Motor Cd20

ENGINE CONTROL SYSTEM
SECTION EC
EC
CONTENTS
CD20T ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION ......................................................... 25
PRECAUTIONS AND PREPARATION ..................... 3
DTC and MI Detection Logic ............................... 25
Special Service Tools ............................................ 3
Diagnostic Trouble Code (DTC) .......................... 25
Engine Fuel & Emission Control System .............. 4
Malfunction Indicator (MI) .................................... 26
Precautions ............................................................ 5
CONSULT-II......................................................... 30
ENGINE AND EMISSION CONTROL OVERALL
TROUBLE DIAGNOSIS — Introduction................ 36
SYSTEM..................................................................... 7
Introduction .......................................................... 36
Engine Control Module Component Parts
Diagnostic Worksheet .......................................... 37
Location.................................................................. 7
TROUBLE DIAGNOSIS — Work Flow .................. 38
Circuit Diagram ...................................................... 9
Work Flow ............................................................ 38
System Diagram .................................................. 10
Description for Work Flow ................................... 39
Vacuum Hose Drawing ........................................ 11
TROUBLE DIAGNOSIS — Basic Inspection ........ 40
System Chart ....................................................... 12
Basic Inspection................................................... 40
ENGINE AND EMISSION BASIC CONTROL
TROUBLE DIAGNOSIS — General Description .. 42
SYSTEM DESCRIPTION ......................................... 13
Diagnostic Trouble Code (DTC) Chart ................ 42
Glow Control System ........................................... 13
Symptom Matrix Chart ......................................... 50
Fuel Injection System .......................................... 13
CONSULT-II Reference Value in Data Monitor
Fuel Injection Timing System .............................. 16
Mode .................................................................... 53
Air Conditioning Cut Control ................................ 18
Major Sensor Reference Graph in Data
Cooling Fan Control............................................. 18
Monitor Mode ....................................................... 54
CRANKCASE VENTILATION SYSTEM ................. 19
ECM Terminals and Reference Value................. 55
Description ........................................................... 19
TROUBLE DIAGNOSIS FOR POWER SUPPLY.... 62
Blow-by Control Valve ......................................... 19
Main Power Supply and Ground Circuit .............. 62
Ventilation Hose................................................... 19
TROUBLE DIAGNOSIS FOR DTC 12 .................... 65
INJECTION NOZZLE............................................... 20
Mass Air Flow Sensor (MAFS) ............................ 65
Removal and Installation ..................................... 20
Test and Adjustment............................................ 20
Engine Coolant Temperature (ECT) Sensor ....... 69
ELECTRONIC FUEL INJECTION PUMP................ 22
Removal ............................................................... 22
Vehicle Speed Sensor (VSS) .............................. 73
Installation ............................................................ 23
Disassembly and Assembly................................. 24
Control Sleeve Position Sensor (CSPS) ............. 76
TROUBLE DIAGNOSIS FOR DTC 18 .................... 80 TROUBLE DIAGNOSES FOR DTC 83, 98........... 123
Electric Governor ................................................. 80 Glow Control System ......................................... 123
TROUBLE DIAGNOSIS FOR DTC 21 .................... 85 TROUBLE DIAGNOSES FOR DTC 85................. 131
Injection Timing Control Valve............................. 85 Air Conditioner Cut Control................................ 131
TROUBLE DIAGNOSIS FOR DTC 31, 82, 84, TROUBLE DIAGNOSES FOR DTC 86................. 134
91, 93 ....................................................................... 90 EGRC-Solenoid Valve ....................................... 134
Engine Control Module (ECM)............................. 90 TROUBLE DIAGNOSES FOR DTC 87................. 141
TROUBLE DIAGNOSIS FOR DTC 28 .................... 91 Brake Switch ...................................................... 141
Cooling Fan (Overheat) ....................................... 91 TROUBLE DIAGNOSES FOR DTC 92................. 145
TROUBLE DIAGNOSIS FOR DTC 34 .................. 101 ECCS-D Relay ................................................... 145
Needle Lift Sensor (NLS)................................... 101 TROUBLE DIAGNOSES FOR DTC 97................. 146
TROUBLE DIAGNOSIS FOR DTC 36 .................. 104 MI & Data Link Connectors ............................... 146
Fuel Cut Solenoid Valve .................................... 104 TROUBLE DIAGNOSES FOR
TROUBLE DIAGNOSIS FOR DTC 42 .................. 108 NON-DETECTABLE ITEMS .................................. 149
Fuel Temperature Sensor (FTS) ....................... 108 Start Signal ........................................................ 149
TROUBLE DIAGNOSIS FOR DTC 43 .................. 112 SERVICE DATA AND SPECIFICATIONS (SDS) . 151
Accelerator Position Sensor & Switch ............... 112 General Specifications ....................................... 151
TROUBLE DIAGNOSIS FOR DTC 47 .................. 119 Injection Nozzle.................................................. 151
Crankshaft Position Sensor (TDC) .................... 119 Inspection and Adjustment ................................ 151
When you read wiring diagrams:

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

X: Applicable
—: Not applicable
Tool number
Description
Tool name
KV11289004
Nozzle cleaning kit
V1 KV11290012
Box
V KV11290110
2
Brush
V KV11290122
3
Nozzle oil sump
scraper
V KV11290140
4
X
Nozzle needle tip
cleaner
V KV11290150
5
Nozzle seat scraper
V KV11290210
6
Nozzle holder
V KV11290220
7
Nozzle hole cleaning
needle
NT296
KV11292010
Nozzle centering device
NT293
KV11100300
No. 2-4 injection nozzle
holder socket
X
NT563
KV119E0030
No. 1 injection nozzle
holder socket
NT648
EC-CD-3
Engine Fuel & Emission Control System
ECM (ECCS-D control module) WIRELESS EQUIPMENT

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

● Handle mass air flow sensor carefully to avoid
damage.
● Do not disassemble mass air flow sensor.
● Do not clean mass air flow sensor with any type
of detergent.
● Do not disassemble No. 1 injection nozzle (built- WHEN STARTING ECM HARNESS HANDLING
in needle lift sensor). ● Do not depress accelerator pedal when ● Connect ECM harness connectors securely.
● Even a slight leak in the air intake system can starting. A poor connection can cause an extremely
cause serious problems. ● Immediately after starting, do not rev up high (surge) voltage to develop in coil and
● Do not shock or jar the camshaft position sensor engine unnecessarily. condenser, thus resulting in damage to ICs.
(TDC). ● Do not rev up engine just prior to ● Keep ECM harness at least 10 cm (3.9 in)
shutdown. away from adjacent harnesses, to prevent an
ECM system malfunction due to receiving
external noise, degraded operation of ICs,
etc.
● Keep ECM parts and harnesses dry.
● Before removing parts, turn off ignition
switch and then disconnect battery ground
cable.
NEF390
EC-CD-4
Precautions
● Before connecting or disconnecting the ECM harness
connector, turn ignition switch OFF and disconnect
negative battery terminal. Failure to do so may damage
the ECM because battery voltage is applied to ECM even
if ignition switch is turned off.
SEF289H
● When connecting ECM harness connector, open the

ECM
ports on harness connector, then meet the ports with the
pins on the ECM as shown. Push slider on harness until
it stops.
Loosen
Tighten
slider ECM harness

connector
NEF754
● When connecting or disconnecting pin connectors into

ECM
or from ECM, take care not to damage pin terminals
(bend or break).
Pins
Make sure that there are not any bends or breaks on
ECM pin terminal, when connecting pin connectors.
Ports
PULL
to open
ports
Slider
Harness connector NEF755
● Before replacing ECM, perform Terminals and Reference

Perform ECM Value inspection and make sure ECM functions properly.
input/output signal
inspection before Refer to EC-CD-55.
replacement.
MEF040D
● If MI illuminates or blinks irregularly during engine

running, water may have accumulated in fuel filter. Drain
water from fuel filter. If this does not correct the problem,
perform specified trouble diagnostic procedures.
● After performing each TROUBLE DIAGNOSIS, perform
‘‘OVERALL FUNCTION CHECK’’ or ‘‘DTC (Diagnostic
Trouble Code) CONFIRMATION PROCEDURE’’.
The DTC should not be displayed in the ‘‘DTC CONFIR-
MATION PROCEDURE’’ if the repair is completed. The
‘‘OVERALL FUNCTION CHECK’’ should be a good result
SAT652J if the repair is completed.
EC-CD-5
Precautions (Cont’d)
● When measuring ECM signals with a circuit tester, never
allow the two tester probes to contact.
Battery Accidental contact of probes will cause a short circuit
voltage and damage the ECM power transistor.
Harness connector
Short
for solenoid valve ECM
NG
Solenoid valve
OK
Circuit tester
SEF348N
EC-CD-6
ENGINE AND EMISSION CONTROL OVERALL SYSTEM CD20T

Location
EGRC - solenoid valve

Needle lift sensor (built - in No. 1 nozzle) Vacuum pump

Electric fuel injection pump
Fuel filter
Engine coolant temperature sensor
Mass air flow sensor
Glow relay
Cooling fan relay

EGR valve
Cooling fan motors
Crankshaft position sensor (TDC)
Glow plugs
NEF767
EC-CD-7
Location (Cont’d)
Electric governor.
Control sleeve position sensor
and fuel temperature sensor
(built-in)
Ejection timing control valve
Accelerator position sensor
Accelerator pedal
Crank pulley
.
Crankshaft position
sensor (TDC)
ECM
.
Accelerator pedal (LHD)
NEF768
EC-CD-8
DATA LINK
CONNECTOR
FUSIBLE LINK
FUSE
30 64 38 61
MALFUNCTION
IGNITION SWITCH
INDICATOR LAMP
26 ON or START
ENGINE CONTROL
MODULE RELAY 68 GLOW INDICATOR
FUSE LAMP
23 27
45
42
43
GLOW RELAY SPEED-
9 IGNITION SWITCH
OMETER
50 ON
11 NEEDLE
BATTERY
LIFT
12 SENSOR
IGNITION SWTICH BATTERY
OFF ON ON ST ACCELERATOR WORK UNIT VEHICLE
SPEED
ACCELERATOR
SENSOR
POSITION SWITCH
FUSE GLOW PLUG 65
16
55 ACCELERATOR
15 POSITION
SENSOR AIR
57 CONDITIONER
THERMO
INJECTION PUMP CONTROL CONTROL
MASS AIR AMP. PANEL
13 INJECTION TIMING
FLOW
RELAY-3
RELAY-2
RELAY-1
19 CONTROL VALVE
SENSOR
51
COOLING FAN
COOLING FAN
COOLING FAN
EC-CD-9
THERMISTOR
FUEL CUT SOLENOID
47 VALVE
54 53
Circuit Diagram
ECM (ECCS-D CONTROL MODULE)

ENGINE COOLANT 5
TEMPERATURE 14
4 ELECTRIC
SENSOR
GOVERNOR
FUEL 49
MOTOR-1
MOTOR-2
63
TEMPERATURE
29 CONTROL
SENSOR
COOLING FAN
COOLING FAN
SLEEVE
(INJECTION PUMP) 52
POSITION
7 SENSOR
NATS IMMU 59
RDNT
BRAKE TACHOMETER 2 33
SWITCH
20 62
39
STOP LAMP SWITCH CRANKSHAFT TRIPLE- AIR
44 21
POSITION PRESSURE CONDITIONER
46 8 RELAY
SENSOR SWITCH
24
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
(TDC)
EGRC-SOLENOID 1
VALVE 28 To compressor
25
CD20T
YEC080
Battery
ECM (Engine control

module)
Ignition switch
Fuel
Fuel tank pressure
regulator
PCV
Fuel pump valve
Malfunction
indicator
Spark
plug
Ignition coil, power
transistor, camshaft
position sensor built
into distributor
EVAP canister
Injector Vehicle speed sensor
EVAP canister purge volume Heated oxygen sensor
control solenoid valve
EC-CD-10
Throttle
position
sensor
Three way Neutral position/
System Diagram
catalyst inhibitor switch

Air cleaner Engine coolant
temperature
Fast idle sensor
cam Knock sensor Air conditioner switch
SR20De
Mass air flow IACV-AAC manifold
IACV-FICD solenoid valve
sensor (Hot wire type) valve
Power steering oil
Muffler pressure switch
SR20DE
under oilpan
Three way catalyst
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
Electrical load signal

CD20T
SEF830S
Vacuum Hose Drawing
V
2
EGRC - solenoid valve
V
3
Vacuum pump
Air duct
V
1
EGR valve
NEF770
V
1 EGRC-solenoid valve to EGR valve
V
2 EGRC-solenoid valve to air duct
V
3 EGRC-solenoid valve to vacuum pump
Refer to ‘‘System Diagram’’ on previous page for vacuum control system.
EC-CD-11
System Chart
Crankshaft position sensor c c Fuel injection control c Electric governor

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

valve
Fuel temperature sensor c
Mass air flow sensor c

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

sensor
c Glow control system c Glow relay & glow lamp

Needle lift sensor c
Accelerator position sensor c

c On board diagnostic system c Malfunction indicator
ECM (On the instrument panel)
Accelerator position switch c
Air conditioner switch c c EGR valve control c EGRC-solenoid valve
Ignition switch (ON & ST POS.) c
c Cooling fan control c Cooling fan relays

Battery voltage c
Vehicle speed sensor c Air conditioning cut control Air conditioner relay
c c
Brake switch c
c Cooling fan motor control c Cooling fan relay

Atmospheric pressure sensor c
EC-CD-12
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION CD20T
Glow Control System

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

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

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

Crankshaft position sensor (TDC) c ECM c governor
Control sleeve position
When starting, the ECM adapts the fuel injection system for the
start control. The amount of fuel injected at engine starting is a
Coolant temperature preset program value in the ECM. The program is determined by
Fuel injection volume
getting lower
the engine speed and engine coolant temperature.
For better startability under cool engine conditions, the lower the
coolant temperature becomes, the greater the amount of fuel
injected. The ECM ends the start control when the engine speed
reaches a coolant temperature dependent value.
Engine rpm
SEF648S
EC-CD-13
Fuel Injection System (Cont’d)
IDLE CONTROL
Engine speed
Crankshaft position sensor (TDC) c
Air conditioner operation

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

Electric
ECM c governor
Accelerator position
Vehicle speed
The amount of fuel injected under normal driving conditions is

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

Accelerator to the ECM.
opening larger
The fuel injection data, predetermined by correlation between
various engine speeds and accelerator positions, are stored in
the ECM memory, forming a map. The ECM determines the
optimal amount of fuel to be injected using the sensor signals in
Engine rpm
comparison with the map.
SEF649S
EC-CD-14
Fuel Injection System (Cont’d)
FUEL TEMPERATURE COMPENSATION
Fuel temperature
Engine speed ECM Electric

Crankshaft position sensor (TDC) c c governor

The amount of fuel leaking at or around high-pressure parts inside the fuel injection pump varies with fuel
temperature and engine speed. This will result in a difference between the target amount of fuel injected
and the actual amount. The ECM compensates for the actual amount depending on the signal from the fuel
temperature sensor, the control sleeve position sensor and the crankshaft position sensor.
DECELERATION CONTROL
Accelerator sensor c
Electric
ECM c governor
Engine speed
Camshaft position sensor (PUMP) c
The ECM cuts power supply delivery to the electric governor during deceleration for better fuel efficiency.
The ECM determines the time of deceleration according to signals from the accelerator sensor and cam-
shaft position sensor (PUMP).
EC-CD-15
Fuel Injection Timing System

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

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

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

Engine speed
Crankshaft position sensor c

Injection
timing
c control
Atmospheric pressure ECM
Atmospheric pressure sensor c valve
Injection timing
Fuel temperature
For better drivability in high altitude areas, the fuel injection tim-
ing is advanced and the fuel quantity is reduced according to the
atmospheric pressure.
timing compensation
Normal
Fuel injection
High altitude
Engine rpm
NEF771
EC-CD-16
Fuel Injection Timing System (Cont’d)
ENGINE COOLANT TEMPERATURE COMPENSATION (During driving)
Engine speed

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

For better exhaust efficiency under cool engine conditions, the

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

Engine speed
Injection
Engine coolant temperature ECM
Engine coolant temperature sensor c c timing con-
trol valve
Ignition timing
For better startability under cool engine conditions, the fuel injec-
tion timing is compensated according to the engine coolant tem-
Engine coolant
perature.
timing compensation
temperature
Fuel injection
High
Low
Engine rpm
SEF651S
EC-CD-17
Air Conditioning Cut Control

INPUT/OUTPUT SIGNAL LINE
Air conditioner ‘‘ON’’ signal
Accelerator valve opening angle

Air
ECM c conditioner
Vehicle speed relay

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

INPUT/OUTPUT SIGNAL LINE
Vehicle speed

Engine coolant temperature sensor c ECM c Cooling fan relay(s)

The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, and air
conditioner ON signal. The control system has 3-step control [OFF/LOW/HIGH].
Operation
Air conditioner is OFF Air conditioner is ON
temperature °C (°F)
Engine coolant
Engine coolant
. .
102 (216) 102 (216)
. .
96 (205) 96 (205)
. . . .
20 80 20 80
(12) (50) (12) (50)
Vehicle speed km/h (mph) Vehicle speed km/h (mph)
Cooling fans do not operate Cooling fans operate at low speed Cooling fans operate at high speed
NEF772
EC-CD-18
CRANKCASE VENTILATION SYSTEM CD20T
Blow-by control
Description
valve ● In this system blow-by gas is sucked into the air inlet pipe
through the control valve after oil separation by the oil sepa-
rator in the rocker cover.
Baffle plate
FRESH AIR
BLOW BY
GAS
SEF851S
Blow-by Control Valve

Blow-by control valve ● Check control valve for clogging and abnormalities.
Intake
manifold
Rocker cover
SEC586B
Ventilation Hose
1. Check hoses and hose connections for leaks.
2. Disconnect all hoses and clean with compressed air.
If any hose cannot be freed of obstructions, replace.
SEC692
EC-CD-19
INJECTION NOZZLE CD20T
CAUTION:
● Do not disassemble injection nozzle assembly. Entrust
disassembly or adjustment to BOSCH service shop.
● Plug flare nut with a cap or rag so that no dust enters the
nozzle.
Nozzle side Removal and Installation

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

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

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

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

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

Injection timing mark
(Yellow painted mark) TDC: Crankshaft pulley notch without painted mark
3. Remove fuel hoses (supply, return and spill) and injection
tubes.
4. Remove air duct and injection pump timing belt cover.
5. Remove injection pump timing belt.
Refer to EM section (‘‘Injection Pump Timing Belt’’).
TDC (Without painted mark)
SEF655S
EC-CD-22
Removal (Cont’d)
6. Remove injection pump sprocket with Tool.
● Remove key from injection pump shaft and store safely.
SEF656S
7. Remove injection pump assembly.
SEF657S
Injection pump sprocket

Alignment Installation
Key mark
1. Install key on injection pump shaft, then install injection pump
sprocket.
2. Install injection pump timing belt.
Refer to EM section (‘‘Injection Pump Timing Belt’’).
3. Adjust injection timing.
Refer to ‘‘Basic Inspection’’, EC-CD-40.
4. Install all parts removed.
NEF866
EC-CD-23
Installation (Cont’d)

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

: Do not reuse
: N·m (kg-m, in-lb) 7 - 10 (0.7 - 1.0, 61 - 87)
: N·m (kg-m, ft-lb)

NEF778
Disassembly and Assembly

CAUTION:
● Do not disassemble the parts not shown in the illustra-
tion above.
● Before installing injection timing control valve, apply a
coat of diesel fuel to O-ring and its mating area. Insert
injection timing control valve straight into bore in fuel
pump body. After properly positioning injection timing
control valve, visually check for fuel leaks.
● After assembling the parts, erase Diagnostic Trouble
Code (DTC), and perform DTC CONFIRMATION PROCE-
DURE (or OVERALL FUNCTION CHECK).
EC-CD-24
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CD20T
DTC and MI Detection Logic

When a malfunction is detected for the first time, the malfunction (DTC) is stored in the ECM memory.
The MI will light up each time the ECM detects a malfunction. However, if the same malfunction is experi-
enced in two consecutive driving patterns and the engine is still running, the MI will stay lit up. For diagnos-
tic items causing the MI to light up, refer to ‘‘Diagnostic Trouble Code (DTC) Chart’’, EC-CD-42.
Diagnostic Trouble Code (DTC)

HOW TO READ DTC
The diagnostic trouble code can be read by the following methods.
1. The number of flashes of the malfunction indicator in the Diagnostic Test Mode II (Self-Diagnostic
Results) Examples: 11, 13, 14, etc.
These DTCs are controlled by NISSAN.
2. CONSULT-II Examples: ‘‘CRANK POS SEN (TDC)’’, etc.
● Output of the trouble code warns that the indicated circuit has a malfunction. However, when
using MI in Mode II there is no indication to determine whether the malfunction is still occurring
or has occurred in the past and row returned to normal.
CONSULT-II can identify the timing of a malfunctions and so use of CONSULT-II (if available) is
recommended.
● DTCs are stored up to a maximum of 7 items that have highest priority in each grouped DTC
occurred at that time. A new entry of DTC can overwrite an existing entry with a lower priority if
the DTC memory is full. If 7 DTCs are read, other remained DTCs can be read after the existing
DTC item has been corrected and the DTC is erased.
HOW TO ERASE DTC
The diagnostic trouble code can be erased by the following methods.
Selecting ‘‘ERASE’’ in the ‘‘SELF-DIAG RESULTS’’ mode with CONSULT-II.

Changing the diagnostic test mode from Diagnostic Test Mode II to Mode I twice. (Refer to ‘‘HOW TO
SWITCH DIAGNOSTIC TEST MODES’’.)
● If the battery terminal is disconnected, the diagnostic trouble code will be lost within 24 hours.
● When you erase the DTC, using CONSULT-II is easier and quicker than switching the diagnostic
test modes.
● Erasing DTC is possible only when the ECM has recognised the DTC item is corrected.
If erasing is not possible, turn the ignition switch to the ‘‘LOCK’’ position once. Wait for at least
5 seconds and then turn it ‘‘ON’’ (engine stopped) again.
HOW TO ERASE DTC (With CONSULT-II)
1. If the ignition switch stays ‘‘ON’’ after repair work, be sure to turn ignition switch to the ‘‘LOCK’’ position
once. Wait for at least 5 seconds and then turn it ‘‘ON’’ (Engine stopped) again.
2. Turn CONSULT-II ‘‘ON’’ and touch ‘‘ENGINE’’.
3. Touch ‘‘SELF-DIAG RESULTS’’.
4. Touch ‘‘ERASE’’. (The DTC in the ECM will be erased.)
1. Touch ‘‘Engine’’. 2. Touch ‘‘SELF-DIAG RESULTS’’. 3. Touch ‘‘ERASE’’. (The DTC in the
ECM will be erased.) C2SSE03
EC-CD-25
Diagnostic Trouble Code (DTC) (Cont’d)
HOW TO ERASE DTC (No Tools)
1. If the ignition switch stays ‘‘ON’’ after repair work, be sure to turn ignition switch to ‘‘LOCK’’ position once.
Wait at least 5 seconds and then turn it ‘‘ON’’ again.
2. Change the diagnostic test mode from Mode II to Mode I twice. When changing modes, wait at least 2
seconds. (Refer to EC-CD-27.)
Malfunction Indicator (MI)

1. The malfunction indicator will light up when the ignition switch
is turned ON without the engine running. This is a bulb check.
● If the malfunction indicator does not light up, refer to EL sec-
tion (‘‘WARNING LAMPS AND CHIME’’) or see EC-CD-27.
2. When the engine is started, the malfunction indicator should
go off.
If the lamp remains on, the on board diagnostic system has
detected an engine system malfunction.
If MI illuminates or flashes irregularly after starting engine,
SAT652J
water may have accumulated in fuel filter. Drain water from
fuel filter.
ON BOARD DIAGNOSTIC SYSTEM FUNCTION
The ON BOARD DIAGNOSTIC SYSTEM FUNCTION
The on board diagnostic system has the following three functions:
1. BULB CHECK : This function checks the MI bulb for damage (blown, open circuit, etc.).
2. MALFUNCTION : This is a usual driving condition. When a malfunction is detected, the
WARNING MI will light up to inform the driver that a malfunction has been
detected.
3. SELF-DIAGNOSTIC : This function allows diagnostic trouble codes to be read.
RESULTS
Refer to ‘‘HOW TO SWITCH DIAGNOSTIC TEST MODES’’ on next page.

Diagnostic Diagnostic
Condition
Test Mode I Test Mode II
Engine
stopped
BULB CHECK SELF-DIAGNOSTIC RESULTS
Ignition
switch in
‘‘ON’’ position Engine
running
MALFUNCTION WARNING —
EC-CD-26
Malfunction Indicator (MI) (Cont’d)
HOW TO SWITCH DIAGNOSTIC TEST MODES
Turn ignition switch to ‘‘ON’’ posi-

tion. (Do not start engine.)
c Diagnostic Test Mode I — BULB CHECK c G c Diagnostic Test Mode I —

MALFUNCTION WARNING
Start engine.
.
Data link connector for CONSULT-II (Connect

CHK and IGN terminals with a suitable harness.)
.
DIAGNOSTIC TEST MODE II
— SELF-DIAGNOSTIC RESULTS
Data link connector for CONSULT-II (Connect ● Switching the diagnostic test mode is not possible when
CHK and IGN terminals with a suitable harness.) the engine is running.
EC-CD-27
DIAGNOSTIC TEST MODE I — BULB CHECK
In this mode, the MALFUNCTION INDICATOR on the instrument panel should stay ON. If it remains OFF,
check the bulb. Refer to EL section (‘‘WARNING LAMPS AND CHIME’’) or see EC-CD-27.
DIAGNOSTIC TEST MODE I — MALFUNCTION WARNING
MALFUNCTION
Condition
INDICATOR
When the malfunction is detected or the ECM’s CPU is malfunctioning. (The ‘‘MI Illumination’’ of the
ON
‘‘DTC Chart’’.) Refer to EC-CD-43.
OFF No malfunction.
● These Diagnostic Trouble Code Numbers are clarified in Diagnostic Test Mode II (SELF-DIAGNOSTIC
RESULTS).
DIAGNOSTIC TEST MODE II — SELF-DIAGNOSTIC RESULTS
In this mode, a diagnostic trouble code is indicated by the number of flashes of the MALFUNCTION INDI-
CATOR as shown below.
Example: Diagnostic trouble code No. 12 and code No. 43
0.6 0.3 0.6 0.3
ON
OFF
0.9 0.3 2.1 0.6 2.1

Unit: second
Code No. 12 Code No. 43
SEF212NA
Long (0.6 second) flashes indicate the number of ten digits, and short (0.3 second) flashes indicate the
number of single digits. For example, the malfunction indicator flashes 4 times for 0.6 sec and then it flashes
three times for about 0.3 sec. This indicates the DTC ‘‘43’’ and refers to the malfunction of the accelerator
position sensor.
In this way, all the detected malfunctions are classified by their diagnostic trouble code numbers. The DTC
‘‘55’’ refers to no malfunction. (See DIAGNOSTIC TROUBLE CODE CHART, EC-CD-44.)
HOW TO ERASE DIAGNOSTIC TEST MODE II (Self-diagnostic results)
The diagnostic trouble code can be erased from the backup memory in the ECM when the diagnostic test
mode is changed twice from Diagnostic Test Mode II to Diagnostic Test Mode I. (Refer to ‘‘HOW TO SWITCH
DIAGNOSTIC TEST MODES’’ on previous page.)
● If the battery terminal is disconnected, the diagnostic trouble code will be lost from the backup
memory within 24 hours.
● Be careful not to erase the stored memory before starting trouble diagnoses.
● If the MI blinks or ‘‘NATS MALFUNCTION’’ is displayed
on ‘‘SELF-DIAG RESULTS’’ screen, perform self-diag-
nostic results mode with CONSULT-II using NATS pro-
gram card (NATS-E940). Refer to EL section.
● Confirm no self-diagnostic results of NATS is displayed
before touching ‘‘ERASE’’ in ‘‘SELF-DIAG RESULTS’’
mode with CONSULT-II.
● When replacing ECM, initialisation of NATS system and
registration of all NATS ignition key IDs must be carried
out with CONSULT-II using NATS program card (NATS-
C2SDR02 E940).
Therefore, be sure to receive all keys from vehicle
owner. Regarding the procedures of NATS initialisation
and NATS ignition key ID registration, refer to CON-
SULT-II operation manual, NATS.
EC-CD-28
RELATIONSHIP BETWEEN MI, DTC, CONSULT-II AND DRIVING PATTERNS
This driving pattern does not satisfy self-diagnostic condition.
This driving pattern satisfies self-diagnostic condition.
SELF-DIAGNOSTIC FINISH
TIME
START
Engine RUN (ON)

(IGN)
STOP (OFF)
1*
MI ON
OFF
ECM Diagnostic DISPLAY 3*

Trouble
Code (DTC) NO 2*
DISPLAY
DEFECT EXIST
STOP
4*
CONSULT-II
SELF- DTC exist
DIAGNOSTIC
RESULTS
DTC does
SCREEN
not exist
&
DATA MONITOR
(AUTO TRIG) 39
4 5
SCREEN 3
2
0 0 0 1
SELF- COUNTER
DIAGNOSTIC
RESULTS
SCREEN
NEF764
*1: When a malfunction is detected, MI will light up. *4: Other screens except SELF-DIAGNOSTIC RESULTS &
*2: When a malfunction is detected for the first time, the DTC DATA MONITOR (AUTO TRIG) cannot display the mal-
will be stored in ECM. function. DATA MONITOR (AUTO TRIG) can display the
malfunction at the moment it is detected.
*3: The DTC will not be displayed any longer after vehicle is
driven 40 times without the same malfunction.
(The DTC still remains in ECM.)
EC-CD-29
Fuse box
CONSULT-II
CONSULT-II INSPECTION PROCEDURE
1. Turn off ignition switch.
2. Connect ‘‘CONSULT-II’’ to data link connector for CON-
SULT-II.
(Data link connector for CONSULT-II is located behind the
fuse box cover.)
Data link connector

for CONSULT-II SEF900P
3. Turn on ignition switch.

4. Touch ‘‘START’’.
5. Touch ‘‘ENGINE’’.
6. Perform each diagnostic test mode according to each service
procedure.
For further information, see the CONSULT-II Operation
Manual.
PEF895K
PEF216U
EC-CD-30
CONSULT-II (Cont’d)
ENGINE CONTROL MODULE COMPONENT PARTS/CONTROL SYSTEMS APPLICATION
DIAGNOSTIC TEST MODE
Item SELF-DIAG-
DATA ACTIVE
NOSTIC
MONITOR TEST
RESULTS
Camshaft position sensor (PUMP) *1 X *2 X
Mass air flow sensor X X
Engine coolant temperature sensor X X
Control sleeve position sensor X X X
ENGINE CONTROL MODULE COMPONENT PARTS
Fuel temperature sensor X X

Vehicle speed sensor X X
Accelerator position sensor X X
Accelerator position switch X
INPUT
Brake lamp switch X *2 X
Crankshaft position sensor (TDC) X X
Needle lift sensor X X
Ignition switch (start signal) X
Ignition switch (ON signal) X
Air conditioner switch X
Brake switch X
Battery voltage X
Injection timing control valve X X X
Fuel cut solenoid valve X X X
Air conditioner relay X
OUTPUT
Glow relay X X
EGRC-solenoid valve X X
Cooling fan relay X X
X: Applicable
*1: Imaginary sensor, which produces secondary engine revolution signal using needle lift sensor pulse.
*2: CONSULT-II may not display, but self-diagnostic results are available with MI.
EC-CD-31
SELF-DIAGNOSTIC MODE
Regarding items detected in ‘‘SELF-DIAG RESULTS’’ mode, refer to ‘‘Diagnostic Trouble Code (DTC)
chart’’. (See EC-CD-28.)
DATA MONITOR MODE
Monitored item ECM
Main
[Unit] input Description Remarks
signals
signals
CKPSvRPM ● The engine speed computed from the
(TDC) [rpm] j j crankshaft position sensor (TDC) sig-
nal is displayed.
CMPSvRPM - ● The engine speed computed from the
PUMP [rpm] j j camshaft position sensor (PUMP) sig-
nal is displayed.
COOLAN TEMP/S ● The engine coolant temperature (deter- ● When the engine coolant temperature
[°C] or [°F] mined by the signal voltage of the sensor is open or short-circuited, ECM
j j engine coolant temperature sensor) is
displayed.
enters fail-safe mode. The engine cool-
ant temperature determined by the
ECM is displayed.
VHCL SPEED SE ● The vehicle speed computed from the
[km/h] or [mph] j j vehicle speed sensor signal is dis-
played.
FUEL TEMP SEN ● The fuel temperature (determined by
[°C] or [°F] j j the signal voltage of the fuel tempera-
ture sensor) is displayed.
ACCEL POS SEN ● The accelerator position sensor signal
[V] j j voltage is displayed.
OFF ACCEL POS ● Indicates [ON/OFF] condition from the
[ON/OFF] j j accelerator position switch signal.
C/SLEEV POS/S [V] ● The control sleeve position sensor sig-
j j nal voltage is displayed.
BATTERY VOLT [V] ● The power supply voltage of ECM is
j j displayed.
START SIGNAL ● Indicates [ON/OFF] condition from the ● After starting the engine, [OFF] is dis-
[ON/OFF] j j starter signal. played regardless of the starter signal.
AIR COND SIG ● Indicates [ON/OFF] condition of the air
[ON/OFF] j j conditioner switch as determined by
the air conditioner signal.
BRAKE SW ● Indicates [ON/OFF] condition of the
[ON/OFF] j stio lamp switch.
BRAKE SW2 ● Indicates [ON/OFF] condition of the
[ON/OFF] j stio lamp switch 2.
IGN SW ● Indicates [ON/OFF] condition from igni-
[ON/OFF] j j tion switch.
MAS AIR/FL SE [V] ● The signal voltage of the mass air flow ● When the engine is stopped, a certain
j j sensor is displayed. value is indicated.
ACT INJ TIMG [°] ● The actual injection timing angle deter-
mined by the ECM (an approximate
j average angle between injection start
and end from TDC) is displayed.
TARGET F/INJ ● The target fuel injection quantity
[mm3/STROKE] j (determined by the ECM according to
the input signal) is indicated.
NOTE:
Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.
EC-CD-32
Monitored item ECM
Main
[Unit] input Description Remarks
signals
signals
FUEL CUT S/V ● The control condition of the fuel cut ● When the fuel cut solenoid valve is not
[ON/OFF] solenoid valve (determined by ECM operating, fuel supply is shut off.
according to the input signal) is indi-
cated.
● OFF ... Fuel cut solenoid valve is not
operating.
ON ... Fuel cut solenoid valve is oper-
ating.
AIR COND RLY ● The air conditioner relay control condi-
[ON/OFF] j tion (determined by ECM according to
the input signal) is indicated.
GLOW RLY ● The glow relay control condition (deter-
[ON/OFF] j mined by ECM according to the input
signal) is displayed.
COOLING FAN ● Indicates the control condition of the
[LOW/HI/OFF] cooling fans (determined by ECM
according to the input signal).
j ● LOW ... Operates at low speed.
HI ... Operates at high speed.
OFF ... Stopped.
EGRC SOL/V A ● The control condition of the EGRC-
[ON/OFF] solenoid valve (determined by ECM
according to the input signal) is indi-
cated.
● OFF ... EGRC-solenoid valve is not
operating.
ON ... EGRC-solenoid valve is oper-
ating.
EC-CD-33
ACTIVE TEST MODE
TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY)
● Engine: Return to the original
trouble condition If trouble symptom disappears, see
TARGET F/INJ ● Control sleeve position sensor
● Fix the target injection quantity CHECK ITEM.
using CONSULT-II.
● Ignition switch: ON
● Operate the cooling fan at ‘‘LOW’’, Cooling fan moves at ‘‘LOW’’, ‘‘HI’’ ● Harness and connector
COOLING FAN
‘‘HI’’ speed and turn ‘‘OFF’’ using speed and stops. ● Cooling fan motor
CONSULT-II.
● Turn solenoid valve ‘‘ON’’ and Solenoid valve makes an operating ● Harness and connector
FUEL CUT SOL/V
‘‘OFF’’ with the CONSULT-II and sound. ● Solenoid valve
listen to operating sound.
● Turn solenoid valve ‘‘ON’’ and Solenoid valve makes an operating ● Harness and connector
EGRC SOL/V A
‘‘OFF’’ with the CONSULT-II and sound. ● Solenoid valve
● Ignition switch: ON (Engine
stopped)
Glow relay makes the operating ● Harness and connector
GLOW RLY ● Turn the glow relay ‘‘ON’’ and
sound. ● Fuel pump relay
‘‘OFF’’ using CONSULT-II and
● Engine: Return to the original
trouble condition If trouble symptom disappears, see
INJ TIMING ● Adjust initial injection timing
● Retard the injection timing using CHECK ITEM.
CONSULT-II.
EC-CD-34
REAL TIME DIAGNOSIS IN DATA MONITOR MODE
CONSULT-II has two kinds of triggers and they can be selected by touching ‘‘SETTING’’ in ‘‘DATA MONI-
TOR’’ mode.
1. ‘‘AUTO TRIG’’ (Automatic trigger):
● The malfunction will be identified on the CONSULT-II screen in real time.
In other words, DTC and malfunction item will be displayed at the moment the malfunction is detected
by ECM.
DATA MONITOR can be performed continuously until a malfunction is detected. However, DATA
MONITOR cannot continue any longer after the malfunction detection.
2. ‘‘MANU TRIG’’ (Manual trigger):
● 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.
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 is detected.
● While narrowing down the possible causes, CONSULT-II should be set in ‘‘DATA MONITOR (AUTO
TRIG)’’ mode, especially in case the incident is intermittent.
Inspect the circuit by gently shaking (or twisting) suspicious connectors, components and harness in
the ‘‘DTC CONFIRMATION PROCEDURE’’. The moment a malfunction is found the DTC will be
displayed. (Refer to GI section, ‘‘Incident Simulation Tests’’ in ‘‘HOW TO PERFORM EFFICIENT
DIAGNOSIS FOR AN ELECTRICAL INCIDENT’’.)
2. ‘‘MANU TRIG’’
● If the malfunction is displayed as soon as ‘‘DATA MONITOR’’ is selected, reset CONSULT-II to
‘‘MANU TRIG’’. By selecting ‘‘MANU TRIG’’ you can monitor and store the data. The data can be
utilized for further diagnosis, such as a comparison with the value for the normal operating condi-
tion.
‘‘SETTING’’ ‘‘AUTO TRIG’’ ‘‘MANU TRIG’’

A malfunction can be A malfunction can not be
displayed on ‘‘DATA displayed on ‘‘DATA
MONITOR’’ screen MONITOR’’ screen
automatically if detected. automatically even if
detected.
PEF529Q
EC-CD-35
TROUBLE DIAGNOSIS — Introduction CD20T
Introduction
The engine has an ECM to control major systems such as fuel
injection control, fuel injection timing control, glow control
system, etc. The ECM accepts input signals from sensors and
instantly drive the electronic fuel injection pump use the data to
based on current ambient conditions. It is essential that both
input and output signals are correct and stable. At the same time,
it is important that there are no problems such as vacuum leaks,
or other problems with the engine.
SEF858S It is much more difficult to diagnose a problem that occurs inter-
mittently rather than catastrophically. Most intermittent problems
are caused by poor electric connections or faulty wiring. In this
case, careful checking of suspected circuits may help prevent the
INFO.
replacement of good parts.
CAUSE A visual check only may not be sufficiënt to determine the cause
of the problems. A road test with CONSULT-II or a circuit tester
connected should be performed. Follow the ‘‘Work Flow’’ on the
next page.
Before undertaking actual checks, take a few minutes to talk with
a customer who approaches with a driveability complaint. The
customer can supply good information about such problems,
SEF233G especially intermittent ones. Find out what symptoms are present
and under what conditions they occur. A ‘‘Diagnostic Worksheet’’
like the example on next page should be used.
Start your diagnosis by looking for ‘‘conventional’’ problems first.
This will help troubleshoot driveability problems on a vehicle with
an electronically controlled engine.
SEF234G
EC-CD-36
TROUBLE DIAGNOSIS — Introduction CD20T
Diagnostic Worksheet
There are many operating conditions that lead to the malfunction
KEY POINTS
of engine components. A good grasp of such conditions can
WHAT ..... Vehicle & engine model make troubleshooting faster and more accurate.
WHEN ..... Date, Frequencies In general, each customer feels differently about a problem. It is
WHERE ..... Road conditions important to fully understand the symptoms or conditions for a
HOW ..... Operating conditions, customer complaint.
Weather conditions, Utilize a diagnostic worksheet like the one shown below in order
Symptoms to organize all the information for troubleshooting.
SEF907L
WORKSHEET SAMPLE
Customer name MR/MS Model & Year VIN
Engine # Trans. Mileage

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

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

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

Incident occurrence
h In the morning h At night h In the daytime
Frequency h All the time h Under certain conditions h Sometimes
Weather conditions h Not affected
h Fine h Raining h Snowing h Others

Weather
[ ]
Temperature h Hot h Warm h Cool h Cold h Humid °F
h Cold h During warm-up h After warm-up

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

h Not affected
h At starting h While idling h At racing
h While accelerating h While cruising
Driving conditions h While decelerating h While turning (RH/LH)
Vehicle speed
0 10 20 30 40 50 60 70 80 90 100 mph
Malfunction indicator h Turned on h Not turned on
EC-CD-37
TROUBLE DIAGNOSIS — Work Flow CD20T
Work Flow
CHECK IN
.
Listen to customer complaints. (Get symptoms.) .......................................... STEP I
.
Check, print out or write down, and erase Diagnostic Trouble Code (DTC).
..................................... STEP II
Symptoms No symptoms, except MI
collected. lights up, or Malfunction
Code exists at STEP II.
.
Verify the symptom by driving in the condition the
customer described. ....................................................................................*1 STEP III
Normal Code Malfunction Code

(at STEP II) (at STEP II)
. .
Verify the DTC by performing the ‘‘DTC CONFIRMATION PROCEDURE’’. .....................................*1 STEP IV
.
Choose the appropriate action. ..................................... STEP V
c
*2
Malfunction Code (at STEP II or IV) Normal Code (at both STEP II and IV)
.
BASIC INSPECTION
SYMPTOM BASIS (at STEP I or III)

........................................................©
.
Perform inspections
according to Symptom
Matrix Chart.
. .
TROUBLE DIAGNOSIS FOR SPECIFIC DTC. STEP VI
.
REPAIR/REPLACE
.
NG FINAL CHECK
Confirm that the incident is completely fixed by performing BASIC INSPECTION
..................................... STEP VII
and DTC CONFIRMATION PROCEDURE (or OVERALL FUNCTION CHECK).
Then, erase the unnecessary (already fixed) DTCs in ECM.
OK
.
CHECK OUT
*1: If the incident cannot be duplicated, refer to GI section (‘‘Incident Simulation Tests’’, ‘‘HOW TO PERFORM EFFICIENT
DIAGNOSIS FOR AN ELECTRICAL INCIDENT’’).
*2: If the on board diagnostic system cannot be performed, check main power supply and ground circuit. Refer to
‘‘TROUBLE DIAGNOSIS FOR MAIN POWER SUPPLY AND GROUND CIRCUIT’’, EC-CD-62.
EC-CD-38
TROUBLE DIAGNOSIS — Work Flow CD20T
Description for Work Flow

STEP DESCRIPTION
Get detailed information about the conditions and the environment when the incident/symptom occurred
STEP I
using the ‘‘DIAGNOSTIC WORKSHEET’’ as shown on the next page.
Before confirming the concern, check and write down (print out using CONSULT-II) the Diagnostic Trouble
Code (DTC), then erase the code. Refer to EC-CD-25.) The DTC can be used when duplicating the incident
STEP II at STEP III & IV.
Study the relationship between the cause, specified by DTC, and the symptom described by the customer.
(The ‘‘Symptom Matrix Chart’’ will be useful. Refer to EC-CD-50.)
Try to confirm the symptom and under what conditions the incident occurs.
The ‘‘DIAGNOSTIC WORK SHEET’’ is useful to verify the incident. Connect CONSULT-II to the vehicle in
STEP III DATA MONITOR (AUTO TRIG) mode and check real time diagnosis results.
If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. Refer to GI section.
If the malfunction code is detected, skip STEP IV and perform STEP V.
Try to detect the Diagnostic Trouble Code (DTC) by driving in (or performing) the ‘‘DTC CONFIRMATION
PROCEDURE’’. Check and read the DTC 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.
STEP IV If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. Refer to GI section.
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 effec-
tive alternative.
The ‘‘NG’’ result of the ‘‘OVERALL FUNCTION CHECK’’ is the same as the DTC detection.
Take the appropriate action based on the results of STEP I through IV.
If the malfunction code is indicated, proceed to specific TROUBLE DIAGNOSIS FOR DTC.
STEP V
If the normal code is indicated, proceed to the BASIC INSPECTION. Refer to EC-CD-40. Then perform
inspections according to the Symptom Matrix Chart. Refer to EC-CD-50.
Identify where to begin diagnosis based on the relationship study between symptom and possible causes.
Inspect the system for mechanical binding, loose connectors or wiring damage using (tracing) ‘‘Harness Lay-
outs’’.
Gently shake the related connectors, components or wiring harness with CONSULT-II set in ‘‘DATA MONI-
TOR (AUTO TRIG)’’ mode.
Check the voltage of the related ECM terminals or monitor the output data from the related sensors with
STEP VI
CONSULT-II. Refer to EC-CD-55.
The ‘‘DIAGNOSTIC PROCEDURE’’ in EC section contains a description based on open circuit inspection. A
short circuit inspection is also required for the circuit check in the DIAGNOSTIC PROCEDURE. For details,
refer to GI section (‘‘Circuit Inspection’’, ‘‘HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRI-
CAL INCIDENT’’).
Repair or replace the malfunctioning parts.
Once you have repaired the circuit or replaced a component, you need to run the engine in the same condi-
tions and circumstances which resulted in the customer’s initial complaint.
Perform the ‘‘DTC CONFIRMATION PROCEDURE’’ and confirm the normal code (Diagnostic trouble code
STEP VII No. 55) 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-CD-25.)
EC-CD-39
TROUBLE DIAGNOSIS — Basic Inspection CD20T
Basic Inspection
Precaution:
Perform Basic Inspection without electrical or mechanical
loads applied;
● Headlamp switch is off,
● Air Conditioner switch is off,
● Rear defogger switch is off,
● Steering wheel is in the straight-ahead position, etc.
SEF142I BEFORE STARTING

1. Check service records for any
recent repairs that may indicate a
related problem, or the current need
Priming pump
for scheduled maintenance.
2. Open engine hood and check the
following:
● Harness connectors for faulty con-
nections
● Vacuum hoses for splits, kinks, or
faulty connections
● Wiring for faulty connections,
pinches, or cuts
SEF671S
3. Using priming pump, bleed air from
fuel system. Refer to ‘‘Fuel Filter
Check’’ in MA section.
.
CONNECT CONSULT-II TO THE
VEHICLE.
Connect ‘‘CONSULT-II’’ to the data link
connector for CONSULT-II and select
.
Data link connector
‘‘ENGINE’’ from the menu. Refer to
for CONSULT-II EC-CD-30.
SAT703J
.
DOES ENGINE START? No Turn ignition switch to
.
c
Diesel tacho tester the ‘‘LOCK’’ position,
Yes wait 5 seconds and then
start engine. If engine
. fails to start, check diag-
Injection tube
nostic trouble code
(DTC).
.
Run engine for 10 minutes.
SEF689S .
CHECK IDLE SPEED.
Read engine idle speed in
‘‘DATA MONITOR’’ mode with
CONSULT-II.
825 rpm ± 25 (in N position)
----------------------------------------------------------------- OR -----------------------------------------------------------------
Check idle speed using tacho-
meter tester.
825 rpm ± 25 (in N position)
.
(Go to V
A on next page.)
PEF190P
EC-CD-40
TROUBLE DIAGNOSIS — Basic Inspection CD20T
Basic Inspection (Cont’d)
V
A
.
OK
CHECK INJECTION TIMING. c Bleed air from fuel sys-
1. Set No. 1 piston at TDC on its com- tem.
pression stroke. After this inspection,
TDC: Without painted mark unnecessary diagnostic
2. Remove injection tubes and air trouble code No. might
bleeder on the back of injection be displayed.
pump. Erase the stored
3. Set dial gauge so its indicator points memory in ECM.
SEF661S
to somewhere between 1.0 and 2.0 Refer to ‘‘ON BOARD
mm (0.039 and 0.079 in) on the DIAGNOSTIC SYSTEM
Plunger lift timing mark scale. DESCRIPTION’’
(Yellow painted mark) 4. Turn crankshaft 2 turns clockwise (EC-CD-25).
and check that dial gauge indicates
the same value again. OK
5. Turn crankshaft counterclockwise
about 100 degrees, then turn crank- .
shaft slowly clockwise, and set dial INSPECTION END
gauge indicator to 0 mm at the posi-
tion it stops.
TDC (Without painted mark)
6. Turn crankshaft clockwise and set it
at plunger lift timing mark using the
mark on the crankshaft pulley.
SEF655S
plunger lift timing mark: Yellow
painted mark
7. Read plunger lift.
Plunger lift:
0.89 ± 0.08 mm (0.0350 ± 0.0031
in) at plunger lift timing mark
Increase ● When repeating the checking,
Decrease
start with step 5.
NG
.
Adjusting c Go to
1. If plunger lift is not within the speci-
SEF662S fied value, adjust by turning injec-
tion pump.
● If indication is smaller than the
specified value, turn pump body
away from engine.
● If indication is larger than the
specified value, turn pump body
towards engine.
2. Tighten injection pump securing
bolts and nuts.
Nut:
: 20 - 25 N·m
(2.0 - 2.6 kg-m, 15 - 18 ft-lb)
Bolt:
SEF657S : 25 - 35 N·m
(2.6 - 3.6 kg-m, 18 - 26 ft-lb)
3. Remove dial gauge and install air
bleeder with new washer.
4. Install injection tubes.
Flare nut:
: 14 - 20 N·m
(1.4 - 2.0 kg-m, 10 - 15 ft-lb)
5. Bleed air from fuel system.
Refer to ‘‘Water Draining, Fuel Filter
Check and Replacement’’ of
‘‘ENGINE MAINTENANCE’’ in MA
section.
EC-CD-41
TROUBLE DIAGNOSIS — General Description CD20T
Diagnostic Trouble Code (DTC) Chart

ENGINE RELATED ITEMS
Detected items
Diagnostic
trouble
(Screen terms for Malfunction is detected when ...
code
CONSULT-II, ‘‘SELF-
No.
DIAG RESULTS’’ mode)
12 Mass air flow sensor cir- ● An excessively high or low voltage from the sensor is detected by the ECM.
cuit
(MASS AIR FLOW SEN)
13 Engine coolant tempera- ● An excessively high or low voltage from the sensor is detected by the ECM.
ture sensor circuit
(COOLANT TEMP SEN)
14 Vehicle speed sensor cir- ● The almost 0 km/h (0 mph) signal from the sensor is detected by the ECM even
cuit when vehicle is being driven.
(VEHICLE SPEED SEN)
15 Control sleeve position ● An excessively high or low voltage from the sensor is detected by the ECM.
sensor circuit ● An incorrect voltage signal from the sensor is detected by the ECM during engine
(CONT SLEEV POS SEN) running.
18 Fuel injection feedback 2 ● The fuel injection feedback system (consists of the ECM, electric governor and
(F/INJ F/B 2) control sleeve position sensor) does not operate properly.
21 Fuel injection timing feed- ● The fuel injection timing feedback system (consists of the ECM, fuel injection tim-
back ing control valve and needle lift sensor) does not operate properly.
(F/INJ TIMG F/B)
Abbreviations for Quick Reference of ‘‘DTC CONFIRMATION PROCEDURE’’

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

IGN: ON : Turning the ignition switch ON is required for the ECM to detect a malfunction (if one exists).
RUNNING : Running engine is required for the ECM to detect a malfunction (if one exists).
LIFTING : Lifting up the vehicle, running engine and spinning wheels are required for the ECM to detect a malfunction (if one
exists).
DRIVING : Driving the vehicle in the specified pattern is required for the ECM to detect a malfunction (if one exists).
EC-CD-42
(Cont’d)
—: Not applicable
DTC *1 *2
Confirmation Overall MI Reference
Check Items
Procedure Function Illumination Page
(Possible Cause)
Quick Ref. Check
● Harness or connectors
(The sensor circuit is open or shorted.) IGN: ON — — EC-CD-65
● Mass air flow sensor
(The sensor circuit is open or shorted.) IGN: ON — Lighting up EC-CD-69
● Engine coolant temperature sensor
(The sensor circuit is open or shorted.) — LIFTING — EC-CD-73
● Vehicle speed sensor
(The sensor circuit is open or shorted.) RUNNING — Lighting up EC-CD-76
● Control sleeve position sensor
● Main power supply circuit (ECM terminals 23 , 45 ),
68 and fuse
(Electric governor and control sleeve position sensor cir- RUNNING
— Lighting up EC-CD-80
cuit) (DRIVING)
● Electronic fuel injection pump
● ECM
● Electric governor
(Injection timing control valve, Needle lift sensor and
Crankshaft position sensor (TDC) circuit]
RUNNING
● Injection timing control valve — Lighting up EC-CD-85
(DRIVING)
● Needle lift sensor
● Crankshaft position sensor
● Air in fuel line
*1: ● This is Quick Reference of ‘‘DTC CONFIRMATION PROCEDURE’’.
Details are described in each TROUBLE DIAGNOSIS FOR DTC.
*2: ● The ‘‘OVERALL FUNCTION CHECK’’ is a simplified and effective way to inspect a component or circuit.
In some cases, the ‘‘OVERALL FUNCTION CHECK’’ is used rather than a ‘‘DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE’’.
When no DTC CONFIRMATION PROCEDURE is available, the ‘‘NG’’ result of the OVERALL FUNCTION CHECK can be con-
sidered to mean the same as a DTC detection.
● During an ‘‘NG’’ OVERALL FUNCTION CHECK, the DTC might not be confirmed.
● This is Quick Reference of ‘‘OVERALL FUNCTION CHECK’’.
Details are described in each TROUBLE DIAGNOSIS FOR DTC.
EC-CD-43
(Cont’d)
Detected items
Diagnostic
trouble
code
No.
28 Cooling fan ● An excessive high engine coolant temperature sensor signal is detected by the
(OVER HEAT) ECM. (Overheat)
31 ECM2 ● ECM calculation function is malfunctioning.

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

exists).
EC-CD-44
(Cont’d)
—: Not applicable
DTC *1 *2
Confirmation Overall MI Reference
Check Items
Procedure Function Illumination Page
(Possible Cause)
Quick Ref. Check
(The cooling fan circuit is open or shorted.)
● Cooling fan
● Radiator hose
● Radiator
● Radiator cap IGN: ON

— Lighting up EC-CD-80
● Water pump (RUNNING)
● Thermostat
● Fan belt
For more information, refer to ‘‘12 MAIN CAUSES OF
OVERHEATING’’. (EC-CD-99)
● ECM
IGN: ON — Lighting up EC-CD-90
(The sensor circuit is open or shorted.)
● Needle lift sensor RUNNING — Lighting up EC-CD-101
● Clogging No. 1 injection nozzle
(The solenoid valve circuit is open or shorted.) RUNNING — Lighting up EC-CD-104
● Fuel cut solenoid valve
(The sensor circuit is open or shorted.) IGN: ON — — EC-CD-108
● Fuel temperature sensor
(The sensor circuit is open or shorted.)
● Accelerator position sensor
● Accelerator position switch
(The sensor circuit is open or shorted.) RUNNING — Lighting up EC-CD-119
● Crankshaft position sensor (TDC)
● No failure
— — — —

Details are described in each specific TROUBLE DIAGNOSIS FOR DTC.
PROCEDURE’’.
EC-CD-45
(Cont’d)
Detected items
Diagnostic
trouble
code
No.
82 Atmospheric pressure ● An excessively high or low voltage from the sensor is detected by the ECM.
sensor *5
(—) *3
83 Glow relay circuit ● Glow relay circuit is open or shorted.
(GLOW RELAY)
84 ECM ● ECM reference voltage (2.5V) is excessively high or low.

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

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

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

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

(PUMP)*4
(—)*3
exists).
EC-CD-46
(Cont’d)
—: Not applicable
DTC *1 *2
Confirmation Overall Func- MI Reference
Check Items
Procedure tion Check Illumination Page
(Possible Cause)
Quick Ref.
● ECM
IGN: ON — — EC-CD-90
(The glow relay circuit is open or shorted.) IGN: ON — — EC-CD-123
● Glow relay
● ECM
(The air conditioner relay circuit is open or shorted.) IGN: ON — — EC-CD-131
● Air conditioner relay
(The EGRC-solenoid valve A circuit is open or shorted.) RUNNING — Lighting up EC-CD-134
● EGRC-solenoid valve
(Brake switch circuits are open or shorted.)
RUNNING — Lighting up EC-CD-141
● Brake lamp switch
● RDNT brake switch
● ECM
(The ECCS-D relay circuit is shorted.)
● ECCS-D relay
● ECM
● ECM
(The injection timing control valve circuit is open or
shorted.)
● Injection timing control valve
● ECM
● Needle lift sensor RUNNING — Lighting up EC-CD-101
● Low battery voltage
PROCEDURE’’.
*3: CONSULT-II may not detect, but self-diagnostic results are available with MI.
*4: Imaginary sensor, which produces secondary engine revolution signal using needle lift sensor pulse.
*5: The atmospheric pressure sensor is located inside the ECM and is not replaceable.
EC-CD-47
(Cont’d)
Detected items
Diagnostic
trouble
code
No.
97 MI ● MI (malfunction indicator) circuit is open or shorted.
(—)*3
98 GLOW LAMP CIRCUIT ● Glow lamp circuit is open or shorted.

(—)*3

exists).
EC-CD-48
(Cont’d)
—: Not applicable
DTC *1 *2
Confirmation Overall Func- MI Reference
Check Items
Procedure tion Check Illumination Page
(Possible Cause)
Quick Ref.
(The MI circuit is open or shorted.)
● MI lamp
● ECM
(The glow indicator lamp circuit is open or shorted.) IGN: ON — — EC-CD-123
● Glow lamp
*1: This is Quick Reference of ‘‘DTC CONFIRMATION PROCEDURE’’.
●
PROCEDURE’’.
*3: CONSULT-II may not detect, but self-diagnostic results are available with MI.
EC-CD-49
Symptom Matrix Chart

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

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

HESITATION/SURGING/FLAT SPOT
EXCESSIVE FUEL CONSUMPTION

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

Malfunction indicator illuminates.
NO START (with first firing)
WHEN DECELERATING
ROUGH IDLE/HUNTING
POOR ACCELERATION
IDLING VIBRATION
DURING DRIVING
LACK OF POWER
BLACK SMOKE
WHITE SMOKE
Reference page
LOW IDLE
AT IDLE
HI IDLE
Fuel cut
New CT/CS AA AB AC AD AE AF AG AH AJ AK AL AM AP HA
Injec- Advanced j j ● ● j ● j j ● j EC-CD-41
tion
timing Retarded j j ● ● j ● j j ● j EC-CD-41
Electric injection
● ● ● ● j j j j j ● j j j ● ● j j ● j j j j — *1
pump mainframe
Injection nozzle j j j j j j j ● j j j ● ● ● EC-CD-20 *2
Glow system j j ● ● ● ● EC-CD-123
EM-
Engine body j j ● ● j j j ● j j j ● ● j j j ● *3
section
EGR system ● ● ● EC-CD-134
Air cleaner and MA-
● ● ● j *4
ducts section
● ; High Possibility Item
j; Low Possibility Item
*1: Insufficient or excess amount. Governor malfunction may be the cause.
*2: Depends on open-valve pressure and spray pattern.
*3: Caused mainly by insufficient compression pressure.
*4: Symptom varies depending on off-position of air duct, etc.
EC-CD-50
SYMPTOM
HI IDLE
Fuel cut
LOW IDLE
ENGINE STALL
LACK OF POWER
HARD/NO START/
IDLING VIBRATION
RESTART (EXCP. HA)

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


WHITE SMOKE
BLACK SMOKE

open, ground short j j j j
Mass air flow sensor circuit EC-CD-65
short j j j
Compensation according to
open, short j j j j j j j j EC-CD-69 engine coolant temperature
EC-CD-51
circuit
does not function.
Vehicle speed sensor circuit open, short j j EC-CD-73
Control sleeve position sensor cir- open, short j j j j j j EC-CD-76
cuit
open, ground short j j j j j j j
Electric governor circuit EC-CD-80
short j j
open, short j j j j Injection timing cannot be

Injection timing control valve circuit EC-CD-85 controlled.
ground short j j j
Needle lift sensor circuit open, short j j j j EC-CD-101
open, ground short j j j j j j j
Engine control module

Fuel cut solenoid valve circuit EC-CD-104 Engine runs on after turning
short j j j
TROUBLE DIAGNOSIS — General Description
ignition switch OFF.

Symptom Matrix Chart (Cont’d)
Compensation for amoun

Fuel temperature sensor circuit open, short j j j j j j j j j j EC-CD-108 t of fuel injected according
to fuel temperature does
not function.
Accelerator position sensor circuit open, short j j j j j EC-CD-112
Crankshaft position sensor (TDC) open, short j j j j
EC-CD-119
circuit noise j j j j j
CD20T
SYMPTOM
HI IDLE
Fuel cut
LOW IDLE
ENGINE STALL
LACK OF POWER
HARD/NO START/
IDLING VIBRATION
RESTART (EXCP. HA)

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


WHITE SMOKE
BLACK SMOKE

Start signal circuit open, short j j EC-CD-149 Start control does not function.
Air conditioner does not stop
open, ground short
Air conditioner switch circuit EC-CD-131 operating.
short Air conditioner does not work.
EC-CD-52
open, ground short j j j j j
Accelerator position switch (Idle)
EC-CD-112 Accelerator position sensor NG
circuit short j j j j j
signal is output.
open j j j j
Ignition switch circuit (ON signal) EC-CD-62
short Engine does not stop.
open j j j
Power supply for ECM circuit EC-CD-62
short j j
open, short j j
EGRC-solenoid valve circuit EC-CD-134
ground short j j j Does not stop operating.
open j j j j j j j Glow lamp does not turn on.
Glow relay circuit EC-CD-123
short j j Glow lamp does not turn off.
open j j j j

Engine control module relay (Self-
EC-CD-62 Ground short makes engine
TROUBLE DIAGNOSIS — General Description
shutoff) circuit short j j j unable to stop.

Symptom Matrix Chart (Cont’d)
Air conditioner does not oper-

open ate.
Air conditioner relay circuit EC-CD-131
Air conditioner does not stop
short j j operating.
open j
Brake switch circuits EC-CD-141
short j
ECM, Connector circuit open, short j j j j j j j j j j j j j j j j j j j j j j j j j EC-CD-90
CD20T
CONSULT-II Reference Value in Data Monitor

Mode
Remarks:
● Specification data are reference values.
● Specification data are output/input values which are detected or supplied by the ECM at the connector.
* Specification data may not be directly related to their components signals/values/operations.
MONITOR ITEM CONDITION SPECIFICATION
CKPSvRPM (TDC) ● Tachometer: Connect
Almost the same speed as the CON-
● Run engine and compare tachometer indication with the CONSULT-II
CKPSvRPM-PUMP SULT-II value.
value.
COOLAN TEMP/S ● Engine: After warming up More than 70°C (158°F)
● Turn drive wheels and compare speedometer indication with the CON- Almost the same speed as
VHCL SPEED SE
SULT-II value the CONSULT-II value
FUEL TEMP SEN ● Engine: After warming up More than 40°C (104 °F)
● Ignition switch: ON Accelerator pedal: release Approx. 0.40V

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

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

● Air conditioner switch: ‘‘OFF’’ Idle -0.5 to -1.5°
ACT INJ TIMG ● Shift lever: ‘‘N’’
● No-load 2,000 rpm +2.5° to +3.5°
● At sea level
● Air conditioner switch: ‘‘OFF’’ Idle 8.0 - 8.8 mm3/stroke
TARGET F/INJ ● Shift lever: ‘‘N’’
● No-load 2,000 rpm Approx. 7.6 mm3/stroke
● At sea level
Brake pedal: released OFF
BRAKE SW ● Ignition switch: ON
Brake pedal: depressed ON
Brake pedal: released OFF
BRAKE SW 2 ● Ignition switch: ON
Brake pedal: depressed ON
FUEL CUT S/V ● Ignition switch: ON → OFF ON → OFF
AIR COND RLY ● Air conditioner switch: OFF → ON OFF → ON
GLOW RLY ● Refer to EC-CD-129.
● When cooling fan is stopped. OFF
COOLING FAN ● When cooling fan operates at low speed. LOW
● When cooling fan operates at high speed. HI
● Air conditioner switch: ‘‘OFF’’ Idle OFF
EGRC SOL/V A ● Shift lever: ‘‘N’’
● No-load 2,800 rpm ON
● At sea level
EC-CD-53
Major Sensor Reference Graph in Data

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

Below is the data for ‘‘ACCEL POS SEN’’, ‘‘C/SLEEV POS/S’’ and ‘‘ACT INJ TIMG’’ when revving engine
quickly up to 3,000 rpm under no load after warming up engine sufficiently.
Each value is for reference, the exact value may vary.
+04’’95
-00’’09
● ‘‘ACCEL POS SEN’’ should increase

x0.1V
while depressing the accelerator

pedal and should decrease while
releasing it.
16:06
+04’’95
-00’’09
● ‘‘C/SLEEV POS/S’’ should increase

x0.1V
when depressing the accelerator

pedal and should decrease when the pedal is
released.
16:06
+04’’95
-00’’09
● ‘‘ACT INJ TIMG’’ should increase

when depressing the accelerator
pedal and should decrease when
the pedal is released.
ACT INJ TIMG
13:22
NEF780
EC-CD-54
ECM Terminals and Reference Value

PREPARATION
Distributor harness The ECM is located beneath the heater unit. To access the ECM,
connector
remove the center console under cover at the passenger side.
Perform all voltage measurements with all connectors con-
nected. Since the ECM harness connector cannot be accessed
from the backside, voltages should be measured at the nearest
connector to the sensors or actuators to be measured.
NEF853
Connector
When measuring:
● Use extreme care not to touch 2 pins at the same time.
● Note that the data is for comparison and may not be exact.
● Use care not to enlarge the opening to keep the seal in good
condition.
Alligator clip DMM

‘‘T’’ pin
SGI841
EC-CD-55
(Cont’d)
ECM HARNESS CONNECTOR TERMINAL LAYOUT
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
NEF781
ECM INSPECTION TABLE

Specification data are reference values and are measured between each terminal and V
46 (Engine control
module ground).
TER- DATA
WIRE
MINAL ITEM CONDITION (DC Voltage and
COLOR
NO. Pulse Signal)
Engine ground
1 Engine is running. (Probe this terminal with
24 B ESSC ground
Idle speed @ tester probe when
46
measuring.)
Approximately 1.1 - 1.5V
Engine is running. (Warm-up condition)
Idle speed
SEF550S
2 L/OR Tachometer
Engine is running.
Engine speed is 2,000 rpm
SEF551S
EC-CD-56
(Cont’d)
TER- DATA
WIRE
COLOR
NO. Pulse Signal)
Approximately 10.5V
Idle speed
4 SEF562S
5 B/L Electric governor ground
49 Approximately 10.5
SEF563S
Approximately 2.6V
Control sleeve position Engine is running.

7 W
sensor power supply Idle speed
SEF559S
Approximately 0V
Idle speed
Crankshaft position sen- NEF867

8 W
sor (TDC) (Signal) Approximately 0V
Engine is running.
NEF868
11 B Needle lift sensor ground Ignition switch ‘‘ON’’ Approximately 0V
EC-CD-57
(Cont’d)
TER- DATA
WIRE
COLOR
NO. Pulse Signal)
Idle speed
NEF869
12 W Needle lift sensor
NEF870

1.9 - 2.3V
Idle speed
13 L/W Mass air flow sensor
2.5 - 2.9V
0.6 - 4.8V
Engine coolant tempera- Output voltage varies
14 L/OR Engine is running.
ture sensor with engine coolant tem-
perature.
Ignition switch ‘‘ON’’

0.4 - 0.6V
Accelerator position sen- Accelerator pedal released
15 W
sor Ignition switch ‘‘ON’’
Approximately 4.0V
Accelerator pedal fully depressed
Ignition switch ‘‘ON’’ Approximately 0V

16 B/Y Start signal
BATTERY VOLTAGE
Ignition switch ‘‘START’’
(11 - 14V)

19 W Ignition switch ‘‘ON’’ Approximately 5V
power supply
Ignition switch ‘‘ON’’ Battery voltage

Brake pedal released (11 -14V)
20
R/B Brake switch 2
39 Ignition switch ‘‘ON’’
0V
Brake pedal depressed
Crankshaft position sen-

sor (TDC) ground & Engine is running.
21 OR Approximately 0V
mass air flow sensor Idle speed
ground
EC-CD-58
(Cont’d)
TER- DATA
WIRE
COLOR
NO. Pulse Signal)
23
BATTERY VOLTAGE
45 R Power supply for ECM Ignition switch ‘‘ON’’
(11 - 14V)
68
Engine is running. (Warm-up condition) BATTERY VOLTAGE

Idle speed (11 - 14V)
25 P EGRC-solenoid valve A
Approximately 0.3V
Ignition switch ‘‘ON’’ Approximately 1.0V
26 OR/L Malfunction indicator Engine is running. BATTERY VOLTAGE

Idle speed (11 - 14V)

Approximately 1.0V
Glow lamp is ‘‘ON’’.
27 OR Glow lamp
Ignition switch ‘‘ON’’ BATTERY VOLTAGE
Glow lamp is ‘‘OFF’’ (11 - 14V)
Engine is running.
Both A/C switch and blower switch are Approximately 0.4V
28 L/W Air conditioner relay ‘‘ON’’
Engine is running. BATTERY VOLTAGE

A/C switch is ‘‘OFF’’ (11 - 14V)
Approximately 2.6V
Control sleeve position Engine is running. (Warm-up condition)

29 R sensor (Reference sig-
nal) Idle speed
SEF561S
30 G/B Engine is running. Approximately 0V

Data link connector for
61 GY/L Idle speed (CONSULT-II is connected and Approximately 4 - 9V
CONSULT-II
64 G/R turned on) Approximately 0V
Engine is running.
33 B Sensors’ ground Approximately 0V
Idle speed
Ignition switch ‘‘LOCK’’ 0V

38 BR Ignition switch
BATTERY VOLTAGE
(11 - 14V)
EC-CD-59
(Cont’d)
TER- DATA
WIRE
COLOR
NO. Pulse Signal)
Engine is running.
Ignition switch ‘‘LOCK’’ 0 - 1V
Engine control module For a few seconds after turning ignition

42 W/G switch to the ‘‘LOCK’’ position
relay (Self-shutoff)
Ignition switch ‘‘LOCK’’
BATTERY VOLTAGE
Following a few seconds delay after turning (11 - 14V)
ignition switch to the ‘‘LOCK’’ position
0 - Approximately 4.2V
Engine is running.
43 OR/W Vehicle speed sensor Lift up the vehicle.

In 2nd gear position
Vehicle speed is 40 km/h (25 mph)
SEF552S

0V
Brake pedal released
44 R/G Stop lamp switch
Ignition switch ‘‘ON’’ Battery voltage
Brake pedal depressed (11 - 14V)

Cooling fan is not operating. (11 - 14V)
Cooling fan relay
47 LG/R
(Low speed) Engine is running.
Approximately 0.4V
Cooling fan is operating.
50 W/R Glow relay Refer to ‘‘Glow control System’’.
Approximately 9V
Idle speed
Injection timing control SEF564S

51 B/Y
valve Approximately 8V
SEF565S
EC-CD-60
(Cont’d)
TER- DATA
WIRE
COLOR
NO. Pulse Signal)
Approximately 2.6V
Control sleeve position Engine is running.

52 B
sensor ground Idle speed
SEF560S
Ignition switch ‘‘LOCK’’ Approximately 0V

53 SB Fuel cut solenoid valve
BATTERY VOLTAGE
(11 - 14V)
Engine is running.
BATTERY VOLTAGE
Cooling fan is not operating. (11 - 14V)
Cooling fan relay Cooling fan is operating at low speed.
54 LG
(High speed)
Engine is running.
Approximately 0.5V
Cooling fan is operating at high speed.
Accelerator position sen- Engine is running.

55 BR Approximately 0V
sor ground Idle speed
Accelerator position sen-
57 LG/W Ignition switch ‘‘ON’’ Approximately 5V
sor power supply
Immobilizer communica- BATTERY VOLTAGE

59 OR Ignition switch ‘‘ON’’
tion (4 - 14V)
Engine is running.
Both air conditioner switch and blower Approximately 0V
62 GY Air conditioner switch switch are ‘‘ON’’ (Compressor operates)

Air conditioner switch is ‘‘OFF’’ (11 - 14V)
0.6 - 4.8V
63 R/Y Fuel temperature sensor Engine is running. Output voltage varies
with fuel temperature.

Approximately 0V
Accelerator position Accelerator pedal released
65 GY
switch (Idle) Ignition switch ‘‘ON’’
Approximately 2.7V
Accelerator pedal depressed
EC-CD-61
TROUBLE DIAGNOSIS FOR POWER SUPPLY CD20T
Main Power Supply and Ground Circuit

IGNITION SWITCH
START
IGNITION SWITCH
ON or START
BATTERY EC-MAIN-01
FUSE
BLOCK
10A 10A (J/B) 15A Refer to EL-POWER.
17 11 36
M1
5B 17C W/R
B/Y BR
: Detectable line for DTC

: Non-detectable line for DTC
W/R W/R
ENGINE
2 3 CONTROL
MODULE
RELAY
E91
1 5
W/G R
B/Y BR W/G R
M50 M52 E43 E89
24 2 7 2
F104 F103 F2 F96
B/Y BR W/G R
B/Y BR W/G R R R
16 38 42 45 23 68
ANL K15 HRL-0 BAT+ BAT+ BAT+
ECM
F106
BAT- BAT- BAT-
1 24 46 B B B
B B B
F15 F18
REFER TO THE FOLLOWING

3 FUSE BLOCK - Junction Box (J/B)
M1
E91 1 2 3 4 F2 1 2 F96
5
L 5 6 7 8 GY 3 4 B
1 2
1 2 1 2 3 4 5 6 7 8 9 10
F103 F104
3 4 5 6 11 12 13 14 15 16 17 18 19 20 21 22 23 24
W W
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC307
EC-CD-62
(Cont’d)
INSPECTION START
.
No
Start engine. CHECK POWER SUP-
c
Is engine running? PLY-I.
1. Disconnect ECM harness
Yes connector.
2. Turn ignition switch to
‘‘ON’’ position.
NEF863 3. Check voltage between
ECM connector terminal
V 38 and ground
. Voltage: Battery voltage

1. Stop engine. If NG, check the following:
2. Disconnect ECM harness connector. ● 10A fuse
3. Turn ignition switch to ‘‘ON’’ position. ● Harness connectors

M52 , F103
● Harness for open or
short-circuit between
ECM and ignition switch.
If NG, replace 10A fuse or
repair harness or connec-
Engine control tors.
module relay YEC327
OK
b
.
OK
CHECK POWER SUPPLY-II. Go to ‘‘CHECK
c
1. Short between ECM connector terminal GROUND CIRCUIT’’ on
V42 and engine ground with a jump wire. page EC-CD-64.
2. Check voltage between ECM terminals
V23 , V
45 , V
68 and ground.
Voltage: Battery voltage
NG
.
NG
NEF782 CHECK HARNESS CONTINUITY Check the following:
c
BETWEEN ENGINE CONTROL MODULE ● Harness connectors
RELAY AND ECM M89 , F96
Check harness continuity between ECM ● Harness for open or
connector terminals V23 , V 68 and engine
45 V short-circuit between
control module relay connector terminal V
5 . engine control module
Continuity should exist. relay and ECM.
If OK, check harness for short. If NG, repair harness or
connectors.
. OK
V
A
NEF783
ECCS-D relay
connector
YEC351
EC-CD-63
(Cont’d)
V
A
ECCS-D relay
connector .
NG
CHECK VOLTAGE BETWEEN ENGINE Check the following:
c
CONTROL MODULE RELAY AND ● 15A fuse
GROUND. ● Harness for open or
Check voltage between engine control mod- short-circuit between
ule relay connector terminals V
2 , V
3 and engine control module
ground with CONSULT-II or tester. relay and battery.
Voltage: Battery voltage If NG, replace fuse or repair
YEC352 harness or connectors.
OK
.
NG
CHECK OUTPUT SIGNAL CIRCUIT. ● Check harness connec-
c
Check harness continuity between ECM tors E43 , F2
relay connector connector terminal V
42 and engine control Repair harness or connec-
module relay connector terminal V 1 . tors.
Continuity should exist.
If OK, check harness for short-circuit.
OK
.
NG
CHECK ENGINE CONTROL MODULE Replace engine control
c
YEC353
RELAY. module relay.
1. Apply 12V direct current between engine
control module relay connector terminals
V1 and V 2 .
2. Check continuity between engine control
module relay connector terminals V3 and
V5 .
12V (V1 -V 2 ) applied:
ECCS-D relay Continuity exists.
connector No voltage applied:
No continuity
OK
.
NG
YEC354 CHECK GROUND CIRCUIT. Repair harness or connec-
c
1. Turn ignition switch to ‘‘LOCK’’ position. tors.
2. Check harness continuity between ECM
connector terminals V 1 , V24 , V
46 and
engine ground.
If resistance is too high, loosen, clean and
retighten engine ground.
OK
.
Check ECM pin terminals for damage and
check the connection of ECM harness con-
nector.
NEF787
.
INSPECTION END
Engine ground
NEF399
EC-CD-64
TROUBLE DIAGNOSIS FOR DTC 12 CD20T
Mass Air Flow Sensor (MAFS)

The mass air flow sensor measures the amount of intake air by
analysing a part of the entire flow. When intake air flows into the
intake manifold, heat is withdrawn from the hot film. By regulat-
ing the electrical current that flows through the hot film, the ECM
maintains the hot film temperature on a constant level. The
amount of electric current that is needed to keep the hot film on
a constant temperature level is proportional to the mass of air
that flows into the engine.
NEF663
Diagnostic
Check Items
Trouble Malfunction is detected when . . .
(Possible Cause)
Code No.
12 ● An excessively high or low voltage from the sensor ● Harness or connectors
is entered to ECM. (The sensor circuit is open or shorted.)
● Mass air flow sensor
DIAGNOSTIC TROUBLE CODE CONFIRMATION

PROCEDURE
1) Turn ignition switch to ‘‘ON’’ position.
2) Select ‘‘DATA MONITOR’’ mode with CONSULT-II.
3) Start engine and wait for at least 20 seconds.
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
1) Start engine and wait for at least 20 seconds.
2) Turn ignition switch to ‘‘LOCK’’ position, wait for at
least 5 seconds and then turn to ‘‘ON’’ position.
3) Perform ‘‘Diagnostic Test Mode II’’ (Self-diagnostic
results).
EC-CD-65
Mass Air Flow Sensor (MAFS) (Cont’d)
BATTERY EC-MAFS-01
15A Refer to EL-POWER.
36
W/R

W/R W/R R
ENGINE
2 3 CONTROL 2
MODULE MASS AIR
RELAY FLOW
SENSOR
E91
F38
1 5 3 4 5
W/G R OR W L/W
W/G R
E43 E89
7 2
F2 F96
W/G R
W/G R R R OR W L/W
42 23 45 68 21 19 13
HRL-0 BAT+ BAT+ BAT+ GND-D HFM-2 HFM-1
ECM
F106
3
E91 1 2 3 4 F2 F38 1 2 F96
5 1 2 3 4 5
L 5 6 7 8 GY 3 4 B
1 2
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC308
EC-CD-66
Mass air flow sensor harness connector DIAGNOSTIC PROCEDURE
INSPECTION START
.
NG
CHECK POWER SUPPLY. Repair harness or connec-
c
2. Disconnect mass air flow sensor harness
connector.
3. Turn ignition switch to ‘‘ON’’ position.
4. Check voltage between mass air flow
NEF788
sensor connector terminal V 2 and
ground.
Voltage: Battery positive voltage
OK
Mass air flow .

sensor connector NG
CHECK GROUND CIRCUIT. Repair harness or connec-
c
2. Disconnect ECM harness connector.
3. Check harness continuity between mass
air flow sensor connector terminal V 3
and ECM connector terminal V 21 .
NEF789 If OK, check harness for short-circuit.
OK
.
NG
CHECK INPUT SIGNAL CIRCUIT. Repair harness or connec-
c
Check harness continuity between mass air tors.
flow sensor connector terminal V4 and
ECM connector terminal V 19 , mass air flow
Mass air sensor connector terminal V 5 and ECM
flow: sensor connector terminal V
13 .
connector
If OK, check harness for short.
OK
NEF790
.
NG
CHECK COMPONENT Replace mass air flow sen-
c
(Mass air flow sensor). sor.
Refer to ‘‘COMPONENT INSPECTION’’ on
connector next page.
OK
.
Disconnect and reconnect harness connec-
tors in the circuits. Then retest.
Trouble is not fixed.
NEF791 .
Check ECM pin terminals for damage or the
connection of ECM harness connector.
.
INSPECTION END
EC-CD-67
COMPONENT INSPECTION
connector 1. Turn ignition switch to ‘‘ON’’ position.
2. Start engine and warm it up sufficiently.
3. Check voltage between mass air flow sensor connector ter-
minal V5 and ground.
Conditions Voltage V
Ignition switch ‘‘ON’’ position (Engine stopped.) Approximately 1.0
NEF792 Idle (Engine is warmed-up sufficiently.) 1.9 - 2.3
4. If NG, remove mass air flow sensor from air duct. Check hot
film for damage or dust.
NEF669
EC-CD-68
Engine Coolant Temperature (ECT) Sensor

Terminal
Sensor The engine coolant temperature sensor is used to detect the
engine coolant temperature. The sensor modifies a voltage sig-
nal from the ECM. The modified signal returns to the ECM as the
engine coolant temperature input. The sensor uses a thermistor
which is sensitive to the change in temperature. The electrical
resistance of the thermistor decreases as temperature
increases.
Gasket
SEF594K
20
〈Reference data〉
10
8 Engine coolant
6 Voltage Resistance
4 Acceptable
temperature
(V) (kΩ)
Resistance kΩ
2 °C (°F)
1.0 −10 (14) 4.4 7.0 - 11.4
0.8
0.4 20 (68) 3.5 2.1 - 2.9
0.2 50 (122) 2.3 0.68 - 1.00
0.1
(−4) (32) (68) (104)(140)(176) (212)
90 (194) 1.0 0.236 - 0.260
Temperature °C (°F) SEF012P
Diagnostic
Check Items
Trouble Code Malfunction is detected when ...
(Possible Cause)
No.
is entered to ECM. (The sensor circuit is open or shorted.)

PROCEDURE
3) Wait at least 5 seconds.
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
1) Turn ignition switch to ‘‘ON’’ position and wait at least
5 seconds.
2) Turn ignition switch to ‘‘LOCK’’ position, wait at least
5 seconds and then turn to ‘‘ON’’ position.
3) Perform diagnostic test mode II (Self-diagnostic
results).
EC-CD-69
(Cont’d)
EC-ECTS-01
ENGINE COOLANT
TEMPERATURE
SENSOR
F12
2 1
L/OR B

L/OR B
14 33
WTFI GND-A
ECM
F106
1 2 F12
GY
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC417
EC-CD-70
(Cont’d)
.
RH strut tower DIAGNOSTIC PROCEDURE
INSPECTION START
.
.
CHECK POWER SUPPLY. NG Repair harness or con-
Engine coolant temperature c
sensor harness connector 1. Turn ignition switch to ‘‘LOCK’’ posi- nectors.
tion.
2. Disconnect engine coolant tempera-
NEF401
ture sensor harness connector.
3. Turn ignition switch to ‘‘ON’’ posi-
tion.
4. Check voltage between engine cool-
Engine coolant temperature ant temperature sensor connector
sensor connector terminal V2 and ground with CON-
SULT-II or tester.
Voltage:
Approximately 4.9V
OK
.
SEF541P CHECK GROUND CIRCUIT. NG Repair harness or con-
c
1. Turn ignition switch to ‘‘LOCK’’ posi- nectors.
tion.
2. Check harness continuity between
engine coolant temperature sensor
Engine coolant temperature connector terminal V 1 and engine
sensor connector
ground.
If OK, check harness for short-cir-
cuit.
OK
.
SEF542P NG
CHECK COMPONENT c
Replace engine coolant
(Engine coolant temperature sensor). temperature sensor.
Refer to ‘‘COMPONENT INSPEC-
TION’’
on next page.
OK
.
Disconnect and reconnect harness
connectors in the circuit. Then retest.

.
Check ECM pin terminals for damage
and check the connection of ECM har-
ness connector. Reconnect ECM har-
ness connector and retest.
.
INSPECTION END
EC-CD-71
(Cont’d)
Check resistance as shown in the figure.
Temperature °C (°F) Resistance kΩ

20 (68) 2.1 - 2.9
50 (122) 0.68 - 1.0
SEF152P 90 (194) 0.236 - 0.260
20 If NG, replace engine coolant temperature sensor.

10
8
6
4 Acceptable
Resistance kΩ
2
1.0
0.8
0.4
0.2
0.1
(−4) (32) (68) (104)(140)(176) (212)
Temperature °C (°F) SEF012P
EC-CD-72
Vehicle Speed Sensor (VSS)

The vehicle speed sensor is installed in the transaxle. It contains
a pulse generator which provides a vehicle speed signal to the
Vehicle speed speedometer. The speedometer then sends a signal to the ECM.
sensor
AEC110
Diagnostic
Check Items
Trouble Code Malfunction is detected when ....
(Possible Cause)
No.
14 ● The almost 0 km/h (0 mph) signal from vehicle ● Harness or connector
speed sensor is sent to ECM even when vehicle is (The vehicle speed sensor circuit is open or
being driven. shorted.)
● Vehicle speed sensor
OVERALL FUNCTION CHECK

Use this procedure to check the overall function of the vehicle
speed sensor circuit. During this check, a DTC might not be
confirmed.
1) Jack up drive wheels.
2) Start engine.
3) Read vehicle speed sensor signal in ‘‘DATA MONI-
TOR’’ mode with CONSULT-II.
The vehicle speed on CONSULT-II should be able to
exceed 10 km/h (6 mph) when rotating wheels with
PEF651U suitable gear position.
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
1) Jack up drive wheels.
2) Start engine.
3) Rotate drive wheel by hand.
4) Check voltage between ECM connector terminal V 43
and ground with voltage tester.
Voltage should vary between approx. 0 - 0.6V.
NEF794
EC-CD-73
Vehicle Speed Sensor (VSS) (Cont’d)
BATTERY
IGNITION SWITCH
ON or START
EC-VSS-01
FUSE
10A 10A BLOCK Refer to EL-POWER.
16 12 (J/B)
M1
5C 13C 14C : Dectable line for DTC

L LG/R Y
LG/R
L 2 3 L/Y
L/Y Y
M50 M52
OR/W 9 1 B 7 5
COMBINATION F104 F103
8 METER L/Y Y
(SPEEDOMETER)
R M38
L/Y Y
2 1
VEHICLE
SPEED
SENSOR
OR/W R
F25
M50
8 6
F104 3
OR/W R
B
F104
11
M50
B
OR/W R
B B B B
43 9
FGG-1
FGG-1 TQS-A
TQS-A
ECM
F106
M6 M28 M26

M1 FUSE BLOCK - Junction Box (J/B)
13 14 15 16 17 18 19 20
M38 1 2 3 F25
1 2 3 4 5 6 7 8 9 10 11 12
GY BR
1 2 1 2 3 4 5 6 7 8 9 10
F103 F104
3 4 5 6 11 12 13 14 15 16 17 18 19 20 21 22 23 24
W W
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC309
EC-CD-74
Vehicle Speed Sensor (VSS) (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START
Combination meter
connector
.
CHECK INPUT SIGNAL CIRCUIT. NG Check the following:
c
1. Turn ignition switch to ‘‘LOCK’’ posi- ● Harness connectors
tion. M50 , F104
2. Disconnect ECM harness connector ● Harness for open or
YEC355
and combination meter harness con- short-circuit between
nector. ECM and combination
3. Check harness continuity between meter.
ECM connector terminal V 43 and If NG, repair harness or
combination meter connector termi- connectors.
nal V 9 .
cuit.
OK
.
CHECK SPEEDOMETER FUNCTION. NG Check the following:
c
Make sure that speedometer functions ● Harness connectors
correctly. M50 , F104
● Harness for open or
OK
short-circuit between
combination meter and
vehicle speed sensor.
If NG, repair harness or
connectors.
Check vehicle speed
sensor and its circuit.
Refer to EL section.
.

.
.
INSPECTION END
EC-CD-75
Control Sleeve Position Sensor (CSPS)

The control sleeve position sensor is installed on the electric
Shaft governor. It senses the position of control sleeve (rotor angle)
while the control sleeve is being driven by the electric governor,
and feeds it back to the ECM.
Sensor coil
SEF641S
Diagnostic
Check Items
(Possible cause)
No.
is detected by ECM. (The control sleeve position sensor circuit is open
.................................................................................. or shorted.)
● An incorrect voltage signal from the sensor is ● Control sleeve position sensor
detected by ECM during engine running.
.
Electronic injection pump DIAGNOSTIC TROUBLE CODE CONFIRMATION
harness connector (control
sleeve position sensor)
PROCEDURE
1) Turn ignition switch to ‘‘ON’’ position and select
‘‘DATA MONITOR’’ mode with CONSULT-II.
2) Start engine and run it for at least 2 seconds at idle
speed.
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
speed.
NEF796 5 seconds and then turn to ‘‘ON’’ position.
3) Perform ‘‘Diagnostic Test Mode II (Self-diagnostic
results)’’.
EC-CD-76
(Cont’d)
INJECTION PUMP
(CONTROL SLEEVE
EC-CSPS-01
POSITION SENSOR)
F50
1 2 3
R B W : Detectable line for DTC

R B W B
29 52 7 33
RWH-R RWG-M RWG-Y GND-A
ECM
F106
1
7 2
F50
6 3
B
5 4
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC418
EC-CD-77
(Cont’d)
Control sleeve position INSPECTION START
sensor connector
.
NG
CHECK POWER SUPPLY CIRCUIT. Repair harness or connec-
c
2. Disconnect ECM harness connector and
electronic injection pump harness connec-
YEC356 tor.
3. Check harness continuity between control
sleeve position sensor connector terminal
V 3 and ECM connector terminal V 7 .
sensor connector
OK
.
NG
CHECK INPUT SIGNAL CIRCUIT. Repair harness or connec-
c
Check harness continuity between control tors.
V 2 and ECM terminal V 52 .
YEC357
OK
.
NG
CHECK REFERENCE SIGNAL CIRCUIT. Repair harness or connec-
Control sleeve position c
sensor connector Check harness continuity between control tors.
V 1 and ECM connector terminal V 29
OK
.
NG
CHECK COMPONENT Have the injection pump
YEC358 c
(Control sleeve position sensor). assembly serviced by an
Refer to ‘‘COMPONENT INSPECTION’’ on authorised service represen-
next page. tative.
OK
.
tors in the circuit. Then retest.

.
nector. Reconnect ECM harness connector
and retest.
.
INSPECTION END
EC-CD-78
(Cont’d)
Control sleeve
position sensor,
Control sleeve position sensor
electric governor & 1. Disconnect electronic injection pump harness connector.
fuel temperature
sensor connector 2. Check continuity between terminals V 1 and V3 , V
2 and V 3 .
Resistance: Approximately 6.0Ω [at 25°C (77°F)]
If NG, take proper action.
NEF680
EC-CD-79
Electric Governor
Return spring
The electric governor is built into the fuel injection pump. It
moves the control sleeve to increase or decrease the amount of
Coil
fuel injected.
Rotor When current flows through the coil, a magnetic force is
produced, rotating the rotor. The rotor shaft is installed to the
control sleeve via a ball pin which is eccentrically situated in
relation to the rotor shaft. With this arrangement, the control
sleeve can be moved in relation to rotor rotation.
Core The rotor’s rotating angle is determined by a balanced condition
Shaft
of magnetic force (generated by current flow regulated by means
of the ECM ) and tension of return spring (installed to rotor). The
Ball pin larger the current flow through the coil, the greater the rotor’s
rotating angle. This means that the control sleeve moves to the
right, increasing the amount of fuel injected.
The ECM regulates the current flow through the coil by chang-
ing the duty cycle ratio which controls the ON-OFF operation of
the electric governor grounding circuit.
Decrease Increase
Control sleeve
SEF632S
Magnet Core
Rotor
Coil
SEF633S
Diagnostic
Check Items
(Possible cause)
No.
18 ● Fuel injection feedback system does not operate ● Main power supply circuit (ECM connector termi-
properly. [This system consists essentially of ECM, nals V23 , V
45 , V
68 ) and fuse
electric governor and control sleeve position sen- ● Harness or connectors
sor.] (Electric governor and control sleeve position sen-
sor circuit)
● Electric governor
● ECM
EC-CD-80
Electric Governor (Cont’d)
PROCEDURE
2) Start engine above 1,200 rpm.
3) Run it for 2 seconds above 1,200 rpm. Return engine
speed to idle.
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
1) Start engine above 1,200 rpm.
2) Run engine for 2 seconds above 1,200 rpm. Return
engine speed to idle.
results).
Note: If malfunction occurs intermittently, conduct suitable

driving pattern for 10 minutes. This makes it possible
to determine DTC.
EC-CD-81
BATTERY EC-GOVNR-01
36
INJECTION PUMP
W/R (ELECTRIC
GOVERNOR)
F50
7 4
R B/L
W/R W/R
ENGINE
2 3 CONTROL
MODULE
RELAY
E91
1 5
W/G R
W/G R
E43 E89
7 2
F2 F96
W/G R
W/G R R R B/L B/L B/L
42 23 45 68 4 49 5
HRL-0 BAT+ BAT+ BAT+ MES-0 MES-0 MES-0
ECM
F106
1
3 7 2
E91 1 2 3 4 F2 F50 1 2 F96
5 6 3
L 5 6 7 8 GY B 3 4 B
1 2
5 4
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC310
EC-CD-82
INSPECTION START
.
CHECK MAIN POWER SUPPLY.
Refer to EC-CD-62.
.
Electronic injection pump harness
connector (Electric governor)
.
NEF800 NG
CHECK POWER SUPPLY CIRCUIT. Repair harness or con-
c
tion.
2. Disconnect ECM harness connector
Injection pump and electronic injection pump har-
connector
ness connector.
injection pump connector terminal
V 7 and ECM connector terminals
V23 , V
45 , V
68 .
YEC359 If OK, check harness for short-circuit.
OK
.
CHECK GROUND CIRCUIT. NG Repair harness or con-
Injection pump c
connector Check harness continuity between nectors.
injection pump connector terminal V 4
and ECM connector terminals V 4 , V5 ,
V49 .
YEC360 OK
.
CHECK COMPONENT NG Have the injection pump
c
(Electric governor). assembly serviced by an
Refer to ‘‘COMPONENT INSPECTION’’ authorised service repre-
on next page. sentative.
OK
.
Disconnect and reconnect harness con-
nectors in the circuit. Then retest.

.
.
INSPECTION END
EC-CD-83
Electric governor
Electronic injection pump
harness connector 1. Disconnect electronic injection pump harness connector.
2. Check continuity between injection pump connector termi-
nals V4 and V 7 .
Resistance: Approximately 1.0Ω [at 25°C (77°F)]
If NG, replace.
YEC361
EC-CD-84
Timer piston Injection Timing Control Valve

The injection timing control valve is built into the fuel injection
High Low pump. It controls the timer piston to change the fuel injection
pressure pressure
timing.
The timing control valve is a solenoid valve located in the line
between high-pressure chamber and low-pressure chamber. It
changes fuel pressure in the high-pressure chamber.
When current flows through the solenoid (the solenoid turns ON),
Fuel injection timing
the timing control valve opens, advancing fuel injection timing.
control valve When current does not flow through it, the timing control valve
SEF638S
closes, retarding injection timing.
The ECM emits an ON-OFF duty cycle signal. The longer the
OFF-duration, the greater the advance angle. The longer the
ON-duration, the greater the retard angle. This means that
changing the ON-OFF duty cycle ratio makes it possible to
achieve an optimal advance angle and accurately control fuel
injection timing.
Diagnostic
Check Items
(Possible cause)
No.
21 ● Injection timing feedback system does not operate ● Harness or connectors
properly. (This system consists essentially of ECM, [Injection timing control valve, needle lift sensor,
injection timing control valve and needle lift sen- crankshaft position sensor (TDC) circuits]
sor.) ● Injection timing control valve
94 ● Injection timing control valve circuit it open or ● Harness or connectors
shorted. (The Injection timing control valve is open or
shorted.)
● Injection timing control valve

PROCEDURE
Note: If both DTC 21 and 34 or 47 are displayed, perform
TROUBLE DIAGNOSIS FOR DTC 34 or 47. (See
EC-CD-101 or EC-CD-119.)
2) Start engine. Run engine for 10 seconds at idle.
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
1) Start engine. Run engine for 10 seconds at idle.
results).
Note: If malfunction occurs intermittently, conduct suitable

driving pattern for 10 minutes. This makes it possible
to determine DTC.
EC-CD-85
Injection Timing Control Valve (Cont’d)
DIAGNOSTIC TROUBLE CODE 94 CONFIRMATION
PROCEDURE
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
5 seconds and turn to ‘‘ON’’ position.
results).
EC-CD-86
BATTERY EC-TCV-01
36
W/R

W/R W/R
ENGINE R
2 3 CONTROL
MODULE 3 INJECTION PUMP
RELAY
(INJECTION TIMING
E91 CONTROL VALVE)
1 5 F49
2
W/G R
B/Y
W/G R
E43 E89
7 2
F2 F96
W/G R
W/G R R R B/Y
42 68 45 23 51
HRL-0 BAT+ BAT+ BAT+ MVS-0
ECM
F106
3
E91 1 2 3 4 F2 1 2 3 F49 1 2 F96
5
L 5 6 7 8 GY BR 3 4 B
1 2
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC311
EC-CD-87
Priming pump
INSPECTION START
.
CHECK FOR AIR IN FUEL FILTER.
1. Move priming pump up and down to
purge air from fuel filter.
2. Perform ‘‘DIAGNOSTIC TROUBLE
SEF671S CODE CONFIRMATION PROCE-
DURE’’.
.
CHECK POWER SUPPLY. NG Check the following:
c
tion. E89 , F96
2. Disconnect injection timing control ● Electronic injection
valve harness connector. pump harness connec-
Fuel injection timing 3. Turn ignition switch to ‘‘ON’’ position. tor F49
control valve harness
connector 4. Check voltage between injection tim- ● 15A fuse
NEF804
ing control valve connector terminal ● Harness for open or
V 3 and ground with CONSULT-II or short-circuit between

tester. injection timing control
Voltage: Battery voltage valve harness connec-
Injection timing control tor and engine control
OK
valve harness connector module relay.
connectors.
.
CHECK OUTPUT SIGNAL CIRCUIT. NG Check the following:
c
YEC362 1. Turn ignition switch to ‘‘LOCK’’ posi- ● Electronic injection
tion. pump harness connec-
2. Disconnect ECM harness connector. tor F49
3. Check harness continuity between ● Harness for open or
injection timing control valve connec- short-circuit between
Injection timing control tor terminal V 2 and ECM terminals injection timing control
valve harness connector
V51 . valve and ECM.
Continuity should exist. If NG, repair harness or
If OK, check harness for short-cir- connectors.
cuit.
OK
.
YEC363
V
A
EC-CD-88
V
A
.
CHECK COMPONENT NG Replace injection timing
c
(Injection timing control valve). control valve.
Refer to ‘‘COMPONENT INSPECTION’’
below.
OK
.

.
.
INSPECTION END
Injection timing control valve
Injection timing 1. Disconnect injection timing control valve harness connector.
control valve
2. Check resistance between terminals V 2 and V3 .
Resistance: Approximately 15Ω [at 25°C (77°F)]
If NG, replace injection timing control valve.
YEC364
EC-CD-89
TROUBLE DIAGNOSIS FOR DTC 31, 82, 84, 91, 93 CD20T
Engine Control Module (ECM)

The ECM consists of a microcomputer and connectors for signal
input and output and for power supply. The module monitors and
controls the engine operation.
NEF807
Diagnostic
Check Item
(Possible Cause)
No.
31 ● ECM calculation function is malfunctioning. ● ECM *
82 ● An excessively high or low voltage from the ● ECM *
atmospheric pressure sensor is detected by the
ECM.
84 ● ECM reference voltage (2.5V) is excessively high ● ECM *
or low.
91 ● ECM version number or switching function is not ● ECM *
plausible.
93 ● Ignition switch ‘‘ON’’ signal evaluation circuit in ● ECM *
ECM is malfunctioning.
* Actually inspecting the ECM inside circuit is impossible. Then, ECM may be replaced.

PROCEDURE
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
3) Turn ignition switch to ‘‘LOCK’’ position, wait at
results).
EC-CD-90
Cooling Fan (Overheat)

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

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

This diagnosis continuously monitors the engine coolant temperature.
If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will
rise.
When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is
indicated.
Diagnostic Trouble Check Items
Malfunction is detected when ...
Code No. (Possible Cause)
28 ● An excessive high engine coolant temperature ● Harness or connectors
sensor signal is detected by the ECM. (Over- (The cooling fan circuit is open or shorted.)
heat) ● Cooling fan
● Radiator hose
● Radiator
● Radiator cap
● Water pump
● Thermostat
● Fan belt

For more information, refer to ‘‘12 MAIN
CAUSES OF OVERHEATING’’, EC-CD-99.
CAUTION:
When a malfunction is indicated, be sure to replace the coolant following the procedure in the MA
section (‘‘Changing Engine Coolant’’, ‘‘ENGINE MAINTENANCE’’). Also, replace the engine oil.
a. Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure
to use coolant with the proper mixture ratio. Refer to MA section (‘‘Anti-freeze Coolant Mixture
Ratio’’, ‘‘RECOMMENDED FLUIDS AND LUBRICANTS’’).
b. After refilling coolant, run engine to ensure that no water-flow noise is emitted.
EC-CD-91
Cooling Fan (Overheat) (Cont’d)
Use this procedure to check the overall function of the cooling
fan. During this check, a DTC might not be confirmed.
WARNING:
Never remove the radiator cap when the engine is hot. Seri-
MAX.
ous burns could be caused by high pressure fluid escaping
OK
from the radiator.
MIN.
Wrap a thick cloth around the cap. Carefully remove the cap
by turning it a quarter turn to allow built-up pressure to
escape. Then turn the cap all the way off.
AEC640 1) Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is
below the proper range, skip the following steps and go to
‘‘DIAGNOSTIC PROCEDURE’’, EC-CD-94.
2) Confirm whether customer filled the coolant or not. If cus-
tomer filled the coolant, skip the following steps and go to
‘‘DIAGNOSTIC PROCEDURE’’, EC-CD-94.
4) Perform ‘‘COOLING FAN’’ in ‘‘ACTIVE TEST’’
mode with CONSULT-II (LOW speed and HI
speed).
SEF111X
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
3) Start engine.
Cooling fan
Be careful not to overheat engine.
4) Set temperature control switch to full cold position.
5) Push Air Conditioner switch to ‘‘ON’’ position.
6) Turn blower fan switch to ‘‘ON’’ position.
7) Run engine at idle for a few minutes with Air Con-
ditioner operating.
8) Make sure that both cooling fans operate at low
speed.
SEC163BA 9) Turn ignition switch to ‘‘LOCK’’ position.
10) Push Air Conditioner switch and blower fan switch
to ‘‘OFF’’ position.
Cooling fan
11) Disconnect engine coolant temperature sensor
Engine coolant harness connector.
temperature sensor
harness connector 12) Connect 150Ω resistor to engine coolant tempera-
ture sensor harness connector.
13) Restart engine and make sure that both cooling
fans operate at higher speed than low speed.
150Ω resistor
MEC475B
EC-CD-92
BATTERY IGNITION SWITCH
ON or START
EC-COOL/F-01
100A FUSE
a 10A BLOCK
(J/B) Refer to EL-POWER.
11
E127 : Detectable line for DTC
5H : Non-detectable line for DTC
40A 50A BR
c b
G W/G
W/G BR G/Y B BR G/Y BR
3 1 COOLING 4 5 1 COOLING 5 1 COOLING

FAN FAN FAN
RELAY-3 RELAY-2 RELAY-1
E47 E54 E45
5 2 3 2 3 2
W/L LG G/B LG W/L LG/R
LG W/L
G/B
2 1
COOLING
2 TRIPLE-
LG LG/R FAN
COOLING PRESSURE
FAN
8
E43
5
HIGH SWITCH M MOTOR-2
M MOTOR-1
E29
F2 LOW
E20
E18
LG LG/R 2
3
1
B B
G
LG LG/R
54 47
ECM B B
F106
E37 E11

3 3 3 E127 FUSE BLOCK - Junction Box (J/B)
E18 , E29 1 2 E20 1 2 E45 E47 E54
1 2 2 1 2 4 1
B B 3 4 B 5 B L B
5 5
1 2 3 4 F2
5 6 7 8 GY
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC312
EC-CD-93
INSPECTION START
.
Cooling fan relay 2
.
CHECK COOLING FAN LOW NG Check cooling fan low
c
SPEED OPERATION. speed control circuit.
1. Disconnect cooling fan relay-3. (Go to PROCEDURE A .)
Cooling fan relay-3 ‘‘ON’’ position.
Cooling fan relay-1 YEC383 3. Perform ‘‘COOLING FAN’’
in ‘‘ACTIVE TEST’’ mode
with CONSULT-II.
------------------------------------------------------------- OR -------------------------------------------------------------
2. Start engine.
3. Set temperature switch at
full cold position.
4. Turn Air Conditioner switch
to ‘‘ON’’ position.
5. Turn blower fan switch to
6. Run engine at idle speed
for a few minutes with Air
SEF111X
Conditioner operating.
7. Make sure that both cool-
ing fans operate at low
speed.
OK
.
Cooling fan
CHECK COOLING FAN HIGH NG Check cooling fan high
c
SPEED OPERATION. speed control circuit.
1. Turn ignition switch to ‘‘LOCK’’ (Go to PROCEDURE B .)
position.
2. Reconnect cooling fan relay-3.
NEF809 3. Disconnect cooling fan relay-1.
5. Perform ‘‘COOLING FAN’’
in ‘‘ACTIVE TEST’’ mode
with CONSULT-II.
------------------------------------------------------------- OR -------------------------------------------------------------
4. Turn Air Conditioner switch
and blower fan switch to
‘‘OFF’’ position.
5. Disconnect engine coolant
temperature sensor har-
ness connector.
SEF111X 6. Connect 150Ω resistor to
engine coolant temperature
sensor harness connector.
Cooling fan 7. Restart engine and make
Engine coolant sure that both cooling fans
temperature sensor operate at higher speed
harness connector
than low speed.
OK
.
V
B
(Go to EC-CD-98.)
resistor
YEC384
EC-CD-94
PROCEDURE A
Cooling fan relay-1 INSPECTION START

connector Cooling fan motor-1
connector
.
c
1. Turn ignition switch to ‘‘LOCK’’ posi- ● 10A fuse
tion. ● 40A, 100A, fusible
YEC385
2. Disconnect cooling fan relay-1 and links
fan motor-1 connector. ● Harness for open or
. 3. Turn ignition switch to ‘‘ON’’ position. short-circuit between
Under the vehicle A/C compressor
4. Check voltage between cooling fan cooling fan motor-1
motor-1 connector terminal V 1 , fan and battery.
.
Cooling fan motor-1 relay-1 connector terminal V 1 and ● Harness for open or
harness connector ground. short-circuit between
Voltage: Battery voltage cooling fan relay-1 and
fuse.
OK
If NG, replace fuse or
fusible links or repair har-
ness or connectors.
NEF416 .
. CHECK GROUND CIRCUIT. NG Repair harness or con-
Under the vehicle . c
Radiator 1. Turn ignition switch to ‘‘LOCK’’ posi- nectors.
lower hose tion.
2. Disconnect cooling fan relay-2 and
.
Cooling fan fan motor-2 harness connector.
motor-2
harness 3. Check harness continuity
connector between cooling fan relay-1 con-
nector terminal V 5 and cooling
fan relay-2 connector terminal
V 4 ; cooling fan motor-1 connec-
tor terminal V 2 and cooling fan
NEF417
relay-2 connector terminal V 3 .
If OK, check harness for short-
circuit.
Cooling fan motor-1
connector Cooling fan relay-2
4. Check harness continuity
Cooling fan connector between cooling fan motor-2
relay-1 connector terminal V 1 and cool-
connector
ing fan relay-1 connector termi-
nal V 3 ; cooling fan motor-2 con-
nector terminal V 2 and ground.
YEC386 If OK, check harness for short-
circuit.
OK
.
Cooling fan Cooling fan motor-2 V
C
relay-1 connector connector
YEC387
EC-CD-95
V
C
Cooling fan relay-1 .

connector NG
CHECK OUTPUT SIGNAL CIRCUIT. Check the following:
c
1. Disconnect ECM harness connector. ● Harness connectors E43 ,
2. Check harness continuity between ECM F2
terminal V47 and cooling fan relay-1 con- ● Harness for open or short-
nector terminal V2 . circuit between cooling fan
Continuity should exist. relay-1 and ECM
If OK, check harness for short-circuit. If NG, repair harness or con-
nectors.
YEC388 OK
.
CHECK COMPONENT NG Replace cooling fan relay.
c
(Cooling fan relay-1, 2).
Refer to ‘‘COMPONENT INSPECTION’’,
EC-CD-100.
OK
.
CHECK COMPONENT NG Replace cooling fan motors.
c
(Cooling fan motors).
EC-CD-100.
OK
.

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

Cooling fan motor-1 relay-2
relay-3 connector connector
connector
.
c
1. Turn ignition switch to ‘‘LOCK’’ position. ● 10A-fuse
2. Disconnect cooling fan relay-2, 3 and ● 40A, 50A, 100A fusible
cooling fan motor-1. links
3. Turn ignition switch to ‘‘ON’’ position. ● Harness for open or
NEF875 4. Check voltage between cooling fan short-circuit between fan
motor-1 connector terminal V 1 ; cooling motor-1, fan relay-3 and
fan relay-2 connector terminal V 1 ; cool- fusible link or fan relay-2,
ing fan relay-3 connector terminals V 1 & 3 and fuse.
V 3 and ground. If NG, replace fuse or fus-
Voltage: Battery voltage ible link or repair harness or
connectors.
OK
.
V
D
EC-CD-96
V
D
.
CHECK GROUND CIRCUIT. NG Repair harness or connec-
Cooling fan motor-1 Cooling fan relay-2 c
connector connector 1. Turn ignition switch to ‘‘LOCK’’ position. tors.
2. Disconnect cooling fan motor-2 harness
connector.
cooling fan motor-1 connector termi-
nal V2 and cooling fan relay-2 con-
nector terminal V 3 ; cooling fan
motor-2 connector terminal V 1 and
cooling fan relay-3 connector termi-
nal V5 ; cooling fan relay-2 connector
terminal V5 and ground.
Cooling fan relay-3 cooling fan motor-2 terminal V 2 and
connector
Cooling fan ground.
motor-2
connector OK
.
c
1. Disconnect ECM harness connector. ● Harness connectors
NEF876 2. Check harness continuity between ECM E43 , F2
terminal V54 and cooling fan relay-3 con- ● Harness for open or
nector terminal V2 & cooling fan relay-2 short-circuit between
connector terminal V2 . cooling fan relay-2, 3 and
Continuity should exist. ECM.
If OK, check harness for short-circuit. If NG, repair harness or
Cooling fan motor-2
connectors.
connector E18 OK
.
CHECK COMPONENT NG Replace cooling fan relays.
c
(Cooling fan relay-2, 3).
EC-CD-100.
OK
YEC389 .
CHECK COMPONENTS NG Replace cooling fan motors.
c
(Cooling fan motors).
EC-CD-100.
Cooling fan OK
relay-3 .
connector Disconnect and reconnect harness connec-
Trouble is not fixed

Cooling fan .
relay-2 Check ECM pin terminals for damage and
connector
YEC390 nector. Reconnect ECM harness connector
and retest.
.
INSPECTION END
EC-CD-97
V
B
Hose adapter
.
NG
CHECK COOLING SYSTEM FOR LEAK. c Check the following
Apply pressure to the cooling system with a for leaks:
tester, and check if the pressure drops. ● Hose
Testing pressure: ● Radiator
157kPa (1.57 bar, 1.6 kg/cm2, 23 psi) ● Water pump
Pressure should not drop. Refer to LC section
CAUTION: (‘‘Water Pump’’).
Higher than the specified pressure may
cause radiator damage.
.
SLC754AA
OK
.
NG
CHECK RADIATOR CAP. c Replace radiator
Apply pressure to cap with a tester. cap.
Radiator cap relief pressure:
Standard
78 - 98 kPa (0.78 - 0.98 bar,
0.8 - 1.0 kg/cm2, 11 - 14 psi)
Limit
59 - 88 kPa (0.59 - 0.88 bar,
0.6 - 0.9 kg/cm2, 9 - 13 psi)
OK
.
SLC755AA NG
CHECK THERMOSTAT. c Replace thermostat.
1. Check valve seating condition at normal
room temperatures.
It should seat tightly.
2. Check valve opening temperature and
maximum valve lift.
Valve opening temperature:
76.5°C (170°F) [standard]
Maximum valve lift:
More than 8 mm/90°C
(0.31 in/194°F)
3. Check if valve is closed at 5°C (9°F)
below valve opening temperature.
For details, refer to LC section
SLC343 (‘‘Thermostat’’).
OK
.
NG
Check engine coolant temperature sensor. c Replace engine cool-
Refer to ‘‘COMPONENT INSPECTION’’, ant temperature sen-
EC-72. sor.
OK
.
If the cause can not be isolated, go to ‘‘12
MAIN CAUSES OF OVERHEATING’’ on
next page.
.
INSPECTION END
Perform FINAL CHECK by the following procedure after

repair is completed.
1. Warm up engine. Run the vehicle for at least 20 minutes. Pay
attention to engine coolant temperature gauge on the instru-
ment panel. If the reading shows an abnormally high
temperature, another part may be malfunctioning.
2. Stop vehicle and let engine idle. Check the intake and
exhaust systems for leaks by listening for noise or visually
inspecting the components.
3. Allow engine to cool and visually check for oil and coolant
leaks. Then, perform ‘‘OVERALL FUNCTION CHECK’’.
EC-CD-98
12 MAIN CAUSES OF OVERHEATING
Engine Step Inspection item Equipment Standard Reference page
OFF 1 ● Blocked radiator ● Visual No blocking –
● Blocked condenser
● Blocked radiator grille
● Blocked bumper
2 ● Coolant mixture ● Coolant tester 50 - 50% coolant mix- See ‘‘RECOMMENDED
ture FLUIDS AND LUBRI-
CANTS’’ in MA section.
3 ● Coolant level ● Visual Coolant up to MAX level See ‘‘Changing Engine
in reservoir tank and Coolant’’, ‘‘ENGINE
radiator filler neck MAINTENANCE’’ in MA
section.
4 ● Radiator cap ● Pressure tester 78 - 98 kPa See ‘‘System Check’’
(0.78 - 0.98 bar, 0.8 - ‘‘ENGINE COOLING
1.0 kg/cm2, 11 - 14 psi) SYSTEM’’ in LC section.
59 - 98 kPa
(0.59 - 0.98 bar, 0.6 -
1.0 kg/cm2, 9 - 14 psi)
(Limit)
ON*2 5 ● Coolant leaks ● Visual No leaks See ‘‘System Check’’
‘‘ENGINE COOLING
SYSTEM’’ in LC section.
ON*2 6 ● Thermostat ● Touch the upper and Both hoses should be See ‘‘Thermostat’’ and
lower radiator hoses hot ‘‘Radiator’’, ‘‘ENGINE
COOLING SYSTEM’’ in
LC section.
ON*1 7 ● Cooling fan ● CONSULT Operating See ‘‘TROUBLE DIAG-
NOSIS FOR DTC 28’’.
OFF 8 ● Combustion gas leak ● Color checker Negative –
chemical tester
4 Gas analyzer
ON*3 9 ● Coolant temperature ● Visual Gauge less than 3/4 –
gauge when driving
● Coolant overflow to ● Visual No overflow during driv- See ‘‘Changing Engine
reservoir tank ing and idling Coolant’’, ‘‘ENGINE
MAINTENANCE’’ in MA
section.
OFF*4 10 ● Coolant return from ● Visual Should be initial level in See ‘‘ENGINE MAINTE-
reservoir tank to reservoir tank NANCE’’ in MA section.
radiator
OFF 11 ● Cylinder head ● Straight gauge feeler 0.1 mm (0.004 in) Maxi- See ‘‘Inspection’’, ‘‘CYL-
gauge mum distortion (warping) INDER HEAD’’ in EM
section.
12 ● Cylinder block and ● Visual No scuffing on cylinder See ‘‘Inspection’’, ‘‘CYL-
pistons walls or piston INDER BLOCK’’ in EM
section.
*1: Turn the ignition switch ON.
*2: Engine running at 3,000 rpm for 10 minutes.
*3: Drive at 90 km/h (55 mph) for 30 minutes and then let idle for 10 minutes.
*4: After 60 minutes of cool down time.
For more information, refer to ‘‘OVERHEATING CAUSE ANALYSIS’’ in LC section.
EC-CD-99
Cooling fan relay 1 Cooling fan relays-1, -2, -3
Check continuity between terminals V
3 and 5 .
V
Conditions Continuity
12V direct current supply between relay
5 Yes
terminals V1 and V 2
1 2
3 No current supply No
If NG, replace cooling fan relay.
Cooling fan relay 3 Cooling fan relay-2

Check continuity between terminals V
3 and 4 .
V
No current supply Yes
5
12V direct current supply between relay
2 4 1 No
terminals V1 and V 2
3
Cooling fan relay 2
5
2 4 1
3
YEC391
Cooling fan motors-1 and -2

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

AEC781 If NG, replace cooling fan motor.
EC-CD-100
Needle Lift Sensor (NLS)

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

PROCEDURE
Note: Before DTC confirmation, be sure to check battery
voltage is above 9V.
2) Start engine and run it for 2 seconds above 1,200
rpm.
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
1) Start engine and run it for 215 seconds above 1,200
rpm.
results).
EC-CD-101
Needle Lift Sensor (NLS) (Cont’d)
NEEDLE EC-NLS-01
LIFT
SENSOR
F48
1 2
W B

W B
12 11
NBF-1 NBF-0
ECM
F106
1 2 F48
BR
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC419
EC-CD-102
Needle Lift Sensor (NLS) (Cont’d)
Priming pump INSPECTION START
.
CHECK FOR AIR IN FUEL FILTER.
1. Move priming pump up and down to
purge air from fuel filter.
2. Perform ‘‘DIAGNOSTIC TROUBLE
CODE CONFIRMATION PROCE-
SEF671S DURE’’.
Needle lift sensor

harness connector .
CHECK INPUT SIGNAL CIRCUIT. NG Repair harness or con-
c
tion.
2. Disconnect ECM harness connector
and needle lift sensor harness con-
nector.
needle lift sensor connector terminal
V 1 and ECM connector terminal V 12 .
SEF606S
cuit.
OK
Needle lift sensor
connector .
c
Check resistance between needle lift nectors.
sensor connector terminal V 2 and
ECM connector terminal V 11 .
YEC393
OK
.
CHECK NO. 1 INJECTION NOZZLE
FOR CLOGGING.
Refer to spray pattern test of ‘‘INJEC-
Needle lift sensor TION NOZZLE’’.
connector
If NG, replace No. 1 injection nozzle.
.
YEC392 .
.
INSPECTION END
EC-CD-103
Fuel Cut Solenoid Valve

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

PROCEDURE
Note: If DTC 13 or 47 is displayed at the same time, perform
TROUBLE DIAGNOSIS FOR DTC13 OR 47 first.
3) Start engine. (If no start, circuit is open).
4) Warm engine up sufficiently.
5) Turn ignition switch to ‘‘LOCK’’ position and wait at
least 5 seconds.
6) Start engine and rev it up above 1,300 rpm.
Release pedal and wait at least 3 seconds.
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
1) Start engine. (If no start, circuit is open).
2) Warm engine up sufficiently.
3) Turn ignition switch to ‘‘LOCK’’ position and wait at
least 5 seconds.
Release pedal and wait at least 3 seconds.
results).
EC-CD-104
Fuel Cut Solenoid Valve (Cont’d)
BATTERY
EC-FCUT-01
36 : Detectable line for DTC
W/R
INJECTION PUMP
(FUEL CUT
SOLENOID VALVE)
F49
1
SB
W/R W/R
ENGINE
2 3 CONTROL
MODULE
RELAY
E91
1 5
W/G R
W/G R
E43 E89
7 2
F2 F96
W/G R
W/G R R R SB
42 68 45 23 53
K15 BAT+ BAT+ BAT+ EAB-1
ECM
F106
3
E91 1 2 3 4 F2 1 2 3 F49 1 2 F96
5
L 5 6 7 8 GY BR 3 4 B
1 2
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC313
EC-CD-105
.
Electronic injection
pump harness connector
(Fuel cut solenoid valve)
INSPECTION START
.
Check power supply. Refer to
EC-CD-62.
.
NEF815
CHECK OUTPUT SIGNAL CIRCUIT. NG Repair harness or con-
c
1. Turn ignition switch to ‘‘ON’’ nectors.
position.
2. Select ‘‘FUEL CUT SOL/V’’ in
‘‘ACTIVE TEST’’ mode with
CONSULT-II.
3. Touch ‘‘ON’’ and ‘‘OFF’’ alter-
nately.
4. Check that operating sound is
emitted.
----------------------------------------------------------------- OR -----------------------------------------------------------------
C2FCS01 1. Turn ignition switch to
‘‘LOCK’’ position.
2. Disconnect ECM harness
connector and electronic
injection pump harness con-
Electronic injection pump nector.
harness connection
3. Check harness continuity
between fuel cut solenoid
valve connector terminal V 1
and ECM connector terminal
V 53 .
YEC365
If OK, check harness for
short.
OK
.
CHECK COMPONENT NG Replace fuel cut solenoid
c
(Fuel cut solenoid valve). valve.
on next page.
OK
.

.
.
INSPECTION END
EC-CD-106
FUSE
1. Remove fuel cut solenoid valve.
2. Check for lifting shaft when applying 12V direct current to
terminals.
If NG, replace fuel cut solenoid valve.
Shaft SEF859S
EC-CD-107
Fuel Temperature Sensor (FTS)

The fuel temperature sensor is used to detect the fuel tempera-
ture in the injection pump. The sensor modifies a voltage signal
from the ECM. The modified signal returns to the ECM as the fuel
temperature input. The sensor uses a thermistor which is sensi-
tive to the change in temperature. The electrical resistance of the
thermistor decreases as temperature increases.
The sensor is built into the inside electrical circuit of the injection
pump.
Diagnostic
Check Items
Trouble Code Malfunction is detected when ...
(Possible Cause)
No.
is detected by ECM. (The sensor circuit is open or shorted.)
● Fuel temperature sensor

PROCEDURE
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
1) Turn ignition switch to ‘‘ON’’ position and wait at
least 5 seconds.
results).
EC-CD-108
Fuel Temperature Sensor (FTS) (Cont’d)
EC-FTS-01
INJECTION PUMP
(FUEL TEMPERATURE
SENSOR)
F50
6 5
R/Y B

R/Y B
63 33
KTF-1 GND-A ECM
F106
1
7 2
F50
6 3
B
5 4
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC420
EC-CD-109
. DIAGNOSTIC PROCEDURE
Electronic injection
pump harness connector
(Fuel temperature sensor) INSPECTION START
.
CHECK POWER SUPPLY. NG Repair harness or con-
c
tion.
2. Disconnect fuel temperature sensor
harness connector.
NEF818
3. Turn ignition switch to ‘‘ON’’ position.
4. Check voltage between injection
pump connector terminal V 6 and
ground with CONSULT-II or voltage
Injection pump tester.
connector
Voltage:
Approximately 5V
OK
.
c
NEF819 1. Turn ignition switch to ‘‘LOCK’’ posi- nectors.
tion.
injection pump connector terminal
Injection pump V 5 and ECM connector terminal V 33 .
connector Continuity should exist.
cuit.
F50
OK
.
CHECK COMPONENT NG Have the injection pump
c
NEF820 (Fuel temperature sensor). assembly serviced by an
Refer to ‘‘COMPONENT INSPECTION’’ authorised service repre-
on next page. sentative.
OK
.
connectors in the circuits. Then retest.
.
.
INSPECTION END
EC-CD-110
Fuel temperature sensor
Wait until fuel temperature sensor reaches room temperature.
Check resistance between terminals V 5 and V 6 .
Fuel temperature °C (°F) Resistance kΩ

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

YEC366 rised service representative.
EC-CD-111
Accelerator Position Sensor & Switch

The accelerator position sensor is installed on the upper end of
the accelerator pedal assembly. The sensor detects the accel-
erator position and sends a signal to the ECM. The ECM uses
the signal to determine the amount of fuel to be injected.
Output voltage between terminal No. 4 and 5 (V)
Throttle valve opening angle (deg)
NEF822
Diagnostic
Check Items
(Possible Cause)
Code No.
● An excessively low or high voltage from the sensor ● Harness or connectors
is detected by the ECM. (The sensor or switch circuit is open or shorted.)
43
● Accelerator position sensor
● Accelerator position switch

PROCEDURE
1)
Turn ignition switch to ‘‘ON’’ position.
2)
Select ‘‘DATA MONITOR’’ mode with CONSULT-II.
3)
Depress accelerator pedal fully and keep it for at least
1 second. Then release it and wait at least 5 seconds.
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
2) Depress accelerator pedal fully and keep it for at least
1 second. Then release it and wait at least 5 seconds.
results).
EC-CD-112
(Cont’d)
PROCEDURE (For accelerator stiching)
4) Depress brake pedal immediately after releasing
accelerator pedal and keep it at least 5 seconds.
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
2) Depress brake pedal immediately after releasing
accelerator pedal and keep it at least 5 seconds.
3) Turn ignition switch to the ‘‘LOCK’’ position, wait at
least 5 seconds and then turn to the ‘‘ON’’ position.
results) with ECM.
EC-CD-113
(Cont’d)
EC-APS-01
ACCELERATOR
POSITION
SENSOR
M68
5 2 4
LG/W W BR : Non-detectable line for DTC
LG/W W BR
M50
21 22 23
F104
LG/W W BR
LG/W W BR
57 15 55
TVO+ TVO TVO-
ECM
F106
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 M68 F104
11 12 13 14 15 16 17 18 19 20 21 22 23 24
B W
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC314
EC-CD-114
(Cont’d)
ECM
EC-APP/SW-01
F106
LGS-E
65
GY

GY : Non-detectable line for DTC
F103
1
M52
GY
GY
ACCELERATOR
DEPRESSED WORK UNIT
M68
RELEASED
1
B
M52
6
F103
B
B B B
F18 F15
1 2
1 2 3 4 5 M68 F103
3 4 5 6
B W
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC315
EC-CD-115
(Cont’d)
Accelerator
pedal INSPECTION START
sensor harness
connector (Accelerator position sensor)
.
NG
CHECK POWER SUPPLY. Check the following:
c
1. Turn ignition switch to ‘‘LOCK’’ position. ● Harness connectors
2. Disconnect accelerator position sensor M50 , F104
NEF823
harness connector. ● Harness for open or
3. Turn ignition switch to ‘‘ON’’ position. short-circuit between
4. Check voltage between accelerator posi- ECM and accelerator
tion sensor connector terminal V 5 and position sensor.
ground with CONSULT-II or voltage If NG, repair harness or
tester. connectors.
Accelerator position Voltage: Approximately 5V
sensor connector
OK
.
CHECK GROUND CIRCUIT. NG Check the following:
c
1. Turn ignition switch to ‘‘LOCK’’ position. ● Harness connectors
2. Check harness continuity between accel- M50 , F104
NEF824 erator position sensor connector terminal ● Harness for open or
V 4 and engine ground. short-circuit between
Continuity should exist. ECM and accelerator
If OK, check harness for short-circuit. position sensor.
OK connectors.
sensor connector
.
CHECK INPUT SIGNAL CIRCUIT. NG Check the following
c
1. Disconnect ECM harness connector. ● Harness connectors
2. Check harness continuity between ECM M50 , F104
terminal V
15 and accelerator position sen- ● Harness for open or
sor connector terminal V2 . short-circuit between
NEF825 Continuity should exist. ECM and accelerator
If OK, check harness for short-circuit. position sensor
OK connectors.
Accelerator position .
sensor connector CHECK COMPONENT NG
Replace accelerator pedal
c
(Accelerator position sensor). assembly.
EC-CD-118.
OK
.
NEF826 tors in the circuit. Then retest.

.
and retest.
.
INSPECTION END
EC-CD-116
(Cont’d)
INSPECTION START
(Accelerator position switch)
.
OK
CHECK OVERALL FUNCTION. c
INSPECTION END
1. Turn ignition switch to ‘‘ON’’
position.
2. Check ‘‘OFF ACCEL POS’’ in
PEF123W ‘‘DATA MONITOR’’ mode with
CONSULT-II.
Accelerator pedal released:
ON
Accelerator pedal depressed:
OFF
---------------------------------------------------------------- OR ----------------------------------------------------------------
1. Turn ignition switch to ‘‘LOCK’’
position.
2. Check continuity between ECM
connector terminal V 65 and
ground.
Continuity:
Accelerator pedal released:
No
NEF705 Accelerator pedal depressed:
Yes
NG
.
NG
CHECK GROUND CIRCUIT. c
Check the following:
1. Disconnect accelerator switch harness ● Harness connectors
connector. M52 , F103
Accelerator
2. Check harness continuity between ● Harness for open circuit
switch accelerator switch connector terminal between accelerator switch
connector V1 and engine ground. and engine ground.
Continuity should exist. If NG, repair harness or con-
nectors.
OK
.
NEF828 NG
CHECK INPUT SIGNAL CIRCUIT. c
Check the following:
Check harness continuity between ECM ● Harness connectors
connector terminal V65 and accelerator F103 , M52
switch connector terminal V3 . ● Harness for open or short-
Continuity should exist. circuit between accelerator
switch and ECM
Accelerator OK
switch connector .
NG
CHECK COMPONENT c
Replace accelerator switch.
(Accelerator switch).
on next page.
OK
.
YEC367 tors in the circuit. Then retest.
.
and retest.
.
INSPECTION END
EC-CD-117
(Cont’d)
sensor connector
M68
Accelerator position sensor
1 2 3 4 5 M68
1. Disconnect accelerator position sensor harness connector.
2 4 2. Make sure that resistance between accelerator position sen-
sor terminals V 2 and V 4 changes when opening throttle
valve manually.
Throttle valve conditions Resistance [at 25°C (77°F)]
YEC368
Completely closed Approximately 1.2 kΩ
Partially open 1.2 - 1.9 kΩ
Completely open Approximately 1.9 kΩ
If NG, replace accelerator pedal assembly.
CAUTION:
● Do not disassemble accelerator pedal assembly.
Accelerator position COMPONENT INSPECTION

sensor connector
Accelerator switch
M68
1. Disconnect accelerator switch harness connector.
1 2 3 4 5 M68 2. Check continuity between accelerator switch connector ter-
1 3 minals V
1 and V 3 .
Accelerator pedal released No
Accelerator pedal depressed Yes
YEC369
If NG, replace accelerator pedal assembly.
CAUTION:
● Do not disassemble accelerator pedal assembly.
EC-CD-118
TROUBLE DIAGNOSIS FOR DTC 47 CD20E
Core Crankshaft Position Sensor (TDC)

The crankshaft position sensor (TDC) monitors engine speed by
means of signals from the sensing plate (with two protrusions)
installed to the crankshaft pulley. The datum signal output is
detected at ATDC 70° and sent to the ECM. The sensor signal
is used for fuel injection control and fuel injection timing control.
Magnet
Coil
SEF615S
Crank pulley
Crankshaft position
sensor (TDC)
SEF616S
Diagnostic
Check Items
(Possible Cause)
No.
47 ● An incorrect signal from the sensor is detected by ● Harness or connectors
ECM during engine running and cranking. (The sensor circuit is open.)

PROCEDURE
Before performing the following procedure, confirm
that battery voltage is more than 9V.
If DTC 34 is displayed at the same time, perform
trouble diagnosis for DTC34 first.
2) Start engine and run it for at least 3 seconds above
1,200 rpm.
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
1) Start engine and run it for at least 3 seconds above
1,200 rpm.
results).
EC-CD-119
Crankshaft Position Sensor (TDC) (Cont’d)
EC-CKPS-01
CRANKSHAFT
POSITION SENSOR
(TDC)
F53
2 3 1
OR W

OR W
21 8
GND-D DZG-1
ECM
F106
1 2 3 F53
B
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC350
EC-CD-120
INSPECTION START
.
CHECK INPUT SIGNAL CIRCUIT. NG Repair harness or con-
c
tion.
Crankshaft position
sensor (TDC) 2. Disconnect crankshaft position sen-
harness connector sor (TDC) and ECM harness con-
SEF617S
nectors.
3. Check continuity between ECM ter-
minal V 8 and crankshaft position
sensor (TDC) connector terminal V 3 .
Crankshaft position Continuity should exist.

harness connector If OK, check harness for short-cir-
cuit.
OK
F53
.
Loosen and retighten engine ground
screws.
NEF832
OK
.
c
Crankshaft position
Check harness continuity between nectors.
sensor connector crankshaft position sensor (TDC) con-
nector terminal V2 and ECM connector
terminal V21 .
F53 Continuity should exist.
OK
NEF833
.
CHECK COMPONENT NG Replace crankshaft posi-
c
[Crankshaft position sensor (TDC)]. tion sensor (TDC).
on next page.
OK
.
.
.
INSPECTION END
EC-CD-121
Crankshaft position sensor (TDC)
1. Disconnect crankshaft position sensor (TDC) harness con-
nector.
2. Loosen the fixing bolt of the sensor.
3. Remove the sensor.
4. Visually check the sensor for chipping.
5. Check resistance between crankshaft position sensor (TDC)
terminals V2 and V 3 .
SEF620S Resistance: Approximately 1.2 - 1.5kΩ

[at 25°C (77°F)]
If NG, replace crankshaft position sensor (TDC).
Crankshaft position
sensor (TDC)
connector
NEF440
EC-CD-122
TROUBLE DIAGNOSES FOR DTC 83, 98 CD20T
.
Glow Control System
Glow lamp indicator When coolant temperature is lower than 75°C (167°F):
● Ignition switch ON
After ignition switch has been turned to ON, the glow relay
turns ON for a period of time depending on engine coolant
temperature, allowing current to flow through the glow plugs.
Time → [S]
● Starting
.
After starting the engine, current will flow through the glow
1.5
plugs for 300 seconds, or until the coolant temperature
exceeds 50°C (122°F).
.
(-40) (-4) (32) (68) (104) (140)
Engine coolant temperature → °C (°F)

.
Pre-glow
Time → [S]
.
(-40) (-4) (32) (68) (104) (140)
.
Engine coolant temperature → °C (°F)
.
Post glow
Time → [S]
.
.
(-40) (-4) (32) (68). (104)
. (140)
Engine coolant temperature → °C (°F) NEF834
COMPONENT DESCRIPTION
Glow plug
Ceramic heater
Resistor The glow plug is provided with a ceramic heating element to
obtain a high-temperature resistance. It glows in response to a
signal sent from the ECM, allowing current to flow through the
glow plug via the glow relay.
SEF857S
Diagnostic
Check Items
(Possible cause)
No.
83 ● Glow relay signal circuit is open or shorted. ● Harness or connectors
(The glow relay signal circuit is open or shorted)
● Glow relay
98 ● Glow indicator lamp circuit is open or shorted. ● Harness or connectors
(The glow indicator lamp circuit is open or
shorted.)
● Glow lamp
EC-CD-123
Glow Control System (Cont’d)
PROCEDURE
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
1) Turn ignition switch to ‘‘ON’’ position, and wait for at
least 5 seconds.
2) Turn ignition switch off, wait for at least 5 seconds
and then turn on.
results).
EC-CD-124
IGNITION SWITCH
ON or START
BATTERY EC-GLOW-01
FUSE
BLOCK
10A (J/B) Refer to EL-POWER.
15A 80A
12 M1 36 i
13C
W/R B/R
LG/R
5
COMBINATION
METER (GLOW
INDICATOR LAMP)
7 M38 : Non-detectable line for DTC
OR
W/R W/R ENGINE R B/R
CON-
2 3 TROL 1 5 GLOW
MODULE RELAY
RELAY E22 , E23 ,
E91
E24
1 5 2 3
W/G R W/R R
W/R R
E89 E2
1 1
F96 F46
W/R R
OR W/G R
M50 E43 E89
20 7 2
F104 F2 F96
OR W/G R
OR W/G R R R W/R
27 42 23 45 68 50 GLOW
GAZ-0 HRL-0 BAT+ BAT+ BAT+ GRL-0 PLUG
ECM
F47
F106
13 14 15 16 17 18 19 20 M1 FUSE BLOCK - Junction Box (J/B)

M38 E2 1 E22 E24 E23
1 2 3 4 5 6 7 8 9 10 11 12 1 3 5
GY B 2 G W W
3
1 2 1 2 3 4 5 6 7 8 9 10
5 E91 1 2 3 4 F2 F96 F104
3 4 11 12 13 14 15 16 17 18 19 20 21 22 23 24
L 5 6 7 8 GY B W
1 2
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC316
EC-CD-125
Glow relay
INSPECTION START
(Glow relay signal circuit)
.
Check power supply to ECCS-D relay.
Refer to ‘‘TROUBLE DIAGNOSIS FOR
Glow relay
harness connector POWER SUPPLY’’ (EC-CD-62).
NEF835
.
c
1. Turn ignition switch to the ‘‘LOCK’’ ● 15A fuse
position. ● 80A fusible link
Glow relay
connector
2. Disconnect glow relay. ● Harness continuity bet-
3. Turn ignition switch to the ‘‘ON’’ ween glow relay and
position. fuse.
4. Check voltage between glow relay If NG, replace fuse or
connector terminals V 1 , V
5 and fusible link or repair har-
ground with tester. ness or connectors.
YEC370
OK
.
CHECK OUTPUT SIGNAL CIRCUIT. NG Check harness connec-
c
1. Turn ignition switch to the ‘‘LOCK’’ tors F96 , E89
Glow relay position. Repair harness or con-
connector
2. Disconnect ECM harness connector. nectors.
ECM connector terminal V 50 and
glow relay connector terminal V 2 .
cuit.
YEC371
OK
.
CHECK GLOW PLUG AND GLOW NG Replace glow plug or
c
RELAY. glow relay.
(EC-CD-129, 130).
OK
.
.
.
INSPECTION END
EC-CD-126
INSPECTION START
(Glow indicator lamp circuit)
Combination meter connector
(speedometer)
.
CHECK POWER SUPPLY CIRCUIT. NG Check the following:
c
1. Turn ignition switch to ‘‘LOCK’’ posi- ● Harness for open or
tion. short-circuit between
2. Disconnect combination meter har- combination meter and
ness connector. battery.
YEC372 3. Turn ignition switch to ‘‘ON’’ position. ● 10A fuse
4. Check voltage between combination If NG, replace fuse or
meter harness connector terminal repair harness or con-
V 5 and body ground. nectors.
Combination meter
connector OK
(speedometer)
.
M38 c
tion. M50 , F104
2. Disconnect ECM harness connector. ● Harness for open or
YEC373
3. Check harness continuity between short-circuit between
ECM connector terminal V 27 and ECM and combination
combination meter connector termi- meter.
nal V 7 . If NG, repair harness or
Continuity should exist. connectors.
cuit.
OK
.
CHECK GLOW INDICATOR LAMP. NG Replace glow indicator
c
Make sure that glow indicator lamp is lamp.
not burnt out.
OK
.
.
.
INSPECTION END
EC-CD-127
INSPECTION START
(Glow plug circuit)
Glow relay connector
.
CHECK POWER SUPPLY-I. NG Check the following:
c
1. Turn ignition switch to ‘‘LOCK’’ posi- ● Harness for open or
tion. short-circuit between
2. Disconnect glow relay harness con- glow relay and battery.
nector. ● 80A fusible link
NEF873 3. Check voltage between glow relay If NG, replace fusible link
harness connector terminal V 5 and and repair harness con-
engine ground. nectors.
Glow relay Glow plug OK
connector connector
.
CHECK POWER SUPPLY-II. NG Check the following:
c
1. Disconnect glow plug harness con- ● Harness connectors
nector. E2 , F46
2. Check harness continuity between ● Harness for open or
glow plug harness connector and short-circuit between
YEC374
glow relay harness connector termi- glow plug and glow
nal V 3 . relay.
Continuity should exist. If NG, repair harness or
If OK, check harness for short-cir- connector.
cuit.
OK
.
CHECK GLOW PLUG AND GLOW NG Replace glow plug or
c
RELAY. glow relay.
(EC-CD-129, 130).
OK
.
.
INSPECTION END
EC-CD-128
SYSTEM OPERATION CHECK
Set voltmeter between glow plug and engine body.
Glow plug plate
SEC554B
1. Pre-glow control system

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

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

* Engine coolant temperature is lower than 50°C
(122°F).

NEF839
Glow relay Glow relay
1. Check relay for coil continuity between glow relay terminals
V
2 V 1 and V 2 .
V3

2. Check relay for proper operation by applying 12V dc voltage
between glow relay terminals V 1 and V 2 and checking con-
V
5
V
1 tinuity between terminals V3 and V 5 .
Coil voltage Continuity V

3 and V
5 Contact point
0V No OFF
Contact point
12V Yes ON
12V dc
Ohmmeter
SEC564B
EC-CD-129
Glow plug
1. Remove glow plug connecting plate.
2. Check each glow plug for continuity.
Continuity should exist:
Approximately 0.5Ω [at 25°C (77°F)]
Ohmmeter
● If NG, replace glow plug.
SEF630K
Glow nut 3. Install glow plug connecting plate securely.

● Do not bump glow plug heating element. If it is bumped,
replace glow plug with new one. (If glow plug is dropped
Glow harness
Connecting
from a height of 0.1 m (3.94 in) or greater, replace with
plate new one.)
● If glow plug installation hole is contaminated with
Washer carbon, remove using a reamer or suitable tool.
Spring washer ● Hand-tighten glow plug by turning it 2 to 3 times, then
tighten using a tool to specified torque.
Glow plug
: 15 - 20 N·m (1.5 - 2.0 kg-m, 11 - 14 ft-lb)
SEC565B
EC-CD-130
TROUBLE DIAGNOSES FOR DTC 85 CD20T
Air Conditioner Cut Control

The Air Conditioner relay is controlled by the ECM. During the
following conditions, the ECM will cut the power supply towards
the air conditioner relay:
● Starting engine
● Quick acceleration from low speed
● Undershooting of idle speed
● High engine coolant temperature [above 107°C (225°F)].
● Malfunctioning of engine speed sensor, accelerator position
sensor or vehicle speed sensor when engine speed is below
2,100 rpm.
Diagnostic
Check Items
(Possible cause)
No.
85 ● Air conditioner relay signal circuit is shorted. ● Harness or connectors
(The air conditioner relay signal circuit is shorted).
● Air conditioner relay

PROCEDURE
1) Turn ignition switch and air conditioner switch to the
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
1) Turn ignition switch and air conditioner switch to the
results).
EC-CD-131
Air Conditioner Cut Control (Cont’d)
IGNITION SWITCH
ON or START EC-A/CCUT-01
FUSE
10A BLOCK
(J/B) Refer to EL-POWER. : Detectable line for DTC
20
M1 , : Non-detectable line for DTC
E104
9G 19A
LG/R LG/R
LG/R LG/R
2 5
AIR CONDITIONER
RELAY
E56
1 3
L/W L/R
To compressor
(Refer to HA-A/C.)
A/C
L/OR 4 L/OR A/C CONTROL
LG 10 SENS PANEL
L/OR E125 M70 M44
LG/R LG
1
1 2 THERMO
TRIPLE- CONTROL
HIGH PRESSURE L/OR 3 AMP.
LOW
SWITCH
M55
E20
NORMAL
4 THERMISTOR
GY
L/W
E43
2 1
F2
L/W GY
L/W GY
28 62
KLI-0 ELI-E ECM
F106

12 11 10 9 M1 FUSE BLOCK - Junction Box (J/B)
M44 1 2 3 M55
20 19 18 17 16 15 14 13
W W E104 FUSE BLOCK - Junction Box (J/B)
3
1 2 1 2 3 4 5 6 7 1 2 3 4
E20 5 E56 E125 F2
3 4 8 9 10 11 12 13 14 15 16 5 6 7 8
B L BR GY
1 2
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC317
EC-CD-132
Air Conditioner Cut Control (Cont’d)
INSPECTION START
(Air conditioner relay signal circuit)
Air conditioner relay
harness connector
.
c
1. Turn ignition switch to ‘‘LOCK’’ posi- ● Harness and connec-
tion. tors for open or short-
2. Disconnect air conditioner relay har- circuit between ignition
ness connector. switch and air condi-
YEC375 3. Turn ignition switch to ‘‘ON’’ position. tioner relay.
4. Check voltage between air condi- ● 10A fuse
tioner relay connector terminals V 2 , If NG, replace or repair
V 5 and engine ground. the parts affected.
Air conditioner relay
harness connector
OK
.
c
tion. E43 , F2
2. Disconnect ECM harness connector. ● Harness for open or
YEC376
3. Check harness continuity between short-circuit between
ECM harness connector terminal V 28 ECM and air condi-
and air conditioner relay harness tioner relay.
connector terminal V 1 . If NG, repair harness or
Continuity should exist. connectors.
cuit.
OK
.
CHECK AIR CONDITIONER RELAY. NG Replace air conditioner
c
Refer to HA section for inspection. relay.
OK
.
.
.
INSPECTION END
EC-CD-133
EGRC-Solenoid Valve
SYSTEM DESCRIPTION
Engine speed
Camshaft position sensor (TDC)
c

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

c
Atmospheric pressure
Atmospheric pressure sensor
c
Mass air flow

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

(Closed)
Low load ON Fully open Large

(Open)
Above 70 (158)
High load OFF Fully closed —
(Closed)
COMPONENT DESCRIPTION
To control valve
The EGR control solenoid valves control vacuum pressure act-
To intake
air flow ing on the EGR valve. The EGR control valve will then be fully
opened or fully closed, as required.
Thus, intake air passages are opened or closed in relation to
Vacuum
signal
exhaust gas and intake air. Utilizing the relationship between
exhaust gas pressure and intake air pressure control, the amount
of EGR (exhaust gas recirculated) is regulated in large or small
volumes.
SEF240PH
Diagnostic
Check Items
(Possible cause)
No.
86 ● EGRC-solenoid valve A circuit is shorted. ● Harness or connectors
(EGRC-solenoid valve A circuit is open or shorted).
● EGRC solenoid valve A
EC-CD-134
EGRC-Solenoid Valve (Cont’d)
PROCEDURE
1) Turn ignition switch to the ‘‘ON’’ position.
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
1) Turn ignition switch to the ‘‘ON’’ position and wait at
least 2 seconds.
results).
EC-CD-135
BATTERY EC-EGRC/V-01
36
W/R

W/R W/R
ENGINE
2 3 CONTROL
MODULE
RELAY
E91 R
1 5 2
EGRC-
W/G R SOLENOID
VALVE
F55
1
W/G R
E43 E89
7 2
F2 F96
W/G R
W/G R R R P
42 68 45 23 25
K15 BAT+ BAT+ BAT+ ARSI-0
ECM
F106
3
E91 1 2 3 4 F2 F55 1 2 F96
5 1 2
L 5 6 7 8 GY B 3 4 B
1 2
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC318
EC-CD-136
INSPECTION START
EGRC solenoid valve A (Circuit for EGRC-solenoid valve A)
harness connector
.
Refer to Trouble Diagnosis for main
power supply (EC-CD-62)
NEF844
.
c
1. Turn ignition switch to the ‘‘LOCK’’ ● Harness continuity bet-
position. ween ECCS-D relay
2. Disconnect EGRC-solenoid valve A and EGRC-solenoid
EGRC solenoid
valve A harness harness connector. valve A connector.
connector 3. Turn ignition switch to the ‘‘ON’’ If NG, repair harness or
position. connectors.
4. Check voltage between connector
terminal V 2 and engine ground.
OK
NEF845
.
c
1. Turn ignition switch to the ‘‘LOCK’’ ● Harness for open or
position. short-circuit between
2. Disconnect ECM harness connector. ECM and solenoid
3. Check harness continuity between valve.
ECM harness connector terminal V 25 If NG, repair harness or
and EGRC solenoid valve A connec- connectors.
tor terminal V1 .
cuit.
OK
.
CHECK COMPONENTS NG Replace malfunctioning
c
(EGRC-solenoid valve). component(s).
EC-CD-140.
OK
.
.
or the connection of ECM harness con-
nector. Reconnect ECM harness con-
nector and retest.
.
INSPECTION END
EC-CD-137
INSPECTION START
EGR EGR CONTROL OPERATION
valve
.
CHECK OVERALL FUNCTION. OK INSPECTION END
c
1. Start engine and warm it up suffi-
ciently. (Air conditioner is ‘‘OFF’’).
2. Perform diagnostic test mode II
NEF433
(Self-diagnostic results).
Make sure that diagnostic trouble
code No. 55 is displayed.
3. Make sure that EGR diaphragm
moves up and down (Use your finger
EGR or a suitable tool) under the following
valve conditions:
At idle:
Spring does not move.
Racing engine from idle to 2800
rpm:
NEF434 Spring moves up and down.
NG
.
CHECK VACUUM SOURCES TO EGR OK CHECK COMPONENTS
c
VALVE. (EGR valve).
1. Disconnect vacuum hoses to EGR (See page EC-CD-140.)
valve.
NG
2. Make sure that vacuum exists under
the following conditions:
At idle:
.
Vacuum should not exist.
Replace malfunctioning
Racing engine from idle to 2800
component(s).
rpm:
Vacuum should exist.
NG
.
V
A
EC-CD-138
V
A
.
CHECK CONTROL FUNCTION. OK CHECK VACUUM
c
1. Turn ignition switch to ‘‘ON’’ HOSE.
position. Check vacuum hose
2. Turn EGRC-solenoid valve for clogging, cracks or
‘‘ON’’ and ‘‘OFF’’ in ‘‘ACTIVE improper connection.
TEST’’ mode with CONSULT-II
C2ESA01 and check operating sound.
-------------------------------------------------------------------- OR --------------------------------------------------------------------
1. Check voltage between EGRC
solenoid valve connector termi-
nal V 1 , and ground with tester
under the following conditions:
Voltage:
At idle
Battery voltage
Approximately 0.4V
NEF435 NG
.
Perform electrical circuit inspection.
Refer to EC-CD-137.
Crack
OK
.
V
B
Clogging
Improper connection
NEF846
.
EGRC-solenoid valve
harness connector
NEF436
EC-CD-139
EGR valve
EGR valve
Apply vacuum to EGR vacuum port with a hand vacuum pump.
EGR valve spring should lift.
If NG, replace EGR valve.
MEF137D
EGRC-solenoid valve
FUSE
Check air passage continuity.
Air passage Air passage
Condition continuity continuity
between V A and V
B between V A and V
C
12V direct current sup-

ply between terminals Yes No
V1 and V 2
BATTERY
No supply No Yes
MEC488B
If NG, replace solenoid valve.
EC-CD-140
Brake Switch
The ECM receives signals from two brake switches. One is a
conventional brake lamp switch, the other is referred to as a
redundant (RDNT) brake switch.
In case the accelerator pedal does not return to the idle position
(pedal sticks), the driver will react by depressing the brake. In
this (emergency) situation, the ECM will disregard the accelera-
tor pedal signal and bring back the engine speed to 1200 rpm.
Diagnostic
Check Items
(Possible Cause)
Code No.
● Brake switch circuits are open or shorted. ● Harness or connectors
(Brake switch circuits are open or shorted.)
87
● Stop lamp switch
● RDNT brake switch

PROCEDURE
2) Depress brake pedal for at least 1 minute.
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
2) Depress brake pedal for at least 1 minute.
results).
EC-CD-141
Brake Switch (Cont’d)
ECM EC-BRK/SW-01
F106
BRA-E BRK-E BRA-E
39 20 44
R/B R/B R/G L : LHD models
R : RHD models
STOP LAMP
SWITCH
(EL section)
R/B R/B
F2 F104
4 15
E43 M50
R/B R/B
R/B R/B
1 1
RDNT RDNT
BRAKE BRAKE
SWITCH SWITCH
E122 M64
2 2
B B
B B B B
B B
E11 E37 M6 M28 M26
2 1 2 3 4 5 6 7 8 9 10 1 2 3 4
M64 , E122 F104 F2
1 11 12 13 14 15 16 17 18 19 20 21 22 23 24 5 6 7 8
BR BR W GY
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC319
EC-CD-142
INSPECTION START
(RDNT brake switch)
RDNT brake switch

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

RDNT brake switch Voltage: Battery voltage RDNT brake switch
harness connector harness connector ter-
OK
minal V 1 and ECM
connector terminal V20 ,
V39 .
connectors.
YEC378
.
c
tion.
RDNT brake switch harness connec-
tor terminal V2 and body ground.
If OK, check harness for short-
circuit.
OK
.
CHECK COMPONENT.
(RDNT brake switch)
on next page.
OK
.
.
.
INSPECTION END
EC-CD-143
2
1 Stop lamp switch and RDNT brake switch
1. Turn ignition switch to ‘‘LOCK’’ position.
1 2
2. Disconnect switch harness connectors.
3. Check continuity between terminals V 1 and 2 .
V
Continuity:
Brake pedal Stop lamp switch RDNT brake switch
Released No No
YEC379 Depressed Yes Yes
If NG, replace stop lamp switch or RDNT brake switch.
EC-CD-144
ECCS-D Relay
The ECCS-D Relay shuts off the main power supply to the ECM
within 5 seconds after the ignition switch has turned to the
Diagnostic
Check Items
(Possible cause)
No.
92 ● ECCS-D relay shut-off time is too late. ● Harness or connectors
(The ECCS-D relay circuit is shorted).
● ECCS-D relay
● ECM

PROCEDURE
1) Turn ignition switch to the ‘‘ON’’ position and select
2) Turn ignition switch to the ‘‘LOCK’’ position and wait
at least 5 seconds.
3) Turn ignition switch to the ‘‘ON’’ position and wait at
least 2 seconds.
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
1) Turn ignition switch to the ‘‘ON’’ position.
2) Turn it to the ‘‘LOCK’’ position, wait at least 5 sec-
onds.
3) Turn ignition switch to the ‘‘ON’’ position and per-
form ‘‘Diagnostic Test Mode II’’ (Self-diagnostic
results).
Refer to ‘‘Trouble Diagnosis for Power Supply’’ (EC-CD-62) for
ECCS-D relay circuit inspection.
EC-CD-145
MI & Data Link Connectors

Malfunction indicator (MI) circuit is monitored for open or short-
circuit. If the circuit is malfunctioning, MI can not report it but
CONSULT-II can.
Diagnostic
Check Items
(Possible cause)
No.
97 ● MI circuit is open or shorted. ● Harness or connectors
(MI circuit is open or shorted).
● MI lamp
● ECM

PROCEDURE
speed.
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
2) Check that MI lits on.
EC-CD-146
MI & Data Link Connectors (Cont’d)
IGNITION SWITCH
ON or START
EC-MIL-01
FUSE
BLOCK Refer to EL-POWER.
10A 10A (J/B)
12 24 M1
13C 15C
LG/R G : Detectable line for DTC

LG/R G
5 9
COMBINATION METER DATA LINK
(MALFUNCTION CONNECTOR
INDICATOR)
M59
M38
13 5 4 16 12 13
OR/L GY/L G/B G/R B B
4B FUSE
BLOCK
OR/L GY/L G/B G/R B (J/B)
M50
19 17 16 18 4 M1
F104 1B
OR/L GY/L G/B G/R B
B
OR/L GY/L G/B G/R B B B B B
26 61 30 64 33
DLA-0 SCITX SCIRX CHECK GND-A
ECM
F106
M6 M28 M26

13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8
M38 M59
1 2 3 4 5 6 7 8 9 10 11 12 9 10 11 12 13 14 15 16
GY W
1 2 3 4 5 6 7 8 9 10
F104
11 12 13 14 15 16 17 18 19 20 21 22 23 24
W
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC320
EC-CD-147
MI & Data Link Connectors (Cont’d)
INSPECTION START
Combination meter (MI circuit)
harness connector
.
CHECK MI BULB. NG Replace MI bulb.
c
1. Turn ignition switch to ‘‘LOCK’’ posi-
tion.
YEC380 2. Disconnect combination meter har-
ness connector.
3. Apply battery voltage between com-
bination meter terminal V 5 and V13 .
4. Check that MI lits on.
Combination meter OK
harness connector
.
c
1. Turn ignition switch to ‘‘ON’’ position. ● Harness for open or
2. Check voltage between combination short-circuit between
meter terminal V 5 and body ground. combination meter and
YEC381
Voltage: Battery voltage ignition switch.
● 10A fuse
OK
If NG, repair or replace
harness or fuse.
.
Combination meter CHECK GROUND CIRCUIT. NG Check the following:
harness connector c
tion. M50 , F104

2. Disconnect ECM harness connector. If NG, repair harness or
3. Check continuity between combina- connectors.
YEC382 tion meter connector terminal V 13 ● Harness and connec-
and ECM connector terminal V 26 . tors for open or short-

Continuity should exist. circuit between ECM
If OK, check harness for short-cir- and combination meter.
cuit.
OK
.
.
.
INSPECTION END
EC-CD-148
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS CD20T
Start Signal
BATTERY EC-S/SIG-01
g
W : Detectable line for DTC

1 : Non-detectable line for DTC
OFF ST IGNITION
SWITCH
E109
ACC ON
6
W/G
W/G
3G
FUSE
BLOCK
10A (J/B)
17 Refer to EL-POWER.
M1 ,
5B E104
B/Y
B/Y
M50
24
F104
B/Y
B/Y
16
ANL
ECM
F106

E104 FUSE BLOCK - Junction Box (J/B)

3 5 1 E109 1 2 3 4 5 6 7 8 9 10
F104
4 2 6 W 11 12 13 14 15 16 17 18 19 20 21 22 23 24
W
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC321
EC-CD-149
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS CD20T
Start Signal (Cont’d)
INSPECTION START
.
CHECK OVERALL FUNCTION. OK INSPECTION END
c
1. Turn ignition switch to ‘‘ON’’
position.
2. Check ‘‘START SIGNAL’’ in
‘‘DATA MONITOR’’ mode with
C2DMM04 CONSULT-II.
IGN ‘‘ON’’ OFF

IGN ‘‘START’’ ON
-------------------------------------------------------------------- OR --------------------------------------------------------------------
1. Turn ignition switch to the
2. Disconnect ECM harness con-
nector.
3. Turn ignition switch to ‘‘START’’
position.
4. Check voltage between ECM
NEF851
connector terminal V 16 and
ground.
Voltage:
Ignition switch ‘‘START’’ —
Battery voltage
Except above —
Approximately 0V
NG
.
Check if 10A fuse is OK. NG Replace 10A fuse.
c
OK
NEF852 .
CHECK INPUT SIGNAL CIRCUIT. NG Check the following:
c
1) Turn ignition switch to ‘‘LOCK’’ posi- ● Harness or connec-
tion. tors M50 , F104
2) Disconnect 10A fuse. ● Harness for open or
3) Check harness continuity between short-circuit between
ECM connector terminal V 16 and fuse ECM and fuse block.
block. If NG, repair harness
Continuity should exist. or connectors.
OK
.
.
ness connector. Reconnect ECM harness
connector and retest.
.
INSPECTION END
EC-CD-150
SERVICE DATA AND SPECIFICATIONS (SDS) CD20T
General Specifications
Unit : rpm Pump numbers
Engine CD20T
Pump assembly
Engine Part number
Maximum engine speed 5,400 number
A/C ON 825 ± 25 NP-VE4/

Idle speed CD20T 16700 2J620
10E2200L736
A/C OFF 825 ± 25
Pump data is not yet available.
Refer to CALIBRATION STANDARD published
by BOSCH.)
Injection Nozzle
INSPECTION AND ADJUSTMENT
Injection nozzle assembly
Unit: kPa (bar, kg/cm2, psi)
Initial injection pressure

14,423 - 15,651 (144.2 - 156.5,
New
148 - 159, 2,091 - 2,269)
15,000 - 16,000 (150.0 - 160.0,
Used
153 - 163, 2,175 - 2,320)
Inspection and Adjustment

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

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

INJECTION TIMING CONTROL VALVE
25 (77) Approximately 1.9
Resistance [at 25°C (77°F)] Ω Approximately 15
EC-CD-151
SERVICE DATA AND SPECIFICATIONS (SDS) CD20T
Inspection and Adjustment (Cont’d)
NOTE
EC-CD-152

Motor Cd20

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ENGINE CONTROL SYSTEM

When you read wiring diagrams:

Special Service Tools

Engine Fuel & Emission Control System

ECM (ECCS-D control module) WIRELESS EQUIPMENT

ECM PARTS HANDLING

● When connecting ECM harness connector, open the

slider ECM harness

● When connecting or disconnecting pin connectors into

● Before replacing ECM, perform Terminals and Reference

● If MI illuminates or blinks irregularly during engine

Engine Control Module Component Parts

EGRC - solenoid valve

Needle lift sensor (built - in No. 1 nozzle) Vacuum pump

Cooling fan relay

Crankshaft position sensor (TDC)

Fuel cut solenoid valve

Ejection timing control valve

Accelerator position sensor

ECM (ECCS-D CONTROL MODULE)

ECM (Engine control

catalyst inhibitor switch

Electrical load signal

Vacuum Hose Drawing

EGRC - solenoid valve

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

Crankshaft position sensor c c Fuel injection control c Electric governor

Control sleeve position sensor c

c Fuel injection timing control c Injection timing control

Mass air flow sensor c

Engine coolant temperature c

c Glow control system c Glow relay & glow lamp

Accelerator position sensor c

Accelerator position switch c

Air conditioner switch c c EGR valve control c EGRC-solenoid valve

Ignition switch (ON & ST POS.) c

c Cooling fan control c Cooling fan relays

c Cooling fan motor control c Cooling fan relay

Glow Control System

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

Fuel Injection System

Engine speed Electric

Air conditioner operation

Control sleeve position

The amount of fuel injected under normal driving conditions is

sensor detects accelerator position. These sensors send signals

Engine speed ECM Electric

Control sleeve position

Fuel Injection Timing System

Injection timing Injection

The optimal fuel injection timing data, predetermined in propor-

HIGH ALTITUDE COMPENSATION

Control sleeve position

Engine coolant temperature

Control sleeve position

For better exhaust efficiency under cool engine conditions, the

ENGINE COOLANT TEMPERATURE COMPENSATION (When starting)

Air Conditioning Cut Control

Accelerator valve opening angle

Engine coolant temperature

Cooling Fan Control

Engine coolant temperature

Air conditioner ‘‘ON’’ signal

Blow-by Control Valve