945)
II
AT-463
http://vnx.su

[ALL]
Reverse Clutch
ECS00EC4
COMPONENTS
SCIA3889E
1.
Reverse clutch drum
2.
D-ring
3.
Seal ring
4.
Reverse clutch piston
5.
Return spring
6.
Spring retainer
7.
Snap ring
8.
Dish plate
9.
Driven plate
10. Retaining plate
11. Snap ring
12. Drive plate
DISASSEMBLY
1.
a.
b.
c.
Check operation of reverse clutch

Install seal ring onto drum support of oil pump cover and install
reverse clutch assembly. Apply compressed air to oil hole.
Check to see that retaining plate moves to snap ring.
If retaining plate does not contact snap ring:
D-ring might be damaged.
Seal ring might be damaged.
Fluid might be leaking past piston check ball.
SAT092F
2.
3.
Remove snap ring.

Remove drive plates, driven plates, retaining plate, and dish
plates.
SCIA5639E
AT-464
http://vnx.su

[ALL]
4.
5.
Set SST on spring retainer and remove snap ring from reverse
clutch drum while compressing return spring.
CAUTION:
Set SST directly over return spring.
Do not expand snap ring excessively.
Remove spring retainer and return springs.
AT
SAT094FC
6.
7.
Remove reverse clutch piston from reverse clutch drum by turning it.
Remove D-ring and seal ring from reverse clutch piston.
G
SAT096F
INSPECTION
Reverse Clutch Snap Rings, Spring Retainer and Return Spring
Check for deformation, fatigue or damage.

If necessary, replace.
Reverse Clutch Drive Plates
Check facing for burns, cracks or damage.

Measure the thickness of facing.
Thickness of drive plate:

Standard value: 1.6 mm (0.063 in)
Wear limit: 1.4 mm (0.055 in)
If not within wear limit, replace.

L
SAT162D
Reverse Clutch Dish Plates
Check for deformation or damage.

Measure the thickness of dish plate.
Thickness of dish plate: 3.08 mm (0.1213 in)
If deformed or fatigued, replace.
SAT163D
Reverse Clutch Piston
Make sure that check balls are not fixed.

Apply compressed air to check ball oil hole opposite the return spring. Make sure there is no air leakage.
AT-465
http://vnx.su

[ALL]
Apply compressed air to oil hole on return spring side to make

sure that air leaks past ball.
SCIA0192E
ASSEMBLY
1.
Install D-ring and Seal ring on piston.

CAUTION:
Take care with the direction of Seal ring.
Apply ATF to D-ring and seal ring.
Do not reuse D-ring and seal ring.
SCIA3735E
2.
Install reverse clutch piston by turning it slowly.

CAUTION:
Apply ATF to inner surface of drum.
SAT096F
3.
4.
Install return springs and spring retainer on reverse clutch piston.

Set SST on spring retainer and install snap ring while compressing return spring.
CAUTION:
Set SST directly over return spring.
SAT094FC
AT-466
http://vnx.su

[ALL]
5.
Install drive plates, driven plates, retaining plate and dish plates.
Refer to AT-533, "REVERSE CLUTCH" .
CAUTION:
Be careful with the order and the direction of plates.
AT
G
SCIA4888E
NOTE:
Install two dish plates fitting each installation direction with
reverse clutch drum groove displaced slightly.
K
SAT170D
6.
Install snap ring.
SCIA5639E
AT-467
http://vnx.su

[ALL]
7.
Measure the clearance between retaining plate and snap ring. If

not within allowable limit, select proper retaining plate. Refer to
AT-533, "REVERSE CLUTCH" .
Specified clearance:
Standard: 0.5 - 0.8mm (0.020 - 0.031 in)
SAT105F
8.
Check operation of reverse clutch. Refer to AT-464, "DISASSEMBLY" .
SAT092F
AT-468
http://vnx.su

[ALL]
High Clutch
ECS00EC5
COMPONENTS
AT
SCIA2951E
1.
Seal ring
2.
Driven plate
3.
Retaining plate
4.
Snap ring
5.
Drive plate
6.
Snap ring
7.
Cancel cover
8.
D-ring
9.
D-ring
10. Return spring
11. High clutch piston
12. Input shaft assembly (High clutch

drum)
DISASSEMBLY
1.
a.
b.
c.
Check operation of high clutch.

Apply compressed air to oil hole of input shaft assembly (high
clutch drum) with nylon cloth.
CAUTION:
Stop up hole on opposite side of input shaft assembly (high
clutch drum) with nylon cloth.
L
SAT176D
2.
Remove seal rings from input shaft assembly (high clutch drum).
CAUTION:
Always replace seal rings when removed.
SCIA4890E
AT-469
http://vnx.su

[ALL]
3.
4.

Remove drive plates, driven plates and retaining plate.
SCIA4891E
5.
6.
Set SST on spring retainer and remove snap ring from input
shaft assembly (high clutch drum) while compressing return
springs.
CAUTION:
Set SST directly over springs.
SAT108FB
7.
Remove high clutch piston from input shaft assembly (high

clutch drum) by turning it.
SAT111F
8.
Remove D-rings from high clutch piston.
SCIA4441E
INSPECTION
High Clutch Snap Ring, Spring Retainer and Return Springs

When replacing spring retainer and return springs, replace them as a set.
AT-470
http://vnx.su

[ALL]
High Clutch Drive Plates


Standard value 1.6 mm (0.063 in)
Wear limit 1.4 mm (0.055 in)
AT
SAT162D
High Clutch Piston

Apply compressed air to check ball oil hole opposite return
spring. Make sure there is no air leakage.
Apply compressed air to oil hole on return spring side to make
SAT186D
Seal Ring Clearance
Install new seal rings onto input shaft assembly (high clutch
drum).
Measure the clearance between seal ring and ring groove.

If not within allowable limit, replace input shaft assembly.

K
SCIA4442E
ASSEMBLY
1.
Install D-rings on high clutch piston.

CAUTION:
Apply ATF to D-rings.
Do not reuse D-rings.
SCIA4441E
AT-471
http://vnx.su

[ALL]
2.
Install high clutch piston by turning it slowly.

CAUTION:
Apply ATF to inner surface of input shaft assembly (high
clutch drum).
SAT111F
3.
Install return springs and spring retainer on high clutch piston.
SAT109F
4.
Set SST on spring retainer and install snap ring while slowly
compressing return springs.
CAUTION:
Set SST directly over return springs.
SAT108FB
CAUTION:
Do not align snap ring gap with spring retainer stopper.
SAT113F
AT-472
http://vnx.su

[ALL]
5.
Install drive plates, driven plates and retaining plate. Refer to

AT-533, "HIGH CLUTCH" .
CAUTION:
Be careful with the order and the direction of plates.
AT
G
SCIA3034E
6.
Install snap ring with flat-bladed screwdriver.
SCIA4891E
7.
Measure clearance between retaining plate and snap ring. If not

within allowable limit, select proper retaining plate. Refer to AT533, "HIGH CLUTCH" .
Specified clearance
Standard:
Allowable limit:
1.8 - 2.2 mm (0.071 - 0.087 in)

2.8 mm (0.110 in)
SCIA4892E
8.
Check operation of high clutch. Refer to AT-469, "DISASSEMBLY" .
SAT196D
AT-473
http://vnx.su

[ALL]
9.
Install seal rings to input shaft assembly (high clutch drum).

CAUTION:
SCIA4890E
CAUTION:
Roll paper around seal rings to prevent seal rings from
spreading.
SAT198D
AT-474
http://vnx.su

[ALL]
Forward and Overrun Clutches
ECS00EC6
COMPONENTS
AT
I
SCIA3892E
1.
Driven plate
2.
Snap ring
3.
Dish plate
4.
Driven plate
5.
Retaining plate
6.
Retaining plate
7.
Snap ring
8.
Drive plate
9.
Forward clutch
10. Retaining plate
11. Drive plate
12. Overrun clutch
13. Dish plate
14. Spring retainer
15. Snap ring
16. Return spring
17. Overrun clutch piston
18. D-ring
19. Seal ring
20. Forward clutch piston
21. D-ring
22. Seal ring
23. Forward clutch drum
DISASSEMBLY
1.
a.
b.
c.
d.
Check operation of forward clutch and overrun clutch.

Install bearing retainer on forward clutch drum.
Apply compressed air to oil hole of forward clutch drum.
Seal ring might be damaged.
SAT123F
AT-475
http://vnx.su

[ALL]
2.
3.
Remove snap ring for forward clutch.

Remove drive plates, driven plates, retaining plate and dish
plate for forward clutch.
SCIA4894E
4.
5.
Remove snap ring for overrun clutch with flat-bladed screwdriver.

Remove drive plates, driven plates, retaining plate and dish
plate for overrun clutch.
SCIA4895E
6.
7.
Set Tool on spring retainer and remove snap ring from forward
clutch drum while compressing return springs.
CAUTION:
CAUTION:
Do not remove return springs from spring retainer.
SAT124FC
8.
Remove forward clutch piston with overrun clutch piston from

forward clutch drum by turning it.
SAT125F
9.
Remove overrun clutch piston from forward clutch piston by

turning it.
SAT126F
AT-476
http://vnx.su

[ALL]
10. Remove D-rings and seal rings from forward clutch piston and
overrun clutch piston.
AT
SCIA3046E
INSPECTION
Snap Rings, Spring Retainer and Return Springs

Replace if necessary.
Forward Clutch and Overrun Clutch Drive Plates


Forward clutch
Overrun clutch
I
SAT162D
Forward Clutch and Overrun Clutch Dish Plates

Measure the thickness of dish plate.
Thickness of dish plate:

Forward clutch 2.7 mm (0.106 in)
Overrun clutch 2.7 mm (0.106 in)
If deformed or fatigued, replace.
SAT163D
Forward Clutch Drum

Apply compressed air to check ball oil hole from the outside of
forward clutch drum. Make sure air leaks past ball.
Apply compressed air to oil hole from the inside of forward
clutch drum. Make sure there is no air leakage.
SAT213D
AT-477
http://vnx.su

[ALL]
Overrun Clutch Piston

Apply compressed air to check ball oil hole opposite the return
spring. Make sure there is no air leakage.
Apply compressed air to oil hole on return spring side. Make
SAT212D
ASSEMBLY
1.
Install D-rings and Seal rings on forward clutch piston and overrun clutch piston.
CAUTION:
Do not reuse D-rings and seal rings.
Take care with the direction of seal rings.
Apply ATF to both parts.
SCIA3046E
2.
Install overrun clutch piston on forward clutch piston by turning it

slowly.
CAUTION:
Apply ATF to inner surface of forward clutch piston.
SAT126F
3.
Install forward clutch piston assembly on forward clutch drum by

turning it slowly.
CAUTION:
Apply ATF to inner surface of forward clutch drum.
SAT125F
AT-478
http://vnx.su

[ALL]
4.
Install spring retainer and return spring on overrun clutch piston.

A
AT
SAT131F
Align the mark on spring retainer with check ball in overrun

clutch piston.
E
G
SAT133F
5.
Set SST on spring retainer and install snap ring while compressing return springs.
CAUTION:
SAT124FC
CAUTION:
Do not align snap ring gap with spring retainer stopper.
SAT134F
AT-479
http://vnx.su

[ALL]
6.
Install drive plates, driven plates, retaining plate and dish plate
for overrun clutch. Refer to AT-534, "OVERRUN CLUTCH" .
CAUTION:
Take care with the order of plates.
SCIA3036E
7.
Install snap ring for overrun clutch.
SCIA4895E
8.
Measure the clearance between overrun clutch retaining plate

and snap ring.
If not within allowable limit, select proper retaining plate. Refer to
AT-534, "OVERRUN CLUTCH" .
Standard 0.7 - 1.1 mm (0.028 - 0.043 in)
Allowable limit 1.7 mm (0.067 in)
SAT135F
9.
Install drive plates, driven plates, retaining plate and dish plate for forward clutch.
CAUTION:
Take care with the order of plates.
AT-480
http://vnx.su

[ALL]
For 85X23 model

A
AT
G
SCIA4496E
For 85X64 model
SCIA4065E
10. Install snap ring for forward clutch.
SCIA4894E
AT-481
http://vnx.su

[ALL]
11. Measure clearance between forward clutch retaining plate and
snap ring.
If not within allowable limit, select proper retaining plate. Refer to
AT-533, "FORWARD CLUTCH" .
Standard 0.45 - 0.85 mm (0.0177 - 0.0335 in)
SAT228D
12. Check operation of forward clutch and overrun clutch. Refer to

AT-475, "DISASSEMBLY" .
SAT123F
AT-482
http://vnx.su

[ALL]
Low & Reverse Brake
ECS00EC7
COMPONENTS
AT
F
SCIA3893E
1.
Driven plate
2.
Dish plate
3.
Snap ring
4.
Spring retainer
5.
D-ring
6.
D-ring
7.
Low & reverse brake piston
8.
Retainer
9.
Snap ring
10. Retaining plate
11. Drive plate
12. Retaining plate
DISASSEMBLY
1.
a.
b.
c.
2.
3.
Check operation of low & reverse brake.

Apply compressed air to oil hole of transaxle case.

Remove retainer, low & reverse brake piston and spring retainer
SCIA4903E
4.
5.

Remove driven plates, drive plate, retaining plate and dish
plates on transaxle case.
SCIA4904E
AT-483
http://vnx.su

[ALL]
6.
In order to remove low & reverse brake piston, apply compressed air to oil hole of retainer while holding low & reverse
brake piston.
CAUTION:
Apply air gradually and allow low & reverse brake piston to
come out evenly.
SCIA3651E
7.
Remove D-rings from low & reverse brake piston.
SCIA4381E
INSPECTION
Low and Reverse Brake Snap Ring, Spring Retainer and Return Springs

Low and Reverse Brake Drive Plate
Check the facing for burns, cracks or damage.

Standard value 1.8 mm (0.071 in)
Wear limit 1.6 mm (0.063 in)
SAT162D
ASSEMBLY
1.
Install D-rings on piston.

CAUTION:
Apply ATF to both parts.
Do not reuse D-ring.
SCIA2998E
AT-484
http://vnx.su

[ALL]
2.
Set and align low & reverse brake piston with retainer.
CAUTION:
This operation is required in order to engage the protrusions of piston to return springs correctly.
Further procedures are given in AT-507, "ASSEMBLY" .
Apply ATF to surface of low & reverse brake piston and
retainer.
AT
SCIA3652E
3.
Install driven plates, drive plates, retaining plate and dish plate on transaxle case. Refer to AT-533,
"Clutch and Brakes" .
CAUTION:
Take care with the order of plates and direction of dish plate.
For 85X23 model
SCIA4624E
AT-485
http://vnx.su

[ALL]
For 85X64 model
SCIA4066E
4.
SCIA4904E
5.
Measure clearance between retaining plate and transaxle case.

If not within allowable limit, select proper retaining plate. (front
side) Refer to AT-534, "LOW & REVERSE BRAKE" .
Standard 1.7 - 2.1 mm (0.067 - 0.083 in)
SCIA3654E
6.
7.
8.
Install low & reverse brake piston (with retainer) and spring
retainer on transaxle case.
Check operation of low & reverse brake. Refer to AT-483, "DISASSEMBLY" .
SCIA4903E
AT-486
http://vnx.su

[ALL]
Rear Internal Gear, Forward Clutch Hub and Overrun Clutch Hub
ECS00EC8
COMPONENTS
AT
SCIA4051E
1.
Overrun clutch hub
2.
Thrust washer
3.
Bearing race
4.
5.
Forward clutch hub
6.
Thrust washer
7.
Rear internal gear
DISASSEMBLY
1.
Remove overrun clutch hub and thrust washer from forward

clutch hub.
SCIA3692E
2.
Remove forward clutch hub from rear internal gear.

M
SAT251D
AT-487
http://vnx.su

[ALL]
3.
Remove bearing from rear internal gear.
SAT252DA
4.
Remove thrust washer from rear internal gear.
SCIA3691E
5.
Remove bearing from forward one-way clutch.
SAT254DA
6.
Remove forward one-way clutch from forward clutch hub.
SAT255D
AT-488
http://vnx.su

[ALL]
INSPECTION
Rear Internal Gear, Forward Clutch Hub and Overrun Clutch Hub
Check rubbing surfaces for wear or damage.

B
AT
D
SAT256D
Bearings and Forward One-way Clutch
Check bearings for deformation and damage.

Check forward one-way clutch for wear and damage.
F
H
SAT158FA
ASSEMBLY
1.
Install forward one-way clutch on forward clutch.

CAUTION:
Take care with the direction of forward one-way clutch.
L
SAT976H
2.
Install bearing on forward one-way clutch.

CAUTION:
Apply petroleum jelly to bearing.
SCIA3658E
AT-489
http://vnx.su

[ALL]
3.
Install thrust washer on rear internal gear.

CAUTION:
Apply petroleum jelly to thrust washer.
Align hooks of thrust washer with holes of rear internal
gear.
SCIA3690E
4.
Install bearing on rear internal gear.

CAUTION:
Apply petroleum jelly to the bearing.
SCIA3659E
5.
Install forward clutch hub on rear internal gear.

CAUTION:
Check operation of forward one-way clutch.
Hold rear internal gear and turn forward clutch hub.
Check forward clutch hub for correct locking and unlocking directions.
If not as shown in figure, check installation direction of
forward one-way clutch.
AAT426
6.
Install thrust washer and overrun clutch hub.

CAUTION:
Align hooks of thrust washer with holes of overrun clutch
hub.
Align projections of rear internal gear with holes of overrun clutch hub.
SCIA3692E
AT-490
http://vnx.su

[ALL]
Output Shaft, Idler Gear, Reduction Pinion Gear and Bearing Retainer
ECS00EC9
COMPONENTS
AT
J
SCIA4061E
1.
Idler gear lock nut
2.
Idler gear
3.
Reduction pinion gear bearing

adjusting shim
4.
Idler gear bearing
5.
Reduction pinion gear bearing outer

race
6.
Reduction pinion gear bearing inner

race
7.
Reduction pinion gear
8.
Snap ring
9.
Radial needle bearing
10. Seal ring
11. Bearing retainer
12. Needle bearing
13. Seal ring
14. Out put shaft
15. Out put shaft bearing
16. Output shaft adjusting shim
DISASSEMBLY
1.
Remove seal rings from output shaft and bearing retainer.
SCIA3660E
AT-491
http://vnx.su

[ALL]
2.
Remove output shaft bearing with flat-bladed screwdrivers.

CAUTION:
Always replace bearing with a new one when removed.
Do not damage output shaft.
SAT165F
3.
Remove snap ring from bearing retainer.
SAT166F
4.
Remove needle bearing from bearing retainer.
SAT167F
5.
Remove idler gear bearing inner race from idler gear.
SCIA4959E
6.
Remove idler gear bearing outer race from transaxle case.
SAT859DD
AT-492
http://vnx.su

[ALL]
7.
Press out reduction pinion gear bearing inner race from reduction pinion gear.
AT
SAT169F
8.
Remove reduction pinion gear bearing outer race from transaxle

case.
E
G
SAT319K
INSPECTION
Output Shaft, Idler Gear and Reduction Pinion Gear
Check shafts for cracks, wear or bending.

Check gears for wear, chips and cracks.
Bearing
Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
When replacing taper roller bearing, replace outer and inner
race as a set.
SPD715
Seal Ring Clearance
Install new seal rings to output shaft.

Measure the clearance between seal ring and ring groove of
output shaft.
Standard clearance:
0.10 - 0.25 mm (0.0039 - 0.0098 in)
Allowable limit:
0.25 mm (0.0098 in)
If not within allowable limit, replace output shaft.

Install new seal rings to bearing retainer.
Measure the clearance between seal ring and ring groove of bearing retainer.
Standard clearance:
0.10 - 0.30 mm (0.0039 - 0.0118 in)
AT-493
http://vnx.su
SAT171F

[ALL]
Allowable limit:
0.30 mm (0.0118 in)
If not within allowable limit, replace bearing retainer.
ASSEMBLY
1.
Press reduction pinion gear bearing inner race on reduction pinion gear.
CAUTION:
Apply ATF to reduction pinion gear bearing inner race.
SAT172FC
2.
3.
Install reduction pinion gear bearing outer race on transaxle

case. Refer to AT-491, "COMPONENTS" .
Checking reduction pinion gear bearing preload. Refer to AT509, "REDUCTION PINION GEAR BEARING PRELOAD" .
SAT319K
4.
Press idler gear bearing inner race on idler gear.

CAUTION:
Do not reuse idler gear bearing.
Apply ATF to idler gear bearing.
SAT174FC
5.
Install idler gear bearing outer race on transaxle case.

CAUTION:
SAT175FD
AT-494
http://vnx.su

[ALL]
6.
Press output shaft bearing on output shaft.

CAUTION:
Do not reuse output shaft bearing.
Apply ATF to output shaft bearing.
AT
SAT863DB
7.
Press needle bearing on bearing retainer.

E
G
SAT176F
8.
Install snap ring to bearing retainer.
SAT166F
9.
After packing ring grooves with petroleum jelly, carefully install

new seal rings on output shaft and bearing retainer.
CAUTION:
SCIA3660E
AT-495
http://vnx.su

[ALL]
CAUTION:
Roll paper around seal rings to prevent seal rings from
spreading.
SAT179F
AT-496
http://vnx.su

[ALL]
Band Servo Piston Assembly
ECS00ECA
COMPONENTS
AT
SCIA4908E
1.
Lock nut
2.
Anchor end pin
3.
Brake band
4.
Strut
5.
O-ring
6.
Servo piston retainer
7.
D-ring
8.
O/D servo piston
9.
O-rings
10. O/D servo piston retainer
11. E-ring
12. Spring retainer
13. O/D servo return spring
14. D-ring
15. Band servo piston
16. Band servo thrust washer
17. Band servo piston stem
18. 2nd servo return spring
DISASSEMBLY
1.
Remove O/D servo piston retainer fitting bolts.
AAT879
2.
3.
Apply compressed air to oil hole in transaxle case to remove O/

D servo piston retainer and band servo piston assembly.
CAUTION:
Hold band servo piston assembly with a rag or nylon waste.
Remove 2nd servo return spring from transaxle case.
SCIA4447E
AT-497
http://vnx.su

[ALL]
4.
Apply compressed air to oil hole in O/D servo piston retainer to

remove O/D servo piston from O/D servo piston retainer.
CAUTION:
Hold O/D servo piston while applying compressed air.
SCIA5645E
5.
Remove D-ring from O/D servo piston.
SCIA3689E
6.
Remove O-rings from O/D servo piston retainer.
SCIA5646E
7.
Remove band servo piston assembly from servo piston retainer

by pushing it forward.
SAT293D
8.
Place band servo piston stem end on a wooden block. While

pushing spring retainer down, remove E-ring.
SAT294D
AT-498
http://vnx.su

[ALL]
9.
Remove spring retainer, O/D servo return spring, band servo

thrust washer and band servo piston stem from band servo piston.
AT
SCIA4746E
10. Remove O-rings from servo piston retainer.

E
G
SCIA3671E
11. Remove D-rings from band servo piston.
SCIA3688E
INSPECTION
Pistons, Retainers and Piston Stem
Check frictional surfaces for abnormal wear or damage.
Return Springs

Measure the free length and outer diameter. Refer to AT-538,
"Band Servo" .
AAT884
AT-499
http://vnx.su

[ALL]
ASSEMBLY
1.
Install D-rings to band servo piston.

CAUTION:
Do not reuse D-rings.
Apply ATF to D-rings.
Pay attention to position of each D-rings.
SCIA3688E
2.
Install band servo piston stem, band servo thrust washer, O/D
servo return spring and spring retainer to band servo piston.
SCIA4746E
3.
Place band servo piston stem end on a wooden block. While

pushing spring retainer down, install E-ring.
CAUTION:
Do not reuse E-ring.
SCIA4336E
4.
Install O-rings to servo piston retainer.

CAUTION:
Pay attention to position of each O-rings.
SCIA3671E
AT-500
http://vnx.su

[ALL]
5.
Install band servo piston assembly to servo piston retainer by

pushing it inward.
AT
SAT303D
6.
Install D-ring to O/D servo piston.

CAUTION:
Do not reuse D-ring.
Apply ATF to D-ring.
G
SCIA3689E
7.
Install O/D servo piston to O/D servo piston retainer fitting the
installation direction on it.
AAT886
8.
Install band servo piston assembly and 2nd servo return spring
to transaxle case.
CAUTION:
Apply ATF to O-rings of band servo piston assembly and
transaxle case.
SCIA3672E
9.
Install O-rings to O/D servo piston retainer.

CAUTION:
Pay attention to position of each O-rings.
SCIA5646E
AT-501
http://vnx.su

[ALL]
10. Install O/D servo piston retainer to transaxle case. Refer to AT497, "COMPONENTS" .
CAUTION:
Do not reuse O/D servo piston retainer fitting bolts.
Apply ATF to O-rings of O/D servo piston retainer and
transaxle case.
AAT879
AT-502
http://vnx.su

[ALL]
Final Drive
ECS00ECB
COMPONENTS
AT
SCIA3346E
1.
Pinion mate gear
4.
Lock pin
7.
2.
Pinion mate gear thrust washer
3.
Pinion mate shaft
5.
Side gear
6.
Side gear thrust washer
8.
Differential case
9.
Final gear
11. Differential side bearing adjusting

shim
DISASSEMBLY
1.
Remove final gear.

J
L
SMT505B
2.
Press out differential side bearings.

CAUTION:
Be careful not to mix up the right and left bearings.
SMT744AA
AT-503
http://vnx.su

[ALL]
3.
Remove differential side bearing outer race, and side bearing

SAT010FA
4.
Drive out lock pin.
SAT904DA
5.
6.
Draw out pinion mate shaft.

Remove pinion mate gears, pinion mate gear thrust washers,
side gears and side gear thrust washers.
SAT316D
INSPECTION
Check mating surfaces of differential case, side gears, pinion

mate gears and pinion mate shaft.
Check washers for wear.
SAT544F
AT-504
http://vnx.su

[ALL]
Bearings
Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
When replacing taper roller bearing, replace outer and inner
race as a set.
AT
SPD715
ASSEMBLY
1.
Attach side gear thrust washers to side gears, then install pinion
mate thrust washers and pinion mate gears in place.
CAUTION:
Apply ATF to any parts.
SMT839
2.
Insert pinion mate shaft.

CAUTION:
When inserting, be careful not to damage pinion mate
thrust washers.
K
SMT087A
3.
a.
Measure the clearance between side gear and differential case

with washers following the procedure below:
Set the special tool and dial indicator on side gear.
SMT097CA
AT-505
http://vnx.su

[ALL]
b.
Move side gear up and down to measure dial indicator deflection. Always measure indicator deflection on both side gears.
with washer:
0.1 - 0.2 mm (0.004 - 0.008 in)
c.
If not within specification, adjust the clearance by changing the

thickness of differential side gear thrust washers. Refer to AT535, "Final Drive" .
SMT611A
4.
Install lock pin.

CAUTION:
Do not reuse lock pin.
Make sure that lock pin is flush with case.
SMT699BA
5.
6.
Press on differential side bearings.

CAUTION:
Apply ATF to differential side bearings.
Install differential side bearing outer race and differential side
bearing adjusting shim on transaxle case. Refer to AT-508,
"Adjustment (1)" .
SAT545FA
7.
Tighten final gear and tighten fixing bolts to the specified torque
in numerical order shown in the figure after temporarily tightening them. Refer to AT-503, "COMPONENTS" .
ATM0432D
AT-506
http://vnx.su
ASSEMBLY
[ALL]
ASSEMBLY
Assembly (1)
1.
PFP:00000
A
ECS004MD
Install differential side oil seals on transaxle case and converter housing.
CAUTION:
Do not reuse differential side oil seals.
Apply ATF to differential side oil seals.
AT
E
SAT181FC
I
SAT182F
2.
Install parking actuator support to transaxle case. Tighten parking actuator support bolts to the specified torque. Refer to AT416, "Components" .
CAUTION:
Pay attention to the direction of parking actuator support.
SAT183F
3.
4.
Install parking pawl on transaxle case and fix it with parking

shaft.
Install return spring and parking pawl spacer.
SCIA4881E
AT-507
http://vnx.su
ASSEMBLY
[ALL]
Adjustment (1)
ECS004ME
DIFFERENTIAL SIDE BEARING PRELOAD

1.
2.
Install differential side bearing outer race without differential side

bearing adjusting shim on transaxle case.
CAUTION:
Apply ATF to differential side bearing outer race.
Install differential side bearing outer race on converter housing.
CAUTION:
Apply ATF to differential side bearing outer race.
SAT870D
3.
4.
Place final drive assembly on transaxle case.

Install transaxle case on converter housing. Tighten transaxle
case fixing bolts to the specified torque. Refer to AT-416, "Components" .
ATM0024D
5.
6.
7.
8.
Attach dial indicator on differential case at converter housing

side.
Insert Tool into differential side gear from transaxle case side.
Move SST up and down and measure dial indicator deflection.
Select proper thickness of differential side bearing adjusting
shim(s). Refer to AT-536, "DIFFERENTIAL SIDE BEARING
PRELOAD ADJUSTING SHIMS" .
Suitable shim thickness = Dial indicator deflection + Specified bearing preload
Bearing preload:
0.05 - 0.09 mm (0.0020 - 0.0035 in)
SAT186FA
AT-508
http://vnx.su
ASSEMBLY
[ALL]
9.
10.
11.
12.
Remove converter housing from transaxle case.

Remove final drive assembly from transaxle case.
Remove differential side bearing outer race from transaxle case.
Reinstall differential side bearing outer race and differential side
bearing adjusting shim selected from SDS table on transaxle
case. Refer to AT-536, "DIFFERENTIAL SIDE BEARING PRELOAD ADJUSTING SHIMS" .
13. Reinstall converter housing on transaxle case and tighten converter housing mounting bolts to the specified torque. Refer to
AT-416, "Components" .
AT
SAT010FC
14. Insert SST and measure turning torque of final drive assembly.
Turn final drive assembly in both directions several times
to seat bearing rollers correctly.
Turning torque of final drive assembly (New bearing):

0.78 - 1.37 N-m (0.8 - 14.0 kg-cm, 6.9 - 12.2 in-lb)
When old bearing is used again, turning torque will be

slightly less than the above.
Make sure torque is close to the specified range.
Preload adapter: KV38105210
G
SAT188FA
REDUCTION PINION GEAR BEARING PRELOAD

1.
2.
a.
Remove converter housing and final drive assembly from transaxle case.
Select proper thickness of reduction pinion gear adjusting shim
using the following procedures.
Place reduction pinion gear on transaxle case as shown.
K
SAT332DA
b.
c.
Place idler gear bearing on transaxle case.

Measure the dimensions B C and D and calculate dimension A.
A = D (B + C)
A: Distance between the surface of idler gear bearing inner race and the adjusting shim mating
surface of reduction pinion gear.
SAT333DA
AT-509
http://vnx.su
ASSEMBLY
[ALL]
Measure the dimension B between the end of reduction pinion gear and the surface of transaxle case.
Measure the dimension B in at least two places.
SAT334DA
Measure the dimension C between the surface of idler gear

bearing inner race and the surface of transaxle case.
Measure the dimension C in at least two places.
SAT335D
Measure the dimension D between the end of reduction pinion gear and the adjusting shim mating surface of reduction
pinion gear.
Measure the dimension D in at least two places.
Calculate dimension A.
A = D (B + C)
SAT336DA
d.
e.
Measure the dimension E between the end of idler gear and

the idler gear bearing inner race mating surface of idler gear.
Measure the dimension E in at least two places.
Select proper thickness of reduction pinion gear bearing adjusting shim. Refer to AT-537, "REDUCTION PINION GEAR BEARING ADJUSTING SHIMS" .
Proper shim thickness = A E 0.05 mm (0.0020 in)*
(*... Bearing preload)
SAT337D
3.
4.
5.
Install reduction gear and reduction gear bearing adjusting shim

selected in step 2-e on transaxle case.
Press idler gear bearing inner race on idler gear.
CAUTION:
Press idler gear on reduction gear.
CAUTION:
Press idler gear until idler gear fully contacts adjusting
shim.
AT-510
http://vnx.su
SAT873DE
ASSEMBLY
[ALL]
6.
7.
Set manual shaft to P position to fix idler gear.

Tighten idler gear lock nut to the specified torque. Refer to AT416, "Components" .
CAUTION:
Lock idler gear with parking pawl when tightening lock nut.
AT
SAT189F
8.
Measure turning torque of reduction pinion gear.

When measuring turning torque, turn reduction pinion
gear in both directions several times to seat bearing rollers correctly.
Turning torque of reduction pinion gear:

0.05 - 0.39 N-m (0.5 - 4.0 kg-cm, 0.43 - 3.47 in-lb)
If turning torque is out of specification, decrease or

increase the thickness of reduction pinion gear bearing
adjusting shim.
G
SAT190FB
9.
After properly adjusting turning torque, clinch idler gear lock nut
as shown.
CAUTION:
Do not reuse idler gear lock nut.
SCIA4451E
OUTPUT SHAFT END PLAY
Measure the clearance between side cover and the end of the
output shaft bearing.
Select proper thickness of output shaft adjusting shim so that
clearance is within specifications.
SAT341D
AT-511
http://vnx.su
ASSEMBLY
[ALL]
1.
Install bearing retainer for output shaft. Refer to AT-416, "Components" .
SAT191F
2.
Install needle bearing on bearing retainer.

CAUTION:
Apply petroleum jelly to needle bearing.
Be careful with the direction of needle bearing.
SCIA4329E
3.
Install output shaft on transaxle case.
SAT035F
4.
Measure the dimensions 1 and 2 at side cover and then

calculate dimension A.
Measure dimension 1 and 2 in at least two places.
A:
A=
Distance between transaxle case fitting surface and adjusting shim mating surface.
1
2:
2
Height of gauge
SAT374F
5.
Measure the dimensions 2 and 3 and then calculate

dimension B.
Measure 2 and 3 in at least two places.
B:
B=
2:
Distance between the end of output shaft bearing outer race and the side cover fitting surface of transaxle case.
2
3
Height of gauge
SAT375F
AT-512
http://vnx.su
ASSEMBLY
[ALL]
6.
Select proper thickness of output shaft adjusting shim so that

output shaft end play (clearance between side cover and output
shaft bearing) is within specifications. Refer to AT-538, "OUTPUT SHAFT ADJUSTING SHIMS" .
Output shaft end play (A B):

0 - 0.15 mm (0 - 0.0059 in)
7.
Install output shaft adjusting shim on output shaft bearing.
AT
SAT440D
Assembly (2)
1.
ECS004MF
Apply locking sealant (Locktite #518) to transaxle case as

shown in illustration.
G
SCIA4919E
2.
Fit the mounting part of output shaft bearing on side cover to

output shaft bearing, and after adjusting knock pin position,
install it with light taps using a soft hammer and things like that.
CAUTION:
When installing, to avoid getting damaged and deformed,
set the mounting part straight to parallel with the mounting
surface.
K
SAT442D
3.
Tighten side cover fixing bolts to specified torque. Refer to AT416, "Components" .
CAUTION:
Do not mix bolts A and B.
Always replace bolts A as they are self-sealing bolts.
AAT850
AT-513
http://vnx.su
ASSEMBLY
[ALL]
4.
Install thrust washer on bearing retainer.

CAUTION:
SCIA4454E
5.
Install forward clutch assembly.

CAUTION:
Align teeth of low & reverse brake before installing.
Make sure that bearing retainer seal rings are not spread.
If forward clutch assembly is correctly seated, points 1
and 2 are at almost same level.
SCIA4920E
6.
Install needle bearing.

CAUTION:
SCIA4921E
7.
Install overrun clutch hub.

CAUTION:
Align teeth of overrun clutch before installing.
SAT030F
AT-514
http://vnx.su
ASSEMBLY
[ALL]
8.
Check operation of forward one-way clutch.

CAUTION:
Hold rear internal gear and turn forward clutch hub.
Check forward clutch hub for correct locking and unlocking directions.
If not as shown in figure, check installation direction of
forward one-way clutch.
AT
AAT426
9.
Install forward clutch hub and rear internal gear on transaxle

case.
CAUTION:
Align teeth of forward clutch before installing.
Make sure that three pawls of thrust washer are correctly
aligned after installing.
SCIA4922E
10. Install rear planetary carrier assembly and rear sun gear according to the following procedures.
a. Install needle bearings on rear planetary carrier.
CAUTION:
Apply petroleum jelly to needle bearings.
Pay attention to the direction of needle bearings.
SCIA4456E
b.
Install rear sun gear on rear planetary carrier.

CAUTION:
Pay attention to the direction of rear sun gear.
SAT027F
AT-515
http://vnx.su
ASSEMBLY
[ALL]
c.
Install rear planetary carrier (with rear sun gear) on transaxle

case.
SAT026F
11. Install needle bearing on front planetary carrier, then install them
together on transaxle case.
CAUTION:
Apply petroleum jelly to thrust needle bearing.
Pay attention to the direction of thrust needle bearing.
SCIA4457E
12. Install low and reverse brake piston according to the following
procedures.
a. Set and align return springs to transaxle case gutters as shown
in illustration.
SAT322F
b.
Set and align low & reverse brake piston with retainer.
CAUTION:
Apply ATF to the surface of low & reverse brake piston and
retainer.
SCIA3652E
AT-516
http://vnx.su
ASSEMBLY
[ALL]
c.
Install low & reverse brake piston and retainer on transaxle

case.
CAUTION:
Align bracket to specified gutter as indicated in the figure.
AT
G
SCIA5653E
d.
Make sure that each protrusion of low & reverse brake piston is
correctly set to corresponding return spring as follows.
Push low & reverse brake piston and retainer evenly and
confirm they move smoothly.
If they cannot move smoothly, remove low & reverse
brake piston and retainer and align return spring correctly as instructed in step a.
SCIA5654E
e.
Push down low & reverse brake piston and retainer and install
snap ring.
L
SCIA3675E
13. Install low one-way clutch to front planetary carrier by turning

carrier in the direction of the arrow shown.
SAT206F
AT-517
http://vnx.su
ASSEMBLY
[ALL]
14. Install snap ring with flat-bladed screwdriver.
CAUTION:
Forward clutch and bearing must be correctly installed for
snap ring to fit into groove of transaxle case.
SCIA3633E
15. Install front sun gear according to the following procedures.

a. Install bearing race on front sun gear.
CAUTION:
Apply petroleum jelly to bearing race.
b. Install needle bearing on front sun gear.
CAUTION:
Pay attention to the direction of needle bearing.
SCIA4033E
c.
Install front sun gear on front planetary carrier.
SCIA4458E
16. Install high clutch hub according to the following procedures.

a. Install needle bearing on front sun gear.
CAUTION:
SCIA4034E
AT-518
http://vnx.su
ASSEMBLY
[ALL]
b.
Install high clutch hub on front sun gear.

A
AT
SCIA4459E
17. Install input shaft assembly (high clutch assembly) according to the following procedures.
a. Install needle bearing on high clutch hub.
CAUTION:
Apply petroleum jelly.
G
SCIA4035E
b.
Install input shaft assembly (high clutch assembly) on high

clutch hub.
K
SCIA4036E
c.
Install needle bearing on input shaft assembly (high clutch

drum).
CAUTION:
SCIA4872E
AT-519
http://vnx.su
ASSEMBLY
[ALL]
18. Install reverse clutch assembly on input shaft assembly (high
clutch drum).
SCIA4461E
Adjustment (2)
ECS004MG
When any parts listed below are replaced, adjust total end play and reverse clutch end play.
Part name
Total end play
Reverse clutch end play
transaxle case
Overrun clutch hub
Rear internal gear
Rear planetary carrier
Rear sun gear
Front planetary carrier
Front sun gear
High clutch hub
High clutch drum
Oil pump cover
Reverse clutch drum
TOTAL END PLAY
Measure the clearance between reverse clutch drum and needle

bearing for oil pump cover.
Select proper thickness of bearing race so that end play is within
specifications.
SCIA3661E
1.
Measure dimensions K and L and then calculate dimension

J.
SCIA3662E
AT-520
http://vnx.su
ASSEMBLY
[ALL]
a.
Measure dimension K.
A
AT
SCIA3663E
b.
c.
Measure dimension L.
Calculate dimension J.
E
J: Distance between oil pump fitting surface of

transaxle case and needle bearing mating surface of
high clutch drum.
J=KL
G
SCIA3664E
2.
a.
Measure dimension M.
Place bearing race and needle bearing on oil pump assembly.
SAT378D
b.
Measure dimension M.
M: Distance between transaxle case fitting surface of
oil pump cover and needle bearing on oil pump cover.
M1 : Indication of gauge.
SAT379D
c.
Measure thickness of straightedge t.

M = M1 t
SAT443D
AT-521
http://vnx.su
ASSEMBLY
[ALL]
3.
Adjust total end play T1 .

T1 = J M
Total end play T1 :
0.25 - 0.55 mm (0.0098 - 0.0217 in)
Select proper thickness of bearing race so that total end play is within specifications. Refer to AT-538,
"Total End Play" .
REVERSE CLUTCH END PLAY
Measure the clearance between oil pump cover and thrust

washer for reverse clutch drum.
Select proper thickness of thrust washer so that end play is
within specification.
SCIA3665E
1.
Measure dimensions O and P and then calculate dimension

N.
SCIA3666E
a.
b.
Place thrust washer on reverse clutch drum.

Measure dimension O.
SCIA3667E
c.
d.
Measure dimension P.
Calculate dimension N.
N: Distance between oil pump fitting surface of transaxle case and thrust washer on reverse clutch drum.
N=OP
SCIA3668E
AT-522
http://vnx.su
ASSEMBLY
[ALL]
2.
Measure dimensions R and S and then calculate dimension

Q.
AT
SAT384D
a.
Measure dimension R.
E
G
SAT385D
b.
c.
Measure dimension S.
Calculate dimension Q.
Q: Distance between transaxle case fitting surface

and thrust washer mating surface.
Q=RS
SAT386D
3.
Adjust reverse clutch end play T2 .

T2 = N Q
Reverse clutch end play:
0.61 - 1.0 mm (0.0240 - 0.039 in)
Select proper thickness of thrust washer so that reverse clutch end play is within specifications. Refer
to AT-539, "Reverse Clutch End Play" .
Assembly (3)
1.
2.
ECS004MH
Install anchor end pin and lock nut on transaxle case.

CAUTION:
Place brake band and strut on outside of reverse clutch drum.
Tighten anchor end pin just enough so that brake band is evenly
fitted on reverse clutch drum.
SAT196F
AT-523
http://vnx.su
ASSEMBLY
[ALL]
3.
4.
Place bearing race selected in total end play adjustment step on

oil pump cover.
CAUTION:
Apply petroleum jelly to bearing race.
Place thrust washer selected in reverse clutch end play step on
reverse clutch drum.
CAUTION:
SCIA3629E
5.
6.
Install oil pump assembly and gasket on transaxle case.

CAUTION:
Tighten oil pump fixing bolts to the specified torque. Refer to AT416, "Components"
SCIA2980E
7.
Install O-ring to input shaft assembly (high clutch drum).

CAUTION:
SCIA2979E
8.
a.
Adjust brake band.

CAUTION:
Tighten anchor end pin to the specified torque.
: 4.9 Nm (0.50 kg-m, 43 in-lb)
b.
c.
Back off anchor end pin two and a half turns.

While holding anchor end pin, tighten lock nut. Refer to AT-535,
"BRAKE BAND" .
SCIA4869E
AT-524
http://vnx.su
ASSEMBLY
[ALL]
9.
Apply compressed air to oil holes of transaxle case and check

operation of brake band.
AT
SAT397D
10. Install final drive assembly on transaxle case.

E
G
SAT228F
11. Install differential lubricant tube on converter housing. Tighten

differential lubricant tube bolts to the specified torque. Refer to
AT-416, "Components" .
SAT063K
12. Install O-ring on differential oil port of transaxle case.

CAUTION:
SCIA3281E
13. Install converter housing on transaxle case.

CAUTION:
Apply locking sealant (Locktite #518) to mating surface of
converter housing.
SCIA4929E
AT-525
http://vnx.su
ASSEMBLY
[ALL]
Tighten converter housing bolts to the specified torque. Refer

to AT-416, "Components" .
ATM0024D
14. Install accumulator piston.

a. Check contact surface of accumulator piston for damage.
SAT406DA
b.
Install O-rings on accumulator piston. Refer to AT-530, "SERVICE DATA AND SPECIFICATIONS (SDS)" .
CAUTION:
SCIA3303E
c.
Install accumulator pistons and return springs on transaxle case.

Refer to AT-530, "SERVICE DATA AND SPECIFICATIONS
(SDS)" .
CAUTION:
Apply ATF to inner surface of transaxle case.
SCIA3304E
15. Install lip seals for band servo oil holes on transaxle case.
CAUTION:
Do not reuse lip seals.
Apply ATF to lip seals.
SCIA3280E
AT-526
http://vnx.su
ASSEMBLY
[ALL]
16. Install low & reverse brake tube and oil sleeve. Tighten Low &
reverse brake tube bolts to the specified torque. Refer to AT416, "Components" .
CAUTION:
Do not reuse oil sleeve.
Apply ATF to oil sleeve.
AT
SCIA4868E
17. Install control valve assembly.

a. Install O-ring to terminal body.
CAUTION:
b. Insert manual valve into control valve assembly.
CAUTION:
Apply ATF to manual valve.
SAT005F
c.
d.
Set manual shaft in Neutral position.

Install control valve assembly on transaxle case while aligning
manual valve with manual plate.
L
SAT094J
e.
f.
Pass terminal cord assembly through transaxle case and install

terminal body on transaxle case by pushing it.
Install snap ring to terminal body.
CAUTION:
SCIA4866E
AT-527
http://vnx.su
ASSEMBLY
[ALL]
g.
Tighten control valve assembly fixing bolts A , B and C to the specified torque. Refer to AT-416, "Components" .
Bolt symbol
Bolt length
mm (in)
Number of bolts
40.0 mm
(1.575 in)
33.0 mm
(1.299 in)
43.5 mm
(1.713 in)
AAT260A
CAUTION:

18. Install PNP switch.
a. Set manual shaft in P position.
b. Temporarily install PNP switch on manual shaft.
c. Move manual shaft to N position.
SCIA3154E
d.
i.
ii.
Use a 3 mm (0.12 in) pin for this adjustment.

Insert the pin straight into the manual shaft adjustment hole.
Rotate PNP switch until the pin can also be inserted straight into
hole in PNP switch.
e. Tighten PNP switch fitting bolts. Refer to AT-416, "Components"
.
f. Remove pin from adjustment hole after adjusting PNP switch.
19. Install bracket on transaxle case.
20. Install O-ring on revolution sensor.
CAUTION:
21. Install revolution sensor on transaxle case.
AT-528
http://vnx.su
SCIA4930E
ASSEMBLY
[ALL]
22. Install torque converter.
a. Pour ATF into torque converter.
CAUTION:
Approximately 1 liter (7/8 Imp qt) of fluid is required for a
new torque converter.
When reusing old torque converter, add the same amount
of fluid as was drained.
AT
SAT428DA
b.
Install torque converter while aligning notches of torque converter with notches of oil pump.
E
G
SAT429D
c.
Measure distance A to Make sure that torque converter is in

proper position.
Distance A
QR20DE models:
QR25DE models:

SCIA5621E
AT-529
http://vnx.su

[ALL]

Engine
PFP:00030
ECS00CXK
QR20DE
Automatic transaxle model

Automatic transaxle assembly
Transaxle gear ratio
RE4F04B (4WD)
Model code number
85X23
85X64
1st
2.785
2nd
1.545
3rd
1.000
4th
0.694
Reverse
2.272
Final drive
4.425
Recommended fluid
Fluid capacity
QR25DE
4.087
Genuine Nissan ATF or equiualent*1

8.5 (7-1/2)
(Imp qt)
*1: Refer to MA-17, "Fluids and Lubricants" .
Shift Schedule
ECS00CXL
VEHICLE SPEED WHEN SHIFTING GEARS AND THROTTLE POSITION

For 85X23 model
Throttle position
Shift pattern
Vehicle speed km/h (MPH)

D1 D2
D2 D 3
D3 D4
D4 D3
D3 D2
D2 D1
Comfort
53 - 61
(33 - 38)
99 - 107
(62 - 67)
156 - 164
(97 - 102)
152 - 160
(94 - 99)
89 - 97
(53 - 60)
41 - 49
(25 - 30)
Auto power
53 - 61
(33 - 38)
99 - 107
(62 - 67)
156 - 164
(97 - 102)
152 - 160
(94 - 99)
89 - 97
(55 - 60)
41 - 49
(25 - 30)
Comfort
34 - 42
(21 - 26)
64 - 72
(40 - 45)
124 - 138
(77 - 82)
82 - 90
(51 - 56)
41 - 49
(25 - 30)
5 - 13
(3 - 8)
Auto power
38 - 46
(24 - 29)
70 - 78
(44 - 48)
124 - 132
(77 - 82)
81 - 89
(50 - 55)
44 - 53
(27 - 33)
5 - 13
(3 - 8)
Full throttle
Half throttle
For 85X64 model

Throttle position
Vehicle speed km/h (MPH)

Shift pattern
D1 D 2
D2 D 3
D3 D4
D4 D3
D3 D2
D2 D1
Comfort
57 - 65
(35 - 40)
107 - 115
(66 - 71)
167 - 175
(104 - 109)
163 - 171
(101 - 106)
97 - 105
(60 - 65)
41 - 49
(25 - 30)
Auto power
57 - 65
(35 - 40)
107 - 115
(66 - 71)
167 - 175
(104 - 109)
163 - 171
(101 - 106)
97 - 105
(60 - 65)
41 - 49
(25 - 30)
Comfort
36 - 44
(22 - 27)
71 - 79
(44 - 49)
131 - 139
(81 - 86)
77 - 85
(48 - 53)
38 - 46
(23 - 28)
5 - 13
(3 - 8)
Auto power
42 - 50
(26 - 31)
79 - 87
(49 - 54)
131 - 139
(81 - 86)
77 - 85
(48 - 53)
45 - 53
(28 - 33)
5 - 13
(3 - 8)
Full throttle
Half throttle
VEHICLE SPEED WHEN PERFORMING LOCK-UP

Unit: km/h (MPH)
Model code No.
Vehicle speed
Throttle position 1/8
85X23
85X64
58 - 66 (36 - 41)
61 - 69 (38 - 43)
NOTE:
Lock-up vehicle speed indicates the speed in D4 position.
Perform lock-up inspection after warming up engine.
Lock-up vehicle speed may vary depending on the driving conditions and circumstances.
AT-530
http://vnx.su

[ALL]
Stall Revolution
ECS00CXM
A
Engine
Stall revolution
rpm
QR20DE
2,450 - 2,950
QR25DE
2,300 - 2,750
Line Pressure
ECS00F1T
AT
Line pressure
kPa (kg/cm2 , psi)
Engine speed
rpm
R position
Idle
500 (5.1, 73)
778 (7.9, 113)
Stall
1,233 (12.6, 179)
1,918 (19.6, 278)
Control Valves
ECS00F1U
Unit: mm (in)
CONTROL VALVE AND PLUG RETURN SPRINGS

For 85X23 model
Item
Parts
Upper body
Lower body
Part No.*
Free length
Outer diameter
Pilot valve spring
31742-3AX03
38.98 (1.535)
8.9 (0.350)
35
31742-3AX00
20.5 (0.807)
6.95 (0.274)
10
1-2 accumulator piston spring
31742-85X02
55.60 (2.189)
19.6 (0.772)
17
31742-80X05
27.0 (1.063)
7.0 (0.276)
19
3-2 timing valve spring
31736-01X00
23.0 (0.906)
6.65 (0.262)
24
Overrun clutch reducing valve spring
31742-80X15
37.5 (1.476)
6.9 (0.272)
26
Torque converter relief valve spring
31742-80X07
31.0 (1.220)
9.0 (0.354)
31
31742-85X00
56.98 (2.243)
6.5 (0.256)
31742-85X01
29.4 (1.157)
6.0 (0.236)
11
Pressure regulator valve spring
31742-80X13
45.0 (1.772)
15.0 (0.591)
16
Overrun clutch control valve spring
31762-80X00
21.7 (0.854)
7.0 (0.276)
20
Accumulator control valve spring
31742-80X02
22.0 (0.866)
6.5 (0.256)
25
Shift valve A spring
31762-80X00
21.7 (0.854)
7.0 (0.276)
30
Shuttle valve spring
31762-41X04
51.0 (2.008)
5.65 (0.222)
32
Shift valve B spring
31762-80X00
21.7 (0.854)
7.0 (0.276)
31742-41X15
30.5 (1.201)
9.8 (0.386)
31742-80X16
32.0 (1.260)
6.9 (0.272)
31872-31X00
17.02 (0.670)
8.0 (0.315)
AT-531
http://vnx.su

[ALL]
For 85X64 model
Unit: mm (in)
Item
Parts
Upper body
Lower body
Part No.*
Free length
Outer diameter
Pilot valve spring
31742-3AX03
38.98 (1.535)
8.9 (0.350)
35
31742-3AX00
20.5 (0.807)
6.95 (0.274)
10
1-2 accumulator piston spring
31742-3AX08
55.26 (2.176)
19.6 (0.772)
17
31742-80X05
27.0 (1.063)
7.0 (0.276)
19
3-2 timing valve spring
31736-01X00
23.29 (0.917)
6.65 (0.262)
24
Overrun clutch reducing valve spring
31742-80X15
37.5 (1.476)
6.9 (0.272)
26
Torque converter relief valve spring
31742-80X07
31.0 (1.220)
9.0 (0.354)
31
Torque converter clutch control valve spring
31742-85X00
56.98 (2.243)
6.5 (0.256)
31742-85X01
29.4 (1.157)
6.0 (0.236)
11
Pressure regulator valve spring
31742-80X13
45.0 (1.772)
15.0 (0.591)
16
Overrun clutch control valve spring
31762-80X00
21.7 (0.854)
7.0 (0.276)
20
Accumulator control valve spring
31742-80X02
22.0 (0.866)
6.5 (0.256)
25
Shift valve A spring
31762-80X00
21.7 (0.854)
7.0 (0.276)
30
Shuttle valve spring
31762-41X04
51.0 (2.008)
5.65 (0.222)
32
Shift valve B spring
31762-80X00
21.7 (0.854)
7.0 (0.276)
31742-41X15
30.5 (1.201)
9.8 (0.386)
31742-80X16
32.0 (1.260)
6.9 (0.272)
31872-31X00
17.02 (0.670)
8.0 (0.315)
Accumulator
ECS00F1V
O-RING
Unit: mm (in)
Part No.*
Inner diameter
(Small)
Part No.*
Inner diameter
(Large)
Servo release accumulator
31526 41X03
26.9 (1.059)
31526 41X02
44.2 (1.740)
N-D accumulator
31526 31X08
34.6 (1.362)
31672 21X00
39.4 (1.551)
Accumulator
AT-532
http://vnx.su

[ALL]
RETURN SPRING
Unit: mm (in)
Accumulator
Part number*
Free length
Outer diameter
Servo release accumulator
31605-80X00
52.5 (2.067)
20.1 (0.791)
N-D accumulator
31605-31X15
43.5 (1.713)
28.0 (1.102)
Clutch and Brakes
ECS00F1W
AT
REVERSE CLUTCH
Model code number
85X23, 85X64
Number of drive plates
Number of driven plates
Drive plate thickness
mm (in)
Driven plate thickness

Clearance
mm (in)
mm (in)
Standard
1.6 (0.063)
Wear limit
1.4 (0.055)
Standard
1.8 (0.071)
Standard
0.5 - 0.8 (0.020 - 0.031)
Wear limit
1.2 (0.047)
Thickness
mm (in)
Part number*
6.6 (0.260)
6.8 (0.268)
7.0 (0.276)
7.2 (0.283)
7.4 (0.291)
7.6 (0.299)
7.8 (0.307)
Thickness of retaining plates
31537-80X05
31537-80X06
31537-80X07
31537-80X08
31537-80X09
31537-80X20
31537-80X21
HIGH CLUTCH
Model code number
7*1 + 1*2
Drive plate
thickness mm (in)
Standard
1.6 (0.063)
Wear limit
1.4 (0.055)
Driven plate
thickness mm (in)
*1
Standard
1.4 (0.055)
*2
Standard
2.0 (0.079)
Clearance
mm (in)
Standard
1.8 - 2.2 (0.071 - 0.087)
Wear limit
2.8 (0.110)
Thickness
mm (in)
Part number*
3.2 (0.126)
3.4 (0.134)
3.6 (0.142)
3.8 (0.150)
4.0 (0.157)
31537-81X11
31537-81X12
31537-81X13
31537-81X14
31537-81X15
FORWARD CLUTCH
Model code number
85X23
85X23, 85X64
mm (in)
Standard
1.6 (0.063)
Wear limit
1.4 (0.055)
AT-533
http://vnx.su

[ALL]
Clearance
mm (in)
mm (in)
Standard
1.8 (0.071)
Standard
0.45 - 0.85 (0.0177 - 0.0335)
Wear limit
1.85 (0.0728)
Thickness
mm (in)
Part number*
3.2 (0.126)
3.4 (0.134)
3.6 (0.142)
3.8 (0.150)
4.0 (0.157)
4.2 (0.165)
4.4 (0.173)
31537-80X76
31537-80X75
31537-80X70
31537-80X71
31537-80X72
31537-80X73
31537-80X74
Model code number
85X64
mm (in)

Clearance
mm (in)
mm (in)
Standard
1.6 (0.063)
Wear limit
1.4 (0.055)
Standard
1.8 (0.071)
Standard
0.45 - 0.85 (0.0177 - 0.0335)
Wear limit
1.85 (0.0728)
Thickness
mm (in)
Part number*
3.2 (0.126)
3.4 (0.134)
3.6 (0.142)
3.8 (0.150)
4.0 (0.157)
4.2 (0.165)
4.4 (0.173)
31537-80X76
31537-80X75
31537-80X70
31537-80X71
31537-80X72
31537-80X73
31537-80X74
OVERRUN CLUTCH
Model code number
85X23, 85X64
mm (in)

Clearance
mm (in)
mm (in)
Standard
1.6 (0.063)
Wear limit
1.4 (0.055)
Standard
1.6 (0.063)
Standard
0.7 - 1.1 (0.028 - 0.043)
Wear limit
1.7 (0.067)
Thickness mm (in)
Part number*
3.0 (0.118)
3.2 (0.126)
3.4 (0.134)
3.6 (0.142)
3.8 (0.150)
31537-80X65
31537-80X66
31537-80X67
31537-80X68
31537-80X69
LOW & REVERSE BRAKE

Model code number
85X23
AT-534
http://vnx.su

[ALL]
mm (in)

Clearance
mm (in)
mm (in)
Standard
1.8 (0.071)
Wear limit
1.6 (0.063)
Standard
1.8 (0.071)
Standard
1.7 - 2.1 (0.067 - 0.083)
Wear limit
3.3 (0.130)
Thickness
mm (in)
Part number*
2.0 (0.079)
2.2 (0.087)
2.4 (0.094)
2.6 (0.102)
2.8 (0.110)
3.0 (0.118)
3.2 (0.126)
3.4 (0.134)
AT
31667-80X00
31667-80X01
31667-80X02
31667-80X03
31667-80X04
31667-80X05
31667-80X06
31667-80X07
Model code number
85X64

Clearance
mm (in)
mm (in)
mm (in)
Standard
1.8 (0.071)
Wear limit
1.6 (0.063)
Standard
1.8 (0.071)
Standard
1.7 - 2.1 (0.067 - 0.083)
Wear limit
3.3 (0.130)
Thickness
mm (in)
2.0 (0.079)
2.2 (0.087)
2.4 (0.094)
2.6 (0.102)
2.8 (0.110)
3.0 (0.118)
3.2 (0.126)
3.4 (0.134)
Part number*
31667-80X00
31667-80X01
31667-80X02
31667-80X03
31667-80X04
31667-80X05
31667-80X06
31667-80X07
CLUTCH AND BRAKE RETURN SPRINGS

Unit: mm (in)
Parts
Part number*
Free length
Outer diameter
Forward clutch (Overrun clutch)

(22 pcs)
31505-80X02
21.4 (0.843)
10.3 (0.406)
High clutch (12 pcs)
31505-80X05
22.5 (0.886)
10.8 (0.425)
Low & reverse brake (24 pcs)
31505-80X07
24.1 (0.949)
6.6 (0.260)
BRAKE BAND
Anchor end pin tightening torque
Nm (kg-m, in-lb)
4.9 (0.50, 43)
Number of returning revolutions for anchor end pin

Lock nut tightening torque
2.5
Nm (kg-m, ft-lb)
34 (3.5, 25)
Final Drive
ECS00F1X
DIFFERENTIAL SIDE GEAR CLEARANCE

Clearance between side gear and differential case with
washer mm (in)
0.1 - 0.2 (0.004 - 0.008)
AT-535
http://vnx.su

[ALL]
DIFFERENTIAL SIDE GEAR THRUST WASHERS
Thickness
mm (in)
Part number*
38424-81X00
38424-81X01
38424-81X02
38424-81X03
38424-81X04
0.75 (0.0295)
0.80 (0.0315)
0.85 (0.0335)
0.90 (0.0354)
0.95 (0.0374)
DIFFERENTIAL SIDE BEARING PRELOAD ADJUSTING SHIMS

Thickness
mm (in)
Part number*
0.48 (0.0189)
0.52 (0.0205)
0.56 (0.0220)
0.60 (0.0236)
0.64 (0.0252)
0.68 (0.0268)
0.72 (0.0283)
0.76 (0.0299)
0.80 (0.0315)
0.84 (0.0331)
0.88 (0.0346)
0.92 (0.0362)
31438-80X00
31438-80X01
31438-80X02
31438-80X03
31438-80X04
31438-80X05
31438-80X06
31438-80X07
31438-80X08
31438-80X09
31438-80X10
31438-80X11
BEARING PRELOAD
Differential side bearing preload
mm (in)
0.05 - 0.09 (0.0020 - 0.0035)
TURNING TORQUE
Turning torque of final drive assembly
Nm (kg-cm, in-lb)
0.78 - 1.37 (8.0 - 14.0, 6.9 - 12.2)
Planetary Carrier and Oil Pump
ECS00F1Y
PLANETARY CARRIER
Clearance between planetary carrier
and pinion washer mm (in)
Standard
0.20 - 0.70 (0.0079 - 0.0276)
Allowable limit
0.80 (0.0315)
OIL PUMP
Oil pump side clearance
mm (in)
0.030 - 0.050 (0.0012 - 0.0020)

Inner gear
Thickness
Thickness of inner gears and outer gears
mm (in)
Part number*
11.99 - 12.0 (0.4720 - 0.4724)

11.98 - 11.99 (0.4717 - 0.4720)
11.97 - 11.98 (0.4713 - 0.4717)
31346-80X00
31346-80X01
31346-80X02
Outer gear
Thickness
mm (in)
Part number*
11.99 - 12.0 (0.4720 - 0.4724)

11.98 - 11.99 (0.4717 - 0.4720)
11.97 - 11.98 (0.4713 - 0.4717)
Clearance between oil pump
housing and outer gear mm
(in)
Standard
Oil pump cover seal ring

clearance mm (in)
Standard
31347-80X00
31347-80X01
31347-80X02
0.111 - 0.181 (0.0044 - 0.0071)
Allowable limit
0.181 (0.0071)
0.1 - 0.25 (0.0039 - 0.0098)
Allowable limit
0.25 (0.0098)
AT-536
http://vnx.su

[ALL]
Input Shaft
ECS00F1Z
SEAL RING CLEARANCE

Input shaft seal ring clearance
(in)
Standard
mm
0.08 - 0.23 (0.0031 - 0.0091)
Allowable limit
0.23 (0.0091)
SEAL RING
Outer diameter mm (in)
1nner diameter mm (in)
Width mm (in)
Part number*
26 (1.024)
22.4 (0.882)
1.97 (0.078)
31525 80X02
AT
Reduction Pinion Gear
ECS00F20
TURNING TORQUE
Turning torque of reduction pinion gear
Nm (kg-cm, in-lb)
0.05 - 0.39 (0.5 - 4.0, 0.43 - 3.47)
REDUCTION PINION GEAR BEARING ADJUSTING SHIMS

NO.
Thickness
mm (in)
Part number
NO.
Thickness
mm (in)
Part number*
5.00 (0.1969)
31439-81X00
33
5.64 (0.2220)
31439-81X63
5.02 (0.1976)
31439-81X01
34
5.66 (0.2228)
31439-81X64
5.04 (0.1984)
31439-81X02
35
5.68 (0.2236)
31439-81X65
5.06 (0.1992)
31439-81X03
36
5.70 (0.2244)
31439-81X66
5.08 (0.2000)
31439-81X04
37
5.72 (0.2252)
31439-81X67
5.10 (0.2008)
31439-81X05
38
5.74 (0.2260)
31439-81X68
5.12 (0.2016)
31439-81X06
39
5.76 (0.2268)
31439-81X69
5.14 (0.2024)
31439-81X07
40
5.78 (0.2276)
31439-81X70
5.16 (0.2031)
31439-81X08
41
5.80 (0.2283)
31439-81X71
10
5.18 (0.2039)
31439-81X09
42
5.82 (0.2291)
31439-81X72
11
5.20 (0.2047)
31439-81X10
43
5.84 (0.2299)
31439-81X73
12
5.22 (0.2055)
31439-81X11
44
5.86 (0.2307)
31439-81X74
13
5.24 (0.2063)
31439-81X12
45
4.60 (0.1811)
31439-85X01
14
5.26 (0.2071)
31439-81X13
46
4.62 (0.1819)
31439-85X02
15
5.28 (0.2079)
31439-81X14
47
4.64 (0.1827)
31439-85X03
16
5.30 (0.2087)
31439-81X15
48
4.66 (0.1835)
31439-85X04
17
5.32 (0.2094)
31439-81X16
49
4.68 (0.1843)
31439 85X05
18
5.34 (0.2102)
31439-81X17
50
4.70 (0.1850)
31439 85X06
19
5.36 (0.2110)
31439-81X18
51
4.72 (0.1858)
31439 83X11
20
5.38 (0.2118)
31439-81X19
52
4.74 (0.1866)
31439 83X12
21
5.40 (0.2126)
31439-81X20
53
4.76 (0.1874)
31439 83X13
22
5.42 (0.2134)
31439-81X21
54
4.78 (0.1882)
31439 83X14
23
5.44 (0.2142)
31439-81X22
55
4.80 (0.1890)
31439 83X15
24
5.46 (0.2150)
31439-81X23
56
4.82 (0.1898)
31439 83X16
25
5.48 (0.2157)
31439-81X24
57
4.84 (0.1906)
31439 83X17
26
5.50 (0.2165)
31439-81X46
58
4.86 (0.1913)
31439 83X18
27
5.52 (0.2173)
31439-81X47
59
4.88 (0.1921)
31439 83X19
28
5.54 (0.2181)
31439-81X48
60
4.90 (0.1929)
31439 83X20
29
5.56 (0.2189)
31439-81X49
61
4.92 (0.1937)
31439 83X21
30
5.58 (0.2197)
31439-81X60
62
4.94 (0.1945)
31439 83X22
31
5.60 (0.2205)
31439-81X61
63
4.96 (0.1953)
31439 83X23
32
5.62 (0.2213)
31439-81X62
64
4.98 (0.1961)
31439 83X24
AT-537
http://vnx.su

[ALL]
Band Servo
ECS00F21
RETURN SPRING
Unit: mm (in)
Return spring
Part number*
Free length
Outer diameter
2nd servo return spring
31605-31X20
32.5 (1.280)
25.9 (1.020)
O/D servo return spring
31605-80X07
31.0 (1.220)
62.6 (2.465)
Output Shaft
ECS00F22
SEAL RING CLEARANCE

Output shaft seal ring clearance
(in)
Standard
mm
0.10 - 0.25 (0.0039 - 0.0098)
Allowable limit
0.25 (0.0098)
SEAL RING
Outer diameter mm (in)
1nner diameter mm (in)
Width mm (in)
Part number*
33.71 (1.327)
30.25 (1.191)
1.95 (0.077)
31525 80X09
END PLAY
Output shaft end play
mm (in)
0 - 0.15 (0 - 0.0059)
OUTPUT SHAFT ADJUSTING SHIMS

Thickness
mm (in)
Part number*
0.80 (0.0315)
0.84 (0.0331)
0.88 (0.0346)
0.92 (0.0362)
0.96 (0.0378)
1.00 (0.0394)
1.04 (0.0409)
1.08 (0.0425)
1.12 (0.0441)
1.16 (0.0457)
1.20 (0.0472)
31438-80X60
31438-80X61
31438-80X62
31438-80X63
31438-80X64
31438-80X65
31438-80X66
31438-80X67
31438-80X68
31438-80X69
31438-80X70
Bearing Retainer
ECS00F23
SEAL RING CLEARANCE

Bearing retainer seal ring
clearance mm (in)
Standard
0.10 - 0.30 (0.0039 - 0.0118)
Allowable limit
0.30 (0.0118)
Total End Play

Total end play
ECS00F24
mm (in)
0.25 - 0.55 (0.0098 - 0.0217)
AT-538
http://vnx.su

[ALL]
BEARING RACE FOR ADJUSTING TOTAL END PLAY
Thickness
mm (in)
Part number*
0.8 (0.031)
1.0 (0.039)
1.2 (0.047)
1.4 (0.055)
1.6 (0.063)
1.8 (0.071)
2.0 (0.079)
0.9 (0.035)
1.1 (0.043)
1.3 (0.051)
1.5 (0.059)
1.7 (0.067)
1.9 (0.075)
31435-80X00
31435-80X01
31435-80X02
31435-80X03
31435-80X04
31435-80X05
31435-80X06
31435-80X09
31435-80X10
31435-80X11
31435-80X12
31435-80X13
31435-80X14
AT
Reverse Clutch End Play

Reverse clutch end play
ECS00F25
mm (in)
0.61 - 1.0 (0.0240 - 0.039)
THRUST WASHERS FOR ADJUSTING REVERSE CLUTCH DRUM END PLAY

Thickness
mm (in)
Part number*
0.80 (0.0315)
0.95 (0.0374)
1.10 (0.0433)
1.25 (0.0492)
1.40 (0.0551)
1.55 (0.0610)
1.70 (0.0669)
1.85 (0.0728)
31508-80X13
31508-80X14
31508-80X15
31508-80X16
31508-80X17
31508-80X18
31508-80X19
31508-80X20
ECS00F26
Unit: mm (in)
Engine
Distance between end of converter housing and torque converter
QR20DE
19 (0.75)
QR25DE
14 (0.55)
Shift Solenoid Valves
ECS00F27
Gear position
ON (Closed)
OFF (Open)
OFF (Open)
ON (Closed)
ON (Closed)
ON (Closed)
OFF (Open)
OFF (Open)
Solenoid Valves
Solenoid valves
ECS00F28
Terminal No.
20 - 30
5 - 20
20 - 30
2.5 - 5
5 - 20
AT-539
http://vnx.su

[ALL]
A/T Fluid Temperature Sensor
ECS00F29

Monitor item
Condition
Cold [20C (68F)]
Hot [80C (176F)]
1.5V
0.5V
2.5 k
0.3 k
Revolution Sensor
ECS00F2A
Condition
Judgement standard
When moving at 20 km/h (12 MPH), use the CONSULT-II pulse frequency measuring function.
When vehicle parks.
450 Hz (Approx.)
Under 1.3V or over 4.5V
Dropping Resistor
ECS00F2B
Resistance
12 (Approx)
AT-540
http://vnx.su

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QUICK REFERENCE INDEX

Engine Lubrication System

Engine Cooling System

Engine Control System

MODEL T30 SERIES

Accelerator Control System

Rear Final Drive

Road Wheels & Tires

Parking Brake System

Brake Control System

Power Steering System

Body, Lock & Security System

Glasses, Window System & Mirrors

Exterior & Interior

Supplemental Restraint System (SRS)

Automatic Air Conditioner

Manual AIr Conditioner

Starting & Charging System

Driver Information System

Wiper, Washer & Horn

Body Control System

Audio Visual, Navigation & Telephone System

Power Supply, Ground & Circuit Elements

2005 NISSAN EUROPE S.A.S.

IMPORTANT SAFETY NOTICE

NISSAN EUROPE S.A.S.

ROCKER COVER ..................................................... 44

HOW TO SELECT PISTON .................................97

ment ..................................................................... 127

OIL PAN AND OIL STRAINER ............................... 154

PRIMARY TIMING CHAIN ...................................... 195

Drain engine coolant when engine is cooled.

Precautions for Disconnecting Fuel Piping

Precautions for Removal and Disassembly

Precautions for Inspection, Repair and Replacement

Use torque wrench to tighten bolts or nuts to specification.

Parts Requiring Angle Tightening

Precautions for Assembly and Installation

Precautions for Liquid Gasket

REMOVAL OF LIQUID GASKET

LIQUID GASKET APPLICATION PROCEDURE

Attach liquid gasket tube to the tube presser (special service

Removing oil pan and timing chain case

Disassembling and assembling

Disassembling and assembling valve

Tightening bolts for bearing cap, cylinder

Loosening or tightening heated oxygen

Removing valve oil seal

Installing valve oil seal

Installing piston assembly into cylinder bore

Removing pilot converter

Pressing the tube of liquid gasket

Removing crankshaft pulley

Quick connector release

Removing fuel tube quick connectors in

Commercial Service Tools

Spark plug wrench

Removing and installing spark plug

Crankshaft pulley removing and installing

Valve seat cutter set

Finishing valve seat dimensions

Removing and installing flywheel

Piston ring expander

Removing and installing piston ring

Valve guide drift