FL - Fuel System (D4EA)

Fuel System (D4EA) GENERAL ‘SPECIFICATION ow FL SERVICE STANDARD. FL4 SEALANT FL4 TIGHTENING TORQUES vnssnsnsnsnsnnn FLS BASIC TROUBLESHOOTING BASIC TROUBLESHOOTING GUIDE exon FL-6 CUSTOMER PROBLEM ANALYSIS SHEET .FL-7 BASIC INSPECTION PROCEDURE FL ECM PROBLEM INSPECTION PROCEDURE FL-43 INSPECTION CHART FOR DIAGNOSTIC ‘TROUBLE CODES. FL-14 SYMPTOM TROUBLESHOOTING GUIDE CHART FL-17 DIESEL CONTROL SYSTEM INSPECTION sr : COMPONENT LOCATION... ENGINE CONTROL MODULE ECM CONNECTOR ECM PIN CHECK SHEET . AIR FLOW SENSOR AIR TEMPERATURE SENSOR ENGINE COOLAANT TEMPERATURE SENSOR CRANSHAFT POSITION SENSOR ‘CAMSHAFT POSITION SENSOR EGR SOLENOID VALVE THROTTLE FLAP SOLENOID VALVE RAIL PRESSURE SENSOR RAIL PRESSURE REGULATOR... ‘ACCELERATION PEDAL POSITION SENSOR FUEL TEMPERATURE SENSORDTC TROUBLESHOOTING PROCEDURES P0600 FL 248 Po100 ih P0602 .... “FL -254 Potot P0603 FL -256 P0102 P0650 FL 258 P0103 ... P0704 FL -262 Pore. Priez FL -267 P13 Pras FL 274 Pots Pred “FL -279 POnT Pitas | FL -281 Pot18 Prias FL -286 P0120 Prt87 . FL -288 P0128 «. Pitas. FL 201 P0182 Prt89 FL -204 P0183 P1190 «.. FL -298 Poi90 P1300 FL-307 P0102 .. Pig2t FL-3t4 P0108 .. P1322 FL-318 0220 P1326 FL -321 P0223 P1327 FL -327 P0231 P1522 FL-331 P0282 «. FL -336 P0261 FL 338 Po262 P1525 FL 343, 0283 P1529 vo FL 345 Po264 P1545 FL -347 Poz6s P1546 FL-351 P0288 P1602 FL -354 0267 P1603 FL -359 P0268 Pi6t6 FL -362 P0269 P1634 FL 370 P0270 P1636 FL-378 Po2rt P1638 FL -380 Po272 P1639 -.. FL -382 P0336 Pies | FL -384 PO34t P1647 FL -386 P0343 Piset . FL -387 Po4ot P1765 FL -390 Poao2 P2135 FL -393, Po4os P2228 FL 401 P0408 “FL -214 P2229 FL -404 P0501 FL-217 P0503 FL -223 P0504 FL -227 P0562 “FL -234 P0563 «.. FL -240 Poses on FL 243.FUEL DELIVERY SYSTEM COMPONENTS nnn ‘SCHEMATIC DIAGRAM .. INJECTOR DESCRIPTION METHODD OF OPERATION CLEANING REMOVAL.. REPLACEMENT INSTALLATION INSPECTION... ACCUMULATOR DESCRIPTION REMOVAL, INSTALLATION HIGH PRESSURE FUEL PUMP DESCRIPTION REMOVAL srnsnsn ACCELERATION PEDAL ‘COMPONENTS: REMOVAL worn INSTALLATION... FUEL FILTER. ‘COMPONENTS... REMOVAL, INSPECTION FUEL TANK COMPONENTS REMOVAL. INSTALLATION... DISASSEMBLY. ASSEMBLY FUEL PUMP DISASSEMBLY SUB FUEL SENDER DISASSEMBLY, FL -407 FL -409 FL 811 FL-412 FL-413 FL-414 FL-415, FL-416 FL 418 FL -423, FL 423 FL 424 FL 425, FL -430 FL-431 FL -431 FL 431 FL 492. “FL 433, “FL 433 vn FL 434 FL -435, ro FL 436 co FL 438 “FL -436 FL -437 FL 438FL-3 FUEL SYSTEM GENERAL SPECIFICATION cogeao7a, Items Specification | Fuel Tank oe Capacity | 58t | foe _ Type | Electrical, intank ype | riven by _| Electrical motor a Type _| Mechanical High Pressure Pump . | Dirven by _| Mechanical gear Fuel fiter = Type __| High pressure type Fuel Pressure (at high pressure side) [ood 4,350 bar (135 MPa, 19,580 psi) ~|_ Type __| HFMS (Hot fm sensor) — Bkgh 120V 10 kgih 126V 18 kgih Tat Mass Air Flow Sensor (MAFS) 20kon aay Specification | 60Kgih T224V 420 Kgl 282V 250 Kih 355V | a7oKgh | 397 | 480 Kgih aver! | : [___Type __| Thermister type | -40°C(-40°F) | 35.14~43.76 KO Sensors | | -20°C(-4°F) | 35.14~ 43.76 KO | 0°C(32°F) 35.14 ~ 43.76 KO Specification | 20°C(68°F) | 35.14~43.76 KO 40°C(104°F) | 36.14~43.76 KO 60°C(140"F) | 36.14~43.76 KO BOrC(176°F) | 35.14 ~ 43.76 KO Intake Air Temperature Sensor (IATS) Output Voltage CT _07~08V (Sensor 1) Wot 38~44V ‘Accelerator Position Sensor (APS) - a | Output Voltage |__—-T 0.276 ~ 0.475 V | (Sensor) [wor 475~235V Camshaft Position Sensor (CMPS) Type Hall IC type Type __| Magnetic sensor type Crankshaft Position Sensor (CKPS)GENERAL FL4 Items: “| Specification Type _| Piezo electrictiy type = OMPa __05v 20MPa 1.03 “40 MPa 157V | Rall Pressure Sensor (RPS) 60MPa Ziel Output Voltage | 100MPa__| 347V 130 MPa 397 135MPa_ [| __4.10V 150 MPa 450 = Type ‘Thermister type | 206 13.2~184k0 [oe 52~66k0 Sensors Fuel Temperature Sensor (FTS) 20°C 227=2.73k0 ‘Specification = 40°C 1.06 ~ 1.28 ka | 60°C 0.54 ~ 0.65 KO | 80°C 0.32 ~0.39 KO ~ Type [Thermistertype ) AOCC4OF) | + 48.14K0 | | 2occarr) [14.13 ~ 16.830 Engine Cootant Temperature Sensor 0°C(32°F) 579KO (ECTS) Specification 20°C(68°F) 2.31 ~2.59 k 40°O(104°F) 115K 60°C(140°F) ossKa | | 80°C(176"F) 0.32k0 Vehicle Speed Sensor (VSS) Type __| HallIC type = a [Type | Electromagnetictype Injector - Coll resistance | 0.33 0 at 20°C Actuators EGR Solenoid Valve Coll resistance | 147~ 16.10 at20°C Throttle Plate Vacuum Modulator | Collresistance | 14.7 ~ 16.1 0 at20°C Fuel Pressure Regulator Valve Collresistance | 2.07 ~ 2.63 0 at 20° SEALANT E Engine Coolant Temperature Sensor "THREE BOND T8 2403 SERVICE STANDARD oe | ‘AICON OFF "72040 1pm Curb Idle Speed (rpm) N-Range - ‘AION ON 7204 40 «pmFLS FUEL SYSTEM TIGHTENING TORQUES : Item Nm bt : Camshaft Poston Sensor (CMP) insaition rap oe Crankshaft Poston Sensor (CKPS) instalation | ae aes Engine Coolant Temperature Sensor (ECTS) Par 44.75 = 20.50 installation bolt Rail Pressure Sensor (RPS) installation 2434-2729 Engine Control_| EGR solenoid valve and Throttle Plate Vacuum 516-8 system Modulator bracket installation bolt EGR Vaive installation nut i 18.44 ~22.18 Glow Plug installation nut | 10~14 7.38 10.33 Glow Plug nut-washer installation 08-15 059~ 1.11 (Oil Pressure Switch installation 16-22 11.06 ~ 16.28 ECM bracket installation boltinut 4-6 «| 285443, Fuel Pressure Regulator Valve installation bolt 4-6 295 ~ 4.48 ‘Accelerator Pedal Module installation bolt 8~12 5.90 ~ 8.85 High Pressure Pipe (Rail Injector) 25 ~29 1844 ~21.39 | High Pressure Pipe (Rail ++ High Pressure Pump 25~29 | 18.44~21.39 Fuel Delivery [High Pressure Pump installation bolt 13-18 9.59 ~ 13.28 System ‘Common Rail installation bolt 8~10 5.90 ~ 7.38 Injector Clamp installation bolt I 25~28 18.44~21.39 | Fuel Filter mounting bolt o~14 664~1033 | _| Fuel Tank Band installation nut 30~54 | (28.8 ~40GENERAL, FL6 BASIC TROUBLESHOOTING —exesraea BASIC TROUBLESHOOTING GUIDE 1__| Bring Vehicle to Workshop 2. [ Analyze Customer's Problem + Ask the customer about the conditions and environment relative to the issue (Use CUSTOMER PROBLEM ANALYSIS SHEET) 3 | Verify Symptom, and then Check DTC and Freeze Frame Data + Connect Hi-Scan (Pro) to Diagnostic Link Connector (DLC). + Record the DTC and freeze frame data, To erase DTC and freeze frame data, refer to Step 5: . 4_ | Confirm the inspection Procedure for the System or Part + Using the SYMPTOM TROUBLESHOOTING GUIDE CHART, choose the correct inspection procedure for the system or part to be checked 5 | Erase the DTC and Freeze Frame Data ' (WARNING) NEVER erase DTC and freeze frame data before completing Step 2 MILIDTC in "CUSTOMER PROBLEM ANALYSIS SHEET". 6 _[ Inspect Vehicle Visually + Go to Step 11, if you recognize the problem. 7_ | Recreate (Simulate) Symptoms the DTC * Try to recreate or simulate the symptoms and conditions of the maifunction as described by customer. + If DTC(s) isfare displayed, simulate the condition according to troubleshooting procedure for the DTC. 8 | Confirm Symptoms of Problem + TFDTC(s) isfare not displayed, go to Step 8. + IF DTCs) is/are displayed, go to Step 11. 9_| Recreate (Simulate) Symptom + Try to recreate or simulate the condition of the malfunction as described by the customer. [10 [Check the DTC * If DTC(s) does(do) not occur, refer to BASIC INSPECTION in INTERMITTENT PROBLEM PROCEDURE + HfDTG{s) occurs), go to Step 11 [11 [Perform troubleshooting procedure for OTCFLT FUEL SYSTEM 12 _| Adjust or repair the vehicle 13. | Confirmation test 14 [END 1. VEHICLE INFORMATION [win = CUSTOMER PROBLEM ANALYSIS SHEET (i) Production Date: (il) Odometer Reading: (km) 2. SYMPTOMS 2 Unable to start © Difficult to start j Engine does not tum over a Incomplete combustion © Initial combustion does not occur Engine tums over slowly o Other ‘= Rough idiing o Incorrect idling 3. ENVIRONMENT 3 Poor idling ‘a Unstable idling (High: _ rpm, Low: __rpm) 3 Other 7 . - 9 Soon after starting 1 After accelerator pedal depressed { After accelerator pedal released o During A/C. ON © Engine stall © Shifting from N to D-range |s Other oe - | Poor driving (Surge) © Knocking « Poor fuel economy 13 Back fire « After fire o Other. Problem frequency © Constant 5 Sometimes })@ Once only © Other Weather Outdoor temperature | Place 1 Fine o Cloudy a Rainy 0 Snowy a Other Approx, °CrPF Highway o Suburbs o Inner City o Uphill « Downhill 12 Rough road o Other | Engine temperature Engine operation 4, MILIDTC MIL (Malfunction Indicator Lamp) 3 Cold w Warming up a Ar warming upo Ary temperature © Starting o Just after starting (__min) a Idling o Racing 1 Driving © Constant speed v Acceleration a Deceleration AIC switch ON/OFF 1 Other: & Remains ON a Sometimes lights up 0 Does not light prc | Normal o DTC. ) a Freeze Frame DataGENERAL FL BASIC INSPECTION PROCEDURE MEASURING CONDITION OF ELECTRONIC PARTS’ RESISTANCE ‘The measured resistance at high temperature after vehicle running may be high or low. So all resistance must be me- sured at ambient temperature (20°C, 68°F), unless there is any notice ® nore The measured resistance in except for ambient temperature (20 C, 68 ‘F) is reference value. INTERMITTENT PROBLEM INSPECTION PROCEDURE ‘Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does not occur again during testing. An example would be if a problem appears only when the vehicle is cold but has not appeared when ‘warm. In this case, technician should thoroughly make out a "CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and condition which occurred when the vehicle was having the issue. 1. Clear Diagnostic Trouble Code (DTC), 2. Inspect connector connection, and check terminal for poor connections, loose wires, bent, broken or corro- ded pins, and then verify that the connectors are always securely fastened, 3. Slightly shake the connector and wiring harness vertically and horizontally 4. Repair or replace the component that has a problem 5. Verify that the problem has disappeared with the road test. © SIMULATING VIBRATION a. Sensors and Actuators Slightly vibrate sensors, actuators or relays with fin- ger. @ warning Strong vibration may break sensors, actuators or relays b. Connectors and Harness Lightly shake the connector and wiring hamess ve- tically and then horizontally SIMULATING HEAT . Heat components suspected of causing the malfunction with a hair dryer or other heat sourre. @ warnne . + DO NOT heat components to the point where they may be damaged. + DO NOT heat the ECM directly. ‘¢ SIMULATING WATER SPRINKLING a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition. @ warninc DO NOT sprinkle water directly into the engine compartment or electronic components. # SIMULATING ELECTRICAL LOAD a. Tur on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, et.)FLO FUEL SYSTEM CONNECTOR INSPECTION PROCEDURE c. Listen for a click when locking connectors. This, sound indicates that they are securely locked. 4, Handling of Connector a. Never pull on the wiring harness when disconnecting connectors. 4. When a tester is used to check for continuity, or srocone to measure voltage, always insert tester probe from wire hamess side. b. When removing the connector with a lock, press or : pull locking lever.GENERAL FLA0 fe. Check waterproof connector terminals from the connector side. Waterproof connectors cannot be accessed from hamess side, @ nore + Use a fine wire to prevent damage to the terminal + Do not damage the terminal when inserting the tester lead, 2. Checking Point for Connector a. While the connector is connected: Hold the connector, check connecting condition and locking efficiency. b. When the connector is disconnected: Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire haress. Visually check for rust, contamination, deformation and bend. ©. Check terminal tightening condition: Insert a spare male terminal into a female terminal, and then check terminal tightening conditions. 4d. Pull lightly on individual wires to ensure that each wire is secured in the terminal 3. Repair Method of Connector Terminal a, Clean the contact points using air gun andlor shop reg © wore . Never use send paper when polishing the contact points, otherwise the contact point may be damaged. . Incase of abnormal contact pressure, replace the female terminal WIRE HARNESS INSPECTION PROCEDURE 4. Before removing the wire harness, check the wire harness position and crimping in order to restore it correctly 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check whether the temperature of the wire harness is abnormally high. 4, Check whether the wire harness is rotating, moving or vibrating against the sharp edge of a part 5. Check the connection between the wire hamess and any installed part 6. If the covering of wire harness is damaged; secure, repair or replace the hamess.FLAT FUEL SYSTEM ELECTRICAL CIRCUIT INSPECTION PROCEDURE © CHECK OPEN CIRCUIT 1. Procedures for Open Circuit + Continuity Check + Voltage Check fan open circuit occurs (as seen in [FIG. 1}), it can be found by performing Step 2 (Continuity Check Method) or Step 3 (Voltage Check Method) as shown below. FIG. co ses08 a “I “eo ‘wl 2. Continuity Check Method NOTE When measuring for resistance, lightly shake the wire hamess above and below or from side to side. ‘Specification (Resistance) 1Q or less -+ Normal Circuit 1MQ or Higher — Open Circuit ‘a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as shown in FIG. 2) In {FIG.2] the measured resistance of line 1 and 2 is higher than 1MQ and below 1 © respectively Specifically the open circuit is line 1 (Line 2 is nor- imal), To find exact break point, check sub line of line 1 as described in next step. FIG. 2 etn ane ie Disconnect connector (8), and measure for resistance between connector (C) and (B1) and between (82) and (A) as shown in (FIG. 3]. In this case the measured resistance between connector (C) and (B1) is higher than 1MQ and the ‘open circut is between terminal 1"of connector (C) and terminal 1 of connector (B1). FIG. 3 oe («1GENERAL FLA2 3,_ Voltage Check Method a, With each connector still connected, measure the voltage between the chassis ground and terminal 1 of each connectors (A), (B) and (C) as shown in (FIG. 4} The measured voltage of each connector is SV, 5V and OV respectively. So the open circuit is bet- ‘ween connector (C) and (B). FIG. 4 ¢ CHECK SHORT CIRCUIT 1. Test Method for Short to Ground Circuit + Continuity Check with Chassis Ground If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing below Step 2 (C- ontinuity Check Method with Chassis Ground) as shown below. FIG. 5 OM. o Te Ww 2. Continuity Check Method (with Chassis Ground) © nore Lightly shake the wire harness above and below, or from side to side when measuring the resistance. ‘Specification (Resistance) 10 or less —+ Short to Ground Circuit MQ or Higher — Normal Circi a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis Ground as shown in [FIG. 6] ‘The measured resistance of line 1 and 2 in this example is below 19 and higher than 1MQ respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken point, check the sub line of ine 1 as described in the folowing step.top secon Disconnect connector (B), and measure the resistance between connector (A) and chassis ground, and between (B1) and chassis ground as shown in (FIG. 7}. ‘The measured resistance between connector (B1) land chassis ground is 10 or less. The short to ground Circuit is between terminal 1 of connector (C) and teminal 1 of connector (B1). FIG. 7 eo 8 FUEL SYSTEM ECM PROBLEM INSPECTION PROCEDURE 4, TEST ECM GROUND CIRCUIT: Measure resistance between terminals 1, 2 ECM C230-1 connector and chassis ground using the backside of ECM hamess connector as ECM side check point. If the problem is found, repair it. Specification (Resistance) Between terminal 1 of C230-1 connector and chassis, ground : 19 or less Between terminal 2 of C230-1 connector and chassis ground: 19 or less Between terminal 3 of 230-1 connector and chassis ground : 19 or less 2, TEST ECM CONNECTOR: Disconnect the ECM connector and visually check the ground terminals on ECM side and harness side for bent pins or poor contact contact pressure. If the problem is found, repair it, 3. If problem is not found in Step 1 and 2, the ECM could be faulty. If so, replace the ECM with a new one, and then check the vehicle again. Ifthe vehicle ope~ rates normally then the problem was likely with the ECM, 4, RE-TEST THE ORIGINAL ECM : Install the original ECM (may be broken) into a known-good vehicle and: ccheck the vehicle. Ifthe problem occurs again, replace the original ECM with a new one. If problem does not ‘occur, this is intermittent problem (Refer to INTERM- ITTENT PROBLEM PROCEDURE in BASIC INSPE- CTION PROCEDURE),GENERAL FL14 INSPECTION CHART FOR DIAGNOSTIC TROUBLE ‘CODES [ pre DESCRIPTION mL P0100 Air Flow Sensor Circuit - Matfunction | [__ Potot ‘ir Flow Sensor Circult- Range/Performance Problem le [___Potoa | Air Flow Sensor Circuit - Low Input Ce P0103 | Air Flow Senor Circuit High Input . [ P0112 __ Intake Air Temperature Circuit - Low input ‘x [epotts [Intake Air Temperature Circuit - High Input oa Engine Coolant Temperature Circuit - Range/Performance Problem a Engine Coolant Temperature Circuit - Low Input — | «| Engine Coolant Temperature Circuit- High Input a Throttle!Pddal Postion Sensor 1 - General Error “Throttle/Pddal Postion Sensor 1 - High Input Fuel Temperature Sensor-Low Input Fuel Temperature Sensor - High Input Fuel Rail Pressure Sensor - General Error Fuel Rail Pressure Sensor - Low Input ° Fuel Rail Pressure Sensor - High Input ; ° ‘Throttie)Pddal Postion Sensor 2 - General Error . ‘Throttie)Pddal Postion Sensor 2 - High Input ° Electric Fuel Pump Relay - Open or Short Gircult a Electric Fuel Pump Relay - Short Circuit a Gylinder 1 - Injector Circuit Low (Over Current Low Side) . Cylinder 1 - Injector Circuit High (Over Current High Side) a Cylinder 1 - injector Circuit Balance (Load Drop is Detected) | Cylinder 2 - Injector Circuit Low (Over Current Low Si ca Cylinder 2 - injector Circuit High (Over Current High Side) Gylinder 2 - injector Circuit Balance (Load Drop is Detected) Cylinder 3 - Injector Circuit Low (Over Current Low Side) Cylinder 3 - Injector Circuit High (Over Current High Side) Cylinder 3- injector Circuit Balance (Load Drop is Detected) Cylinder 4- Injector Circuit Low (Over Current Low Side) Cylinder 4 - Injector Circuit High (Over Current High Side) Cylinder 3 - Injector Circuit Balance (Load Drop is Detected) : Crankshaft Position Sensor Circuit Range/Performance Problem Camsshatt Position Sensor Circuit Range/Performance (Single Sensor) Camsshaft Position Sensor Circuit High Input | Exhaust Gas Recirculation Flow insutficent Detected | Exhaust Gas Recirculation Flow Excessive Detected [EGR Actuator Circuit-Open or Short Circuit . erasFUEL SYSTEM a pre DESCRIPTION le P0406 EGR Actuator Circuit - Short Circuit = ° P0501 Vehicle Speed Sensor - Range/Performance Problem a P0503 _| Vehicle Speed Sensor - IntermittentHigh oo a E PO504 Stop Lamp (Brake) Switch - Malfunction - a | Pose2 System Voltage - Low Input — a PO563 System Voltage - High Input z a | P0600 CAN Communication Line - Malfunction a { P0601 EEPROM - Check Sum Error _ ° P0602 _| EEPROM Programming Error ° PO603__| EEPROM and Configuration - Data Set Error - ° P0650 __| Malfunction Indicator Lamp - Malfunction - a P0704 | Clutch Switch - Malfunction a P1182 | Fuel Pressure Regulator - Short Circuit : . P1183 | Fuel Pressure Regulator - Open or Short Circult a . P1184 _| Fuel Pressure Regulator - General Error 7 i Pitas Fuel Pressure Monitoring - Maximum Pressure Exceeded = P1186 Fuel Pressure Monitoring - Maximum Pressure at Engine Speed Toolow |, P1187 Fuel Pressure Monitoring - Regulator Valve Stick oe L P1188 Fuel Pressure Monitoring - Leakage = ° P1189 Fuel Pressure Monitoring - Governor Deviation at Engine Speed Too High ° | P1190 Intake Throttle Actuator - Malfunction a P1300 Injector Specific Data Fault a a P1321 | Glow indicator Lamp - Short Circuit = a P1322 | Glowlndicator Lamp Open Circuit — a P1326 Giow Relay - Short Circuit | a P1327 ‘(| GlowRelay-Open Circuit a P1522 | Sensor Supply Voltage 1-Low Input a P1623 ‘Sensor Supply Voltage 1 - High Input : a P1524 Sensor Supply Voltage 2-Low Input - P1525 __| Sensor Supply Voltage 2 High Input | P1529 TCM Engine Check Lamp Request ° P1545 ‘st Gear Recognition Switch - Short Circuit : a P1546 ‘st Gear Recognition Switch - Open or Short Circuit a _ P1616 Main Relay-Malfunction ° P1634 Water Heater Relay - Malfunction z a P1636 _| Voltage Regulator for Injector : 4 P1638 | ECMError ae P1639 ECM Error (A/D converter) | P1646 [ Capacitor’ Voltage - High Input a P1647 Capacitort Voltage - Low Input aGENERAL prc DESCRIPTION P1652 Ignition Switch - Malfunction P1653 Error Check after IG OFF - Malfunction "P1680 Immobilizer Malfunction - SMARTRAVAntena Error P1692 Immobilizer Indicator Lamp Error P1603. Immobilizer Malfunction - Transponder Error [P1685 | Immobilizer Matfunction - EEPROM Error [ Pr6s6 Immobilizer Malfunction - Authentication not successful P1697 Immobilizer Malfunction - Invalid tester request P1698 Immobilizer Malfunction - Key IDE not valid P1765 | Immobilizer Reduction Signal - Malfunction P2135 ‘Acoslerator Postion Sensor Switch 1/2 Voltage Correction P2228 | Atmospheric Pressure Sensor-Lowinput P2229 ‘Atmospheric Pressure Sensor-High Input @ nore ©: MIL ON & Fautt code memory 4: MIL OFF & Fault code memory Refer to the Group "BE" forthe troubleshooting procedures of the DTC P1690, P1692, P1693, P1695, P16- 96, P1697 and P1698.FLAZ FUEL SYSTEM SYMPTOM TROUBLESHOOTING GUIDE CHART (I) Problem Possible cause Engine does not start Run out of petrol Starter out of order Pump hose supply cut High pressure leakage Fuse out of order The compensation of individual injector not adapted Drift ofthe rail pressure sensor not detected (Cam and Crank signals missing simultaneously EGR valve blocked open (engine doesnt star) Fuel pressure regulator valve contaminated, stuck, jammed Fue! quality / presence of water ao inversion of low pressure fuel connections Fue fiter not adapted 7 Low pressure fuel circuit sealed : Sealed fuel fiter = : Intermittent faul | Air ingress in the low pressure fuel circuit ‘Fuel retum circuit of the pump sealed Air heaters out of order Engine compression too low Leakage at eh injector valve Low pressure fuel pump out of order High pressure pump out of order Injector jammed open Bug software of hardware fault not detectedGENERAL FLA18 Problem Possible cause Engine starts with difficulty or starts and stall Run out of fuel Fuel return hose of nozzle holder cut High pressure leakage Fuse out of order Airfiter sealed | Alternator or voltage regulator out of order ‘The compensation of individual injector not adapted Drift of the water temperature sensor not detected Drift ofthe rail pressure sensor not detected Battery voltage too low EGR vaive blocked open (engine doesn't start) Fuel pressure regulator valve contaminated, stuck, jammed Fuel quality / presence of water Inversion of low pressure fuel connections Fuel fiter not adapted Low pressure fuel circuit sealed Sealed fuel fter . Oil level too high / too low ° Catalytic converter sealed or damaged Intermittent fault connection Ar ingress in the lw pressure fuel circuit Fue! return circuit of the pump sealed Air heaters out of order Engine compression too low Fuel return hose of nozzle holder sealed _ Carbon deposit on the injector (sealed holes) Needle tk jection possible over a cern pressure) [Petrol in fuel Bug software or hardware fauit not detectedPoor starting when hot lem FUEL SYSTEM. Possible cause The compensation of individual injector not adapted _ Drift ofthe rail pressure sensor not detected Drift ofthe water temperature sensor not detected EGR valve blocked open (engine doesn't start) Fuel pressure regulator valve contaminated, stuck, jammed Air fiter sealed . | Fuel fter not adapted Ac ingress in the low pressure fuel circuit Fuel quality / presence of water Fuel return circuit of the pump sealed Sealed fuel fiter Engine compression to [Intermittent fault connection Carbon deposit on the injector (sealed holes) Needle stuck (injection possible over a certain pressure) Petrol in fuel Bug software or hardware faul Unstable idling Fuel return hose of nazzle holder cut “The compensation of individual injector not adapted Drift ofthe rall pressure sensor not detected Drift of the sensors used to evaluates the air flow not detected Hamess resistance increased Fuel filter not adapted Ar ingress in the low pressure fuel circut Fuel quality / presence of water Sealed fuel fier Air ft sealed Fuel return hose of nozzle holder sealed High pressure leakage Ar heaters out of order Engine compression too low Bad flanging of the injector High pressure pump out of order Injector not adapted Carbon deposit on the injector (sealed holes) "Needle stuck (injection possible over a certain pressure) Injector jammed openGENERAL ENN an i Problem | Idle speed too high / too low Possible cause | Drift of the engine coolant temperature sensor not detected Incorrect state of the electrical pack devices Clutch not well set ‘Alternator or voltage regulator out of order Bug software or hardware fault not detected Blue, white, black smokes The compensation of individual injector not adapted Drift of the sensors used to evaluate& the air flow not detect Drift of the rail pressure sensor not detected Fuel pressure regulator ave contaminated, stuck, jammed Drift of the engine coolant temperature sensor not detected EGR valve blocked open (engine doesn't start) Oil level to0 high / too low Fuel quality presence of water Catalytic converter sealed or damaged Air filter sealed (il suction (engine racing) Air heaters out of order Engine compression too low Bad flanging of the injector Injector washer not adapted, forgotten, doubled Injector not adapted Carbon deposit on the injector (sealed holes) Injector jammed open Petrol in fuel Engine rattling, noisy engine “The compensation of individual injector not adapted EGR valve blocked closed (noisy engine) EGR valve blocked open (engine doesn't start) Drift of the engine coolant temperature sensor not detected Air heaters out of order | Engine compression too low Drift of the sensors used to evaluated. the air flow not detected Fuel return hose of nozzie holder sealed Drift of the rail pressure sensor not detected Injector washer not adapted, forgotten, doubled Injector not adapted Can Needle stuck (injection possible over a certain pressure) deposit on the injector (sealed holes) Injector jammed openFL21 FUEL SYSTEM Problem Possible cause ‘The compensation of individual injector not adapted Intermittent fault connection a | | Dai pressure sensor not detected regulator valve contaminated, stuck, jammed Bug software or hardware fault not detected Accelerator position sensor blocked (cable jammed) EGR valve blocked open (engine doesnt start) n | | Burst noise Untimely acceleration/éeceleration and termittent faut cone engine racing | Oil suction (engine racing) | Drift of the rail pressure sensor not detected Bug software or hardware fault not detected Air ilet circuit open Incorrect state of the electrical pack devices Accelerator position sensor blocked (cable jammed) EGR valve blocked open (engine doesn't start) — Turbo charger damaged Gap when accelerating and at re-coupling _| Fuel fiter not adapted a (response time) Sealed fuel fiter Engine compression too low High pressure leakage Fuel pressure regulator valve contaminated, stuck, jammed Needle stuck (Injection possible over a certain pressure) Bug software or hardware fault not detectedGENERAL FL.22 Problem Possible cause Engine stop/stalling Run out of fuel Pump hose supply cut | High pressure leakage use out of order Fuel quality/ presence of water Low pressure fuel circuit sealed = : Sealed fuel fiter Gam and Grank signals missing simultaneously EGR valve blocked open (engine doesnt star) Fuel pressure regulator valve contaminated, stuck, jammed ‘Altemator or voltage regulator out of order Intermittent fault connection | Calallic converter sealed or damaged | il suction (engine racing) Low pressure fuel pump out of order High pressure pump out of order Faulty ignition key Petrol in fuel Bug software or hardware fault not detectedProblem FUEL SYSTEM [ Possible cause Engine udder | Run out of fuel | Fuel return hose of nozzle holder cut | incorrect state of the electrical pack devices f individual injector not adapted | Drift of the sensors used to evaluateé the air flow not detected [EGR valve blocked open (engine doesn't start Fuel fiter not adapted low pressure fuel circu presence of water ‘Sealed fuel fiter ci Intermittent fault connection Harness resistance increased Air heaters out of order Engine compression too low Fuel return hose of nozzle holder sealed Valve clearance Low pressure fuel pump out of order Injector washer not adapted, forgotten, doubled Carbon deposit on the injector (sealed holes) Needle stuck (injection possible over a certain pressure) Injector jammed open Petrol in fuel Bug software of hardware fault not detectedGENERAL | Lack of power FL24 Possit The compensation of individual injector not adapted ‘Accelerator position sensor blocked (cable jammed) Incorrect stale ofthe electrical pack devices = Drift ofthe sensors used to evaluated the air flow not detected EGR valve blocked open (engine doesn't start) Air inlet circuit open Air filter sealed Oil level too high / too low Catalytic converter sealed or damaged ‘Turbo charger damaged Fuel fiter not adapted ‘Sealed fuel fter Leakage at the injector valve Fuel return circuit of the pump sealed Fuel retum hose of nozzle holder seale Engine compression too low Injector not adapted Carbon deposit on the injector (sealed holes) [ Valve clearance _ cause ‘Too much power EGR valve blocked closed (noisy engine) The compensation of individual injector not adapted Oilsuction (engine recing) Injector not adapied Bug software of hardware fault not detectedFL.25 Problem FUEL SYSTEM Possible cause Excessive fuel consumption Fuel relum hose of nozzle holder eut Leakage at the Fuel pressure regulator valve Leakage at fuel temperature sensor | Leakage at the spacers High pressure leakage [Airinlet circuit open Air fiter sealed The compensation of individual injector not adapted EGR valve blocked open (engine doesn't star) Incorrect state of the electrical pack devices Gillevel too high / too low Fue! quality / presence of water Catalytic converter sealed or damaged Turbo charger damaged Engine compression too low Injector not adapted Bug software or hardware fault not detected . (Over speed engine when changing the gear box ratio ‘Accelerator position sensor blocked (cable jammed) * ‘The compensation of individual injector not adapted Intermittent fault connection Clutch not well set iil suction (engine racing) ‘Turbo charger damaged Injector not adapted | Bug software or hardware fault not detected Exhaust smells EGR valve blocked open (engine doesn't start) il suction (engine racing) [Turbo charger damaged Oil level too high / too low ‘The compensation of individual injector not adapted Catalytic converter sealed or damaged Injector washer not adapted, forgotten, doubled Injector not adapted Carbon deposit on the injector (sealed holes) Needle stuck (injection possible over a certain pressure) Injector jammed open __ _ Bug software or hardware fault not detectedGENERAL FL-26 Problem Possible cause ‘The compensation of individual injector not adapted EGR vaive blocked open (engine doesnt start) Drift of the used to evaluates the airflow not detected Airfiter sealed Fuel qualily / presence of water Oil level too high /t00 tow ‘Turbo charger damaged Catalytic converter sealed or damaged Oil suction (engine racing) Ar heaters out of order Engine compression too low High pressure leakage | Intermittent fault connection Bad flanging ofthe injector Injector washer not adapted, forgotten, doubled Injector not adapied Carbon deposit on the injector (sealed holes) ‘Needle stuck (injection possible over a certain pressure) Injector jammed open | Petrolin fuel Bug software or hardware fault not detected | Pump hose supply cut | Fuel return hose of nozzle holder cut Leakage at the fuel pressure regulator vale Leakage at fuel temperature sensor ‘Smokes (black, white, blue) when accelerating Fuel smells Leakage at the spacers High pressure leakageFL27 FUEL SYSTEM. Problem I Possible cause Accelerator position sensor blocked (cable jammed) Incorrect state of the electrical pack devices | Air ft sealed : | Inversion of low pressure fuel connections Fuel filter not adapted Fuel quality / presence of water | 86 in the low pressui The engine collapses at take off Sealedfuelfiter Catalytic converter sealed or damaged Clutch not well set Intermit Drift of teh rail pressure sensor not detected Fuel pressure regulator valve contaminated, stuck, jammed Petrol in fuel | Bug software or hardware fault not detected Faulty ignition key The engine does not stop (Oil suction (engine racing) Bug software or hardware fault not detected Buzzer noise (discharge by the injectors) | Clip broken (vibrations, resonance, noises) Incorrect state ofthe electrical pack devices Catalytic converter sealed or damaged Different mechanical noises Air inlet circuit open | | Bad flanging of the injector Clutch not well set Turbo charger damaged | | Valve clearance | fuel circuitGENERAL ‘SYMPTOM TROUBLESHOOTING GULDE CHART (uy FL.28 ac Bs Trouble symtoms i 3 i : i ly : i g i He] Re te acer so| a (oor) o 2_/22/22/22/3—/ ¢ | § )223| 2 Self-diagnosis 1 1 1 1 1 1 : 1 a Trmebiizer 2 Vehicle supply volage 3 2 es Main Relay 4 3 [4 Fuse/piug wing harness 5 3 [2 Ignition ewitch egnal 6 4 0 | 8 ‘rankshaft Poston Sensor 7 a No fuel 8 Wrong ful a. | Lack of ue 2 Air in fuel system 10 8 3 4 Low-pressure circuit (fuel) "1 13 4 5 7 High-pressure circuit (fuel) 16 14 14 19 16 Fuel filter 12 9 5 6 5 Elect uel pa 75 11 6 Fuel pre-heater 13 10 6 | 7 Fuel pressure Regulator Valve 18 9 16 13, 15 Incorrect connection of injector 14 17 3 ae 13, injector 7 [10 [19 @ [10 | 1 | 1 (compresion, valve sosrana,) 19 20 2 | ~ |e Defective ECM 20 Camshaft Position sensor 5 Engine Coolant Temperature Sensor 15, 2 15 en — 16FL.29 FUEL SYSTEM ae 2 ‘Trouble symtoms 3 5 5 . a : 8 i g j g 2 g£/ 22/2 Bel & § |2e3| 5 Accelerator Position Sensor 8 Mechanical fault in accelerator pedal 9 Air filter clogged 2 “se | 3 Vacuum system leaking 2 Waste-gate valve connection 12 Fuel Temperature Sensor 16 as Brake switch Vehicle speed signal ‘Checking oil level Radiator fan Radiator defective or clogged Ignition switch defective AJCON compressor switch A/CON switch Plug contacts 6 Leak in connecting surface between 13 turbochager and Intake manifoldGENERAL, FL30 Trouble symtoms Engine overheating constantly in operation 90 out o flickers Engine overrun, Diagnosis lamp not AICON cannot be switched on Accel. Clouds of black ‘smoke with ignition key Can not shut off Radiator fan Check items + | White/Blue smoke Self-diagnosis Immobilizer | Vehicle supply voltage Main Relay Fuse/plug wiring harness: alee Ignition switch signal 3 Crankshaft Position Sensor No fuel Wrong fuel 2 Lack of fue! Air in fual system 3 Low-pressure circuit fuel) 6 High-pressure circuit (fuel) 7 Fuel filter 4 Electric fuel pump Fuel pre-heater 5 Fuel pressure Regulator Valve 6 Incorrect connection of injector Injector Engine mechanical components (compression, valve clearance...) Defective ECM 5 ‘Camshaft Position sensor Engine Coolant Temperature Sensor a|2i{e6|s oral Loss of coolant Glow-plug systemFL31 FUEL SYSTEM fe nn AS aaheliay Trouble symtoms constantly in operation AICON cannot be Diagnosis lamp not switched on Engine overrun, White/Blue smoke Clouds of black smoke Engine overheating Can not shut off with ignition key 90 out or flickers Radiator fan § Check items Rail Pressure Sensor ‘Accelerator Position Sensor 3 6 Mechanical fault in accelerator pedal EGR Mass Air Flow Sensor Air fiter clogged ‘Vacuum system leaking ‘Turbocharger defective Waste-gate valve connection 5 Fuel Temperature Sensor @ (Checking timing belt tension Clutch switch . Brake switch Vehicle speed signal Checking oil level 7 Radiator fan’ 4 Radiator defective or clogged 5 Ignition switch defective 2 ‘AICON compressor switch AICON switch 3 Plug contacts Leak in connecting surface between turbochager and Intake manifoldGENERAL FL-32 WHEN GLOW(PREHEATING) LAMP IS ILLUMINATED AT ALL TIMES (ECU AUTOMATIC RECONGITION PROCEDURE) 1 ing ECM Automatic Recognition routine using HI-SCAN, 3. When MTIAT is properly selected, press [ESC] key to stop the automatic recognition. Note 4. Ifthe ECU is at the intial state, start the automa- It is normal if the glow lamp with ignition On is tic recognition routine to adapt the Transaxle ty- illuminated during preheating(max. 10 seconds) pe. ‘asscording to the ambient temperature and then 5. After adaption, about 5 seconds after with ignition put off. The glow Iamp is illuminated at all times OFF, check whether the adaption is normal or for the vehicle with ECM having not performed not though glow lamp illumination with ignition ‘automatic recognition procedure. ON, When the customer's complaint arises from glow 6 Whenever ECM is replaced with a new one or an lamp illumination at all time, if there is no DTC code(P1321) existing, test the ECM by perform- used one from other transaxle type of vehicle, ‘automatic recognition routine is necessary. CASE 1) WHEN ECM IS NOT RECOGNIZED IN AT OR MT (Check DTC code using HI-SCAN. Is the DTC code P1321 (short circuit of glow | YES _}_ Check and repair a shorvan open circu it necessary lamp) displayed? Jr ‘Select the [ECU AT/MT AUTOMATIC RECOGNITION] using HI-SCAN. | When itis recognized as the initial state, + Ifit displays (Do you want AUTOMATIC RECOGNITION?], select [YES] to start the automatic recognition routine, I I When itis recognized as AT instead of MT. ‘+ MT vohicle must not have CAN ‘communication ine (ECM pin No.9 and 410) and ECM pin No.56 should not be ‘grounded. ‘+ Repair if the state is not same as the above. I is normal tit recognizes properly according to transaxle type. + For MT vehicle : Currently Manual transmission is selected + For AT vehicte : Currently Automatic transmission is selected. When itis recognized as MT instead of AT. + AT vehicle must have CAN communication} line (ECM pin No.9 and 10) and ECM pin 'No.56 should be grounded to the body. ‘+ Repair if the state is not same as the above, | [About 5 seconds after with ignition OFF, check whether the adaption is, completed normally oF not through glow lamp illumination with ignition ON.FUEL SYSTEM CASE 2) WHEN ECM INCORRECTLY ADAPTED FOR TRANSAXLE. ‘Check DTC code using HI-SCAN. YES | Chock and repair a shortian open circuit, + isthe DIC code P1921 (ehort circuit of glow | ——— i recessary ; lamp) displayed? NO ‘Select the [ECM AT/MT AUTOMATIC RECOGNITION] using H-SCAN When itis adapted as AT instead When itis adapted as MT instead of MT of AT Initiate the ECM using HI-SCAN. ¥ ‘Select the [ECM ATIMT AUTOMATIC RECOGNITION] using HI-SCAN, ‘About 5 seconds after with ignition OFF, check whether the adaption is normal ‘oF not through glow lamp illumination with ignition ON.GENERAL FL.34 DIESEL CONTROL SYSTEM INSPECTION cepoanca If the disel control system components (sensors, ECM, injector, etc.) fail, interruptionto the fuel supply or failure to supply the proper amount of fuel for variousengine operating conditions will result. The following situations may be encountered 4, Engine is hard to start or does not start at all 2. Nstable idle, 3. Poor driveability I any of the above conditions are noted, frst perform a routine diagnosis that includes basic engine checks (ignition system matfunction, incorrectengine adjustment, etc.). Th- en, inspect the disel contor! system components with the HLSCAN (Pro). W Nore + Before removing or installing any part, read the diagnostic trouble codesand then disconnect the batiery negative (-) terminal + Before disconnecting the cable from battery terminal, turn the ignition switch to OFF. Removal or connection of the battery cable during engine ‘operationor while the ignition switch is ON could ‘cause damage to the ECM. + Wehecking the generator for the charging state, do not disconnect the battery “+ terminal to prevent the ECM from damage due to the voltage + Weharging the battery with the extemal charger, disconnect the vehicleside battery terminals to prevent damage to the ECM. ‘SELF-DIAGNOSIS. ‘The ECM monitors the input/output signals (some signals at all times and theothers under specified conditions). When the ECM detects an irregularity, it records the diagnostic, ‘rouble code, and outputs the signal to the Data Link con- Nector. The diagnosis results can be read with the MIL or HL-SCAN(Pro). Diagnostic Trouble Codes(DTC) will remain in the ECM as long as battery power is maintained. The diagnostic trouble codes will, however, be erased when the battery terminal or the engine control module(ECM) connector isdisconnected, or by the HI-SCAN (Pro), W@ nore Ifa sensor connector is disconnected with the ignition switch turned on, the diagnostic trouble code (DTC) is recorded. In this case, disconnect the battery negative terminal (-) for 15 seconds or more, and the diagnosis memory will be erased. CHECKING PROCEDURE (SELF-DIAGNOSIS) @ nore + When attery voltage is excessively low, diagnostic trouble codes can not be read. Be sure to check the battery for voltage and the charging system before starting the test + Diagnosis memory is erased if the battery or the ECM connector is disconnected. Do not discon- rect the battery before the diagnostic trouble codes are completely read and recorded, INSPECTION PROCEDURE (USING GENERIC ‘SCAN TOOL) 1 2. ‘Tum OFF the ignition switch. Connect the scan too! to the data link connector on the lower crash pad Tum ON the ignition switch. Use the scan tool to check the diagnostic trouble code. Repair the faulty part from the diagnosis chart Erase the diagnosti¢ trouble code. Disconnect the GST. @ wore When deleting diagnostic trouble code, use scan too! as possible. When deleting diagnostic trouble code by disconnecting battery terminal(-), data for ECM co- nntrol may delete simultaneously.FL-35 FUEL SYSTEM. COMPONENT LOCATION — gcsserae Shp milDIESEL CONTROL SYSTEM FL.36 Gi) Mass Air Flow Sensor (MAFS) [2] Intake Air Temperature Sensor (IATS) [3] Engine Coolant Temperature Sensor (ECTS) [@) Camshatt Position Sensor (CMPS) [5] Crankshatt Position Sensor (CKPS) [G) Injector (7) Rail Pressure Sensor (RPS) [8] Throttle Flap Solenoid Valve [8] EGR Solenoid Vaive Fuel Pressure Regulator Valve [1] Accelerator Position Sensor (APS) [22] Fue! Temperature Sensor (FTS) (3) Main Relay fi] ecm [15] Fue! Pump Relay Throttle Flap Actuator Multi-Purpose Check Connector [18] DLC (Data Link Connector)FUEL SYSTEM FL37 rr eooeeDIESEL CONTROL SYSTEM FL38 rootFUEL SYSTEM FL-39 16 8 é g 158 7DIESEL CONTROL SYSTEM FL40 ENGINE CONTROL MODULE ECM CONNECTOR ccscocrr e230 (el | i [ECM 0230-1 CONNECTOR] WrOEsaoA PIN FUNCTION CONNECTED TO REMARK 7 | Ground Chassis ground = 7 2. | Ground Chassis ground - im Chassis ground = 4 Main Relay 5 inRelay : 6 | Not connected - : [7 [Not connected | @ | Not connected I z 9 [CANLOW Tom [AT Only 10 | CAN HIGH TCM ] 11 | Immobilizer System Immobilizer (SMARTRA) Immobilizer Only 12. | Fuel Consumption signal output Trip Computer : 18 | Main Relay control output Main Relay = | 14 auto Case Main incicator Lamp contol putput | Auto Crise Main Incicator Lamp | Svtecrese Conta! 45 | Glow Plug Relay control output Glow Plug Relay 16 | EGR Solenoid Valve control output EGR Solenoid Valve 17 | immobilizer Lamp control output Z | immobilizer Lamp [Immobilizer Only | Throttle Fiap Solenoid Valve control output Throttle Flap Solenoid Valve ‘Condensor Fan Relay control output (High) Condensor Fan Relay (High) Condensor Fan Relay control output (Low) Condensor Fan Relay (Low) 21 | Air Conditioner Compressor Relay control output Air Conditioner Compressor Relay 22 | Not connected 23 | Auxiliary Water Heater Relay control output, | Auxiliary Water Heater Relay 24 | Electric Fuel Pump Relay control output 25 | Not connected Electric Fuel Pump RelayFL41 FUEL SYSTEM ee Sal} Pi FUNCTION CONNECTED TO REMARK 26 | Not connected | 27 [ Not connected 26 | Not connected 28 | Not connected | 30 | Not connected 31 | Not connected | "32 | Not connected 33 | Not connected 34 | Not connected 36 | Not connected 36 | Not connected 37 | Not connected 238 | Not connected 230 | Not connected 40 | Auto Cruise Control Supply ‘Auto Cruise Control Switch _| Auto Cruise Control ‘System Only 41 | Not connected 42 | Not connected 443 | Not connected [ ‘44 | Not connected ‘45 | Not connected 46 | Not connected 47 | Engine Speed signal output Tachometer | 48 | Diagnostic Data Line (K-Line) ~_[ Data Link Connector (DLC) 49 | Vehicle Speed Sensor (VSS) signal input |Vehicle Speed Sensor (VSS) _ [60 |Notconnected = st | At Condon Pressure Such Signal cs 52 | Air Conditioner Pressure Switch Signal (MIDDLE) | Triple Switch 53 | 1st Gear Recognition Switch Signal ~_ | 1st Gear Recognition Switch 84 | Brake Switch Signal 2 (Redundant) ~_ | Brake Switch a 55 | Not connected : 56 | AMT or MT Auto Recognition Input MT: OPEN, AIT: Ground a 57 | Not connected : '6 | Battery Voltage Supply after Ignition Key Ignition Key 59 | Brake Switch Signal 4 ~ | Brake Switch = “60 | Air Conditioner “ON” Signal ‘Air Conditioner Switch 61 | Clutch Switch Signal (MT ONLY) Clutch Switch (M/T ONLY) [62 [Blower Switch Input aa Biower Switch 63 | Not connectedDIESEL CONTROL SYSTEM FL-42 PIN : FUNCTION CONNECTED TO REMARK 64 | Not connected 65 | Not connected 66 | Not connected [67 | Not connected 68 | Not connected 68 | Not connected 70 | Not connected [71 | Not connected 72 | Not connected I 73 | Not connected | ‘Auto Cruise Control System Only 74 | Auto Cruise Activator Button Ground Auto Cruise Control Switch 7 | Auto Cruise Activator Button Signal_ ‘Auto Cruise Control Switch 76 | Accelerator Position Sensor (APS) 1 Ground oe Coenen 77 | Accelerator Position Sensor (APS) 1 Signal Input [ 78 | Accelerator Position Sensor (APS) 1 Supply 79 | Accelerator Position Sensor (APS) 2 Ground 80 | Accelerator Position Sensor (APS) 2 Signal Input 'B1 | Accelerator Position Sensor (APS) 2 Supply [ECM C230-2 CONNECTOR] ‘CONNECTED TO REMARK PIN FUNCTION 1. | Fuel Temperature Sensor signal input Fuel Temperature Sensor (FTS) 2. | Fuel Temperature Sensor ground Fuel Temperature Sensor (FTS) 3 | Engine Coolant Temperature Sensrsgnalinpur | Eraie Goolant Temperature Engine Coolant Temperature Sensor ground Engine Coolant Temperature Sensor (ECTS) 5 | Intake Air Temperature Sensor input tel cee ee | 6 | Immoblizer Ground | Immobilizer (SMARTRA) Immobilizer Only 7_| Mass Air Flow Sensor ground | Mass Air Flow Sensor (MAFS) 8 _| Mass Air Flow Sensor signal input | Mass Air Flow Sensor (MAFS) 9. | Rail Pressure Sensor supply | Rail Pressure Sensor (RPS) i Pressure Sensor signal input Rail Pressure Sensor ( i Pressure Sensor ground Rall Pressure Sensor (RPS) 1-12 [Not connects 73 [Not connected 14 | Not connectedFL43 FUEL SYSTEM 6 eS PIN FUNCTION ‘CONNECTED TO __ REMARK 16 | Not connected oS ae 16 | Mass Air Flow Sensor supply Mass Air Flow Sensor (MAFS) 147 | Not connected 48 | Crankshaft Poston Sensor signal input] eae 19 | Crankshaft Position Sensor signal input [-] co SS ‘Crankshaft Position Sensor 20 | Crankshaft Position Sensor shield | (ckPs) 21 | Not connected 22 | Camshaft Position Sensor signal input omar Poenen eneck 22 | camshat Poston Sensor ground | Gamsna Poston Sencar 24 | Not connected 25 | Not connected [26 | Not connected | 27 | Fuel Pressure Regulator Valve high side Fuel Pressure Regulator Valve : 28 | Fuel Pressure Regulator Valve low side Fuel Pressure Regulator Valve 5 | 29 | Matfunction Indicating Lamp (MIL) output Malfunction Indicating Lamp (MIL 30 | Glow Time Indicator Lamp control output Glow Time Indicator Lamp 31 | Not connected 22 | Not connected [23 [injector (Cylinder 1) low side Injector (Cylinder 1) [34 [Notconnected 26 | Not connected 36 | Injector (Cylinder 1 and 4) high side Injector (Cylinder 1 and 4) 37 | Injector (Cylinder 2 and 3) high side Injector (Cylinder 2 and 3) 28 | Injector (Cylinder 4) low side Injector (Cylinder 4) 39 | Injector (Cylinder 3) low side Injector (Cylinder 3) 40 | Injector (Cylinder 2) low side Injector (Cylinder 2)DIESEL CONTROL SYSTEM FL-44 ECM PIN CHECK SHEET [ECM C230-1 CONNECTOR] input/output signal Pin Descripti Vehicle Status Note PIN in Description ehicle Status | a 7 _| Battery minus ___ all | Ground (0~086V) 2_| Battery minus [al Ground (0~ 05V) 3. | Battery minus All | Ground (0 ~ 0.5V) 4_| Battery plus via Fuse (7.5A) __| Ignition ON DC __| Vbatt 5 _| Battery plus via Fuse (208) Ignition ON DC | Vbatt 6 [NA 7_[NA_ 3 [NA 9 | cANLOW 70. | CANHIGH (a [Na . Fuel 80mee 12 | Fuetconsumpton signal ouput | Engineruming | Pulse | f7~voe | a a [tantton ON DC Ground (0~0.5V)_ | cei . Ignition OFF De Voatt 14 [NA | | ignition ON (Glow . | Dc | Ground(o~05V) 15. | Glow relay __| ignition ON (Glow om DC | Vbatt 16 |zcrveve erarenmen SMM | rye IG. ON (Lamp ON) | OC Ground (0 ~ 0.6V) | 47 _| immoblizer indication lamp IG. ON(amp | pc fee DC | Vbat | | 2sec. after engine | PWN. : 18 | Throttle flap actuator | oat key OFF 300HZ | 7 | | OV sca a IG. ON (Fan ON) Ground (0 ~0. 19 | Fan relay - High speed fen ON 96 —— IG. ON (Fan OFF) Veat i 1G. ON (Fan ON) Ground (0 0.5V) 20 | Fan relay - Low speed : J 96 nul ) IG. ON (Fan OFF) VbatFL45 FUEL SYSTEM PIN Pin Description Vehicle Status -——_puvoutput signal _ Note = Type Level : ignition ON . eaten be Ground (0 ~0.6V) 21 | AIC compressor relay = igrition ON (ComplOre), eg |e fa d = | Engine running | pe Saas 2s PIC ratreanotercan | (Het ON round @-05%) | prc neater eater relay control en = option only ine running (HeeteroFF) [PC | Veatt | ing secaafter oo | IG.ON (Relay ON) oo oe 24 | Electric fuel pump relay be — In 5 secafter IGON (Relay OFF et | { 25 [NA L 26 [NA 27 [NA 28 [NA r 29 [NA 0g (NAG z 3t [NA 32 [NA 33 [NA [ 34 [NA 36 [NA 36 [NA 37 [NA NA NA Cruise control supply IGON ‘Analog NA E NA 43 [NA [NA 45 [NA | [NA | | - | 47 | Engine speed output signal Engnine running | Pluse oe hs 48_| Diagnosis - K interfaceDIESEL CONTROL SYSTEM FL46 ies : Input/output signal : PIN Pin Description Vehicle Stats ee evel Note v 49 | Vehicle speed sensor signal __| Vehicle running _| Pluse 50 [NA z | | Engine running vii ‘NC pressure switch signal (Fan | (Comp. ON) : °* speed hig) crgnernnng | | (Comp. OFF) eee ca Engine running a ; 62. | A/G medium switch input (Fan | (Comp. ON) ce speed low) Engi ae gine running . | (Cae or Ground (0 ~ 0.5) : Ignition ON(ISt DG | pat 53 | 4st gear recognition switch ieee = MT only Ignition ON (Other ] = oan) be Ground (0 ~ 0.5V) 7 Ignition ON (Brake . resus) pe Ground (0 ~ 0.5V) 54 | Redundant brake switch signal iat | Ignitn ON (Brake Released) ee 2 55 [NA z - = fae : Ignition ON (MT) _| DC Voatt . auto recognition Ignition ON (AT) _ | DC Ground (0 = 0.6V) 57_[NA Ignition ON De Voalt Terminal 15 * 7 = eee eee lanier OFF De Ground (0 0.8V) Ignition ON (Brake Pressed) ee Vealt 59 | Brake switch signal Ignition ON (Brake e eee oc Ground (0 ~ 0.5V) Ignition ON (AIC [ ewon pe Vbatt 60 | AC on signal [isnt | Ignition ON (AG 7 eg pe Ground (0 ~ 0.8V) Brseos SOM | oc Ground (0 ~ 0.5V) re 61 | Clutch switch signal E a MT only ignition ON (Clutch | Released) ee . Ignition ON . (Bower sw ony [DC Ground (0 ~ 0.6V) 62 | Blower switch input signal a Ignition ON | (Blower Sw oFF) | PC ee 63 [NA = L = 7 64 [NA izFLA7 FUEL SYSTEM : [ Inputioutput signal N PIN Pin Description 708 Sen lote 65 [NA | fae 66 [NA 67 _[NA 68 [NA Se : 68 [NA 70 [NA 71_[NA = 72 [NA 73 [NA 2 | | 74 [Cruise control activator ground —_| All | ‘Ground (0- 0.5V) IG. ON (Main SW s om 4300mV ~ 4500mV IG. ON (Set SW aa 75. | Ctuise control activator button | ON) pease signal b= IG. ON (Resume . evioM 1300mV ~ 1500mV 1G. ON (Cancel = r oe Ground(0~0.8V) , | Accelerator pedal sensor 1, ] = E 1 lee all | Ground (0 ~0.5v) as sign | sition ON (ile) | Analog | 0.6 ~ 0.85V . "9° Vignition ON (WOT) | Analog |35~4.7V Co Ignition ON ‘Analog | 8V ‘Accelerator pedal sensor2, | . ie | eae All Ground (0 ~ 0.5V) | [ignition ON (Idle) [Analog | 0.25~0.51V e 80 | Accelerator pedal sensor 2, sign = Ignition ON (WOT) [Analog | 1.6~2.V 61 |e eee lgrition ON 5v supplyDIESEL CONTROL SYSTEM FL48 [ECM €35-2 CONNECTOR] ri Pane = Inputioutput signal ew Pin Description Vehicle Status pavoutpet ana Note No. Type Level 1 [NA 2__| Fuel temp sensor ground All ; Ground (0 ~ 0.8V) Tgnton ON Blow | ralog | apoved 36 3 | Qodlant temperature sensor ) : signal i ; Igor ON Taraog | asow .6V Coolant temperature sensor = | 4 | Seana | Ground (0 ~0.6V) igen ON Gow [araog | above LIV 5 | Airtemperature sensor signal | = | ignition ON (above eo Analog | below 0.7V 6 | Immobiizer ground All Ground (0 ~ 0.5V) a Mass airflow sensor ground | All : Ground (0 ~0.8V) Ignition ON & z 8 | Mass air flow sensor signal ernie 545~ 605 mgs 9 _| Rail pressure sensor supply Ignition ON’ "| (6 #0.25V) | | 220 ~ 300bar 10 | Rail pressure sensor signal Ignition ON Analog (below 1.5V cree til) 11 | Rall pressure sensor ground All, ‘Ground (0 ~ 0.5V) 12 [NA | 13 [NA = 14 [NA 48 [NA 16 _| Mass air flow sensor supply ignition ON 47~52V 17 [NA ae ‘Crankshaft position sensor plus | 18 Engine running | Sine wav signal i. a | Positive peak voltage at = a idle:minimum 1.65V 49 | Crankshaft position sensor minus | Engine running | Sine wav signal ‘20 | Crankshaft position sensor shield | All : | Ground (0 ~ 0.5V) 21 [NA | 22. | Camshaft position sensor signal_| Engine running | Analog 45- | J Lee. 23. | Camshaft position sensor ground | All Ground (0 ~ 0.8V) 24 [NA |FL49 FUEL SYSTEM. I f PIN I input/output signal Pin Description Vehicle Status Ne No. . Type | Level ne 25 [NA 26 [NA | Rall pressure regulator"high | eine runni PWM 27 | side" (MPROP) Engine running | 4KHZ | Gp Raliprsaue regan ow me UE 28 | ee Roe} Engine running | Fyn | ignition ON = tnd ON (Lamp | pg Ground (0 ~ 0.5V) 29 | Malfunction indication lamp ignition ON (Lamp | ‘gi oc | vost Ignition ON (Lamy | | ne Ground (0 ~ 0.8V) 30 | Glow indication lamp s ignition ON (Lamp Sry Voat 31 [NA : CL 32_ [NA oul | | 33. | Injector for cylinder 4 Engine running | Analog ‘casas 34 [NA i NA 36_| Injector high bank’ (oyl. 1 and 4) | Engine running [DC 10 Volt or more [37 [injector “high bank (cyl. 2 and 3) | Engine running | DC 10 Volt or more 38_| Injector for cylinder 4 Engi 19-21 39 _| Injector for cylinder 3 mamerunning | Analog |} Vgc a8 40_| Injector for eylinder 2 ccaDIESEL CONTROL SYSTEM. AIR FLOW SENSOR (MAF & IAT) AIR FLOW SENSOR (AFS) — czecoova MAF uses the features of sensor heater, after HOT FILM units calculate the intake air quantity, then send the signal to ECM. ECM uses the signal to decide the timing for EGR_ operation. HOT FILM AFS OUTPUT FEATURES Mass air flow (kg/h) Output voltage (V) 8 4.19 ~ 1.20 10 1.25 ~ 1.27 | 15 139-142 30 175-178 60 222-227 | 120 279 ~2.85 250 361-358 S| 4.0 480 ( 424~ 432 60) peag 88 38 B Output votag 00 0 i) 850 a7 a0 aa ‘Airmass flow (kath) ‘TROUBLESHOOTING HINTS 4. When Ignition switch is tured on, if AFS output volt- ‘age is not "0" (engine stops), inspect the malfunction of AFS and ECM. 2, Even though AFS output voltage is abnormal, if engine is at idle, inspect the following conditions. 1) Chect the poor attachment of airfiow, cut air du- ct, and air cleaner filter branched from AFS. 2) Bad combustion in the cylinder or fault injector 3. Even ifno AFS malfunction occurs, check the mounting dircection of AFS. W@ Nore + Use correct digital voltmeter. + Before inspection, warming up the engine til the engine coolant temperature is up to 80" ~ S0°C- WIRING HARNESS INSPECTION Refer to P0102, P0103 DTC inspection procedures.FL51 FUEL SYSTEM AIR TEMPERATURE SENSOR(ATS) AIR TEMPERATURE SENSOR (ATS) ersssoie SENSOR INSPECTION 1. Inspect the resistance of sensor using a mult-tester. 2. Measure teh resistance between ATS and terminal CONDITION | TEMPERATUR | RESISTANCE Eee) (kQ) 39,260 22.260 13.850 8.609 5.499 3.604 2.420 1.662 1.166, 0.835 0.609 0.452 | 0.340 0.261 0.202 | 0159 | oar [_at02 Ignition ON 3. If resistance value is out of standard, replace the intake air temperature sensor is integrated in AFS. WIRING HARNESS INSPECTION Refer to P0112, P0113 DTC inspection procedures.DIESEL CONTROL SYSTEM FL52 ENGINE COOLANT TEMPERATURE SENSOR (ECT) ECTS (ENGINE COOLAANT TEMPERATURE SENSOR) —eyaicrao ‘The engine coolant water temperature sensor is located in the engine coolant passage of the cylinder head. It detects the water teperature and relays signals to the ECM. It employs a thermistor, whichis sensitive to changes in tempe- Fature. The electric resistance of a thermistor decreases in response to temperature rise. The ECM judges engine co- clant temperture by the sensor output voltage and provides optimum fuel enrichment when the engine is cold ‘TROUBLESHOOTING HINTS. ‘When idling speed is not appropriate or blacksmoke arises itis likely to be a defect of water temperature sensor. WIRING HARNESS INSPECTION Refer to P0117, P0118 DTC inspection procedures. USING MULTITESTER 1, Remove the water temperature sensor from the engine coolant passage of the cylinder head. 2. With the temperature sensing portion of the engine coolant temperature sensor immersed in hot water, check resistance. 1) WTS sensor (check pin : terminal 1 and 2) Temperature (6) Resistance (KO) : = 4 i 2 Ta13 = 1685 0 5780 0 2a ee, i 1148 I 60 08 I 20 03 I 100) ote | 110 0.14~ 0.15 120 TT ottes 2) Gauge nuit (check pin : terminal 2 and 3) Temperature (°C) Resistance (KO) 60 125 | 85 42.6 ~ 542 | | 110 22.1 ~262 125 162 PinNO, Deserition EEE] +] E6TS tgral 2 _| Signal for gauge | 3 | cers gona 3. If the resistance deviates from the standard value greatly, replace the sensor.FL-53 FUEL SYSTEM => ESSE INSTALLATION 1. Apply aealant THREE BOND TB 2403 or equivalent to threaded portion, 2. Install water temperature sensor and tighten it to specified torque. Tightoning torque 20 ~ 40 N-m (14.75 ~ 29.50 Ib-ft) 3. Connect the hamess connector securely. 4. After running engine, check coolant leak.DIESEL CONTROL SYSTEM FL54 CRANKSHAFT POSITION SENSOR (CKP) CRANSHAFT POSITION SENSOR (CKP) eocasssc Piston position on combustion chamber is the substantial to define the starting of injection timing. All engine pistons are connected to crankshaft by connecting rod. Sensor ‘on crankshaft can supply the informations concerning all piston positions, revolution speed is defined by revolution per minute of crankshaft. The signal induced from crankshaft position sensor is sent to ECM. SENSOR INSPECTION 1. Remove CKP sensor. 2. Measure resistance between the terminals 1 and 2 Resistance : 0.77 ~ 0.95 kA (20°C) Description ‘Sensor shiekd (GKPS signal) (OKPS signals) Pin NO. 3. Measure the gap between CKP sensor and sensor wheel : Gap : 0.5 ~ 1.5 mm 4. Install CKP sensor. Tightening torque: 3.9 ~ 5.9 N'm (2.9 ~ 4.36 Ibft) WIRING HARNESS INSPECTION Refer to P0336 DTC inspection procedures.FL.55 FUEL SYSTEM CAMSHAFT POSITION SENSOR (CMP) CAMSHAFT POSITION SENSOR (TDC) casszaae TCD sensor senses the TDC sensor(Camshaft Position Sensor) point of ON.1, 4 cylinder on its compression stroke. Its signal is fed to ECM to be used to determine the sequence of fuel injection. Crank angular sensor senses the crank angular of each cylinder, and input the pulse signal to ECM. Its signal is fed to ECM to be used to determine the engine speed and adjust the fuel injection timing and igrition timing. WIRING HARNESS INSPECITON Refer to P0341, P0343 DTC inspection procedures.DIESEL CONTROL SYSTEM EGR SOLENOID VALVE EGR SOLENOID VALVE ccassaco ‘With exhaust-gas recirculation (EGR) a portion of the exh- ‘aust gas is led into the engine's intake tract. Up toa certain degree, an increasing portion ofthe residual exhaust gas content has a positive affect upon the exhaust-gas emissions. For ECM control, the actual drawn-in fresh-air mass is measured and compared at each operating point with the air mass setpoint value. Using the signal generated by the control circuit, the ECG valve opensso that exhaust gas can flow into the intake tract. EGR SOLENOIDD VALVE INSPECTION FL56 WIRING HARNESS INSPECTION Refer to P0405, P0406 DTC inspection procedures. Check condition = Check item (Using Hiscan(pro) Engine condition Standard value | Solenoid vaive ‘Check the sound for proper EGR solenoid valve OR ON. Ignition switch : ON operation Ps VALVE INSPECTION Measure resistance between the terminals 1 and 2 = PinNO. | _ Descrintion 12 1 ‘Solenoid power [2 | Solenoid conto! Check item Specified value [EGR solenoid valve | resistance 14-170FL; THROTTLE CONTROL 7 FUEL SYSTEM. THROTTLE FLAP SOLENOID VALVE —ccoscean. In order to decrease engine vibration and noise at engine stop ECM operates throttle lap solenoid valve to open and vacuum from alternator let the actuator operated to close the throttle flap for a moment, WIRING HARNESS INSPECTION Refer to P0405, P0406 DTC inspection procedures. ‘THROTTLE FLAP SOLENOID VALVE INSPECTION | Check condition | check item ctackconation | engine conton standard value | Solenoid valve : chon | Check the sound for proper [ Throttle flap solenoid valve ORE TON a ‘operation VALVE INSPECTION "Check item Specified value Measure resistance between the terminals 1 and 2. Throttle lap solenoid ary valve resistance Pin NO. Desccption 1 ‘Solenoid power Solenoid sider |__2 ‘Solenoid controDIESEL CONTROL SYSTEM FL-58 RAIL PRESSURE SENSOR (RPS) RAIL PRESSURE SENSOR (RPS) essacees In order to output a voltage signal to the ECM which corr- cesponds to the applied pressure, the rail pressure sensor ‘must measure the instantaneous pressure in the ral, The {uel flows to the rail pressure sensor through an opening in the ral, the end of which is sealed off by the sensor diaphragm. Pressurized fuel reaches the sensor's diaphragm through a blind hole. The sensor element (serniconductor device) for converting the pressure to an electric signal is ‘mounted on this diaphragm. The signal generated by the sensor is inputted to an evaluation circuit which amplifies the measuring signal and sends ito the ECM. USING HI-SCNA | Setvalue | Check item Dataclisplay | Check conaitions | Rallpressure | fALSGAN) Rail pressure sensor | Rail pressure Engine at idle 220 ~ 300 bar 260bar WIRING HARNESS INSPECTION PROCEDURES. Refer to P0190, P0192, P0193 DTC inspection procedures, ‘SENSOR REPLACEMENT Replace the RPS if signal voltage exceeds the ste value Tightening torque 33 ~37 Nim (24.34 ~ 27.29 Ib) & caution 1. Always renew the sealing washer (soft iron sealing ring) even if old sensor is re-used. 2, When removing seal, take care not to damage sealing surface. 3. When instaling RPS, provide the sealing washer with grease if necessary.FL59 FUEL SYSTEM RAIL PRESSURE CONTROL VALVE RAIL PRESSURE REGULATOR (MPROP) eeaneaaa ‘The rail pressure-control valve sets the correct pressure in the rail as a function of engine loading, and maintains it at this level. Ifthe rail pressure is excessive, the pressure- control valve opens and a portion of the fuel returns from the rail to the fuel tank via a collector line. If the rail pressure is too low, the pressure-control valve closes and seals off the high-pressure stage from the low-pressure stage. Rail pressure control valve is intgrated in high-pressure pump. TROUBLESHOOTING HINTS Atafter run test mode or fuel cut mode, if within set time engine rpm is not dropped below the lower set value, error is detected. The reasons are short circuit, connecting resistance, faulty rail pressure sensor, continuity of fuel pump relay, faulty rail pressure control valve, defective high pre~ ssure pump, ECU fault, etc. WIRING HARNESS INSPECTION Refer to P1182, P1183 DTC inspection procedures. RAIL RPRESSURE CONTROL VALVE INSPECTION USING VOLTMETER Check item Set value (Q) Rail pressure contor! = Valve resistance oleae =e PinNO.[ Description ep [ron ar apse ‘Valve side> 2 | MPROP Low press. sie eracooseDIESEL CONTROL SYSTEM FL-60 ACCELERATION POSITION SENSOR (APS) ACCELERATION PEDAL POSITION 2. Supply the terminal 3 with DC SV. uaa ata) ESCBDES! 3. Check the voltage between the terminals 1 and 4. 'APS senses the driver's acceleration input and sends it to —— Idle: 0.7 ~0.8V ECM, Using the signal, ECM decides the fuel injection quantity and ignition timing WOT:3.8~4.4V ‘SENSOR INSPECTION 4, Disconnect the voltmeter and supply the terminal 6 1. Connect voltmeter to the terminals 1 and 4 of APS1 with DC SV. connector, 5. Connect vottmeter(B) tothe terminals 2 and 5 of APS2 connector(A), 6. Check the voltage between the teminals 2 and 5. Idle : 0.27 ~ 0.48v WOT: 1,75 ~2.38V WIRING HARNESS INSPECTION Refer to P0120, P0123, P0220, P0223, P2135 DTC inspection procedures. ah ao np Ep, ‘Harness connector>FL61 FUEL SYSTEM FUEL TEMPERATURE SENSOR (FTS) 100 Cie 110 014 = 0.18 FUEL TEMPERATURE SENSOR —ceaccoro 120 oiiies ‘The fuel temperatur sensor (FTS) senses fuel temperature and send it to ECM. Using the signal, ECM decides the fuel injection quantity. Pino. | Description +_| Sensor ground [_2_| FTS sional ‘TROUBLESHOOTING HINTS ‘When idling speed is not appropriate or blacksmoke arises itis tkely to be a defect of fuel temperature sensor. WIRING HARNESS INSPECTION Refer to P0182, P0183 DTC inspection procedures. — USING MULTITESTER 3. Ifthe resistance deviates from the standard value greatly, replace the sensor. 1. Remove the fuel temperature sensor. . INSTALLATION 2, With the temperature sensing portion of the fuel ter perature sensor immersed in hot water, check resist- 1 APPlY sealant THREE BOND TB 2409 or equivalent to threaded portion, ance fos en re an 2. Install fue! temperature sensor and tighten ito specified torque, Temperature(*C) Resistance (kQ) ~40 48.14 i aia 21683 20 ~ 40 Nem (14.75 ~ 29.50 Ib-f) ° 5.790 7 3. Connect the hamess connector securely 20 “| 231-250 0 44a]. Aer running engine, check fuel leak ca 053° I 80 eeDIESEL CONTROL SYSTEM FL62 DTC TROUBLESHOOTING PROCEDURES [DTC P0100 | MASS OR VOLUME AIR FLOW CIRCUIT COMPONENT LOCATION — stisaeic Z MAFS (Mass Air Flow Sensor) has a builtin intake air temperature sensor and is located between the air cleaner assembly and the throttle device. The MAFS uses a hot film type sensing-element to measure the mass of intake air entering the engine, And send the signal to ECM ‘A large amount of intake air represents acceleration or high load conditions while a small amount of intake air represents deceleration or idle. ‘The ECM uses this information to control the EGR solenoid valve and correct the fuel amount. Ifthe signal exceeds threshold value, the ECM judges this as a fault and DTC is set.FL-63 FUEL SYSTEM eS eee DTC DETECTING CONDITION — «180082 Z w Item Detecting Condition Possible Cause DTC Strategy _| « Voltage range check Enable Conditions | » Engine run | Threshold Value | 47 V < Sensor supply voltage < 5.1V Short to battery in Diagnostic Time 1 sec signal circuit | ME Short to battery in | Fuel Limit power circuit prety + Faulty MAFS: | | + Faulty ECM EGR Off iE _ | © EGR valve deactivited | ee «© Fuel quantity limitation | quantity SPECIFICATION ECs SS = MAFS Idle Position (without EGR) “Idle Position (with EGR) Mass air flow ‘450~550 mgistroke I 280-360 mg/stroke [Connection information} MAFS (C219) wars cou — Sais cote rage + | ceeoa emirate [Wars cal SS 2_| c2a02 Terminal 16 | Sensor power 7 1 Ser god od 3 | cee02 Teminal 7 | Sensor ground . > wars 4 161 161 Power al fe Secure mes sy =| 62502 Torin | IAF Sal {connecrory MAFS Hames sid conectr OM sie ternal =[1=] ge Eaeaeraeaaal «| ca e220DTC TROUBLESHOOTING PROCEDURES SIGNAL WAVEFORM © €7deacca” = FL64 HA? 2.4 U DT: 350.0008 CHB: 4.2 bo MAES: 1 1 apse po AMS : q om : [z00n ENO) [RECD] [EW This test should be inspacted after depressing the HOLD mode from run during the sudden acceleration. ‘As accel pedal with the MAFS is pressed down fully, the intensity of the waveform increases from less than 1V to over 4V. ‘The waveform pattern become increasing upward rapidly when the engine speed increases. Ifthe waveform pattern becomes distorted after the sudden. ‘acceleration, replace the MAFS. Connect scantool to Data Link Cable (DLC). 2. Warm up engine to normal operating temperature. Monitor that " Mass Air Flow Sensor " parameter on the scantool is changing without EGR actuator operation or without EGR actuator operation while idling engine speed, FIG4 1.2 CURRENT DATA x [cr actuator 95.8 % [ENGINE SPEED 764 pn \VEHICLE SPEED SENSOR @ = Kn/h [FUEL PRESSURE 275.0bar [FUEL PRESS. REGULATOR 16.8 % [BAROMETRIC PRESS.SNSR 161 kPa [CLUTCH SW.CIVT ONLY) ON [Fix] [SCRN] [FULL] [PaRT] |GRPH) [HELP|FL65 FUEL SYSTEM FIG2 1.2 CURRENT Dara x [EGR ACTUATOR [ENGINE SPEED 768 rpm |VEHICLE SPEED SENSOR @ == Kn/h [FUEL PRESSURE 278. 7bar [FUEL PRESS. REGULATOR 16.2 % IBAROMBTRIC PRESS.SNSR 181 KPa ICLUTCH SW.CH/T ONLY) ON FIX | [SCRN] [FULL] [PART] [GRPH] [HELP Fig 1) Normal value without EGR actuator : Approx. 450 ~ 550 mag/stroke Fig 2) Normal value with EGR actuator : Approx. 280 ~ 360 mg/stroke Is the current data displayed correctly ? YES > Faults intermittent caused by poor contact in the sensor's and/or ECM's connector or was repaired and ECM mem- ‘ory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair” procedure. iy > Go to "WiHamess Inspection” procedure. TERMINAL'& CONNECTOR INSPECTION e000 =e) 1. Many malfunctions in the electrical system are caused by poor hamess and terminals, Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3, Has a problem been found? Repair as necessary and go to "Verification of Vehicle Repair” procedure. Go to" Power Circuit Inspection " procedure.DTC TROUBLESHOOTING PROCEDURES FL66 POWER CIRCUIT INSPECTION — £aasi701 z a 4. Check for short in hamess. 4) Ignition “OFF” 2) Disconnect MAF sensor connector. 3) Ignition “ON" & Engine "OFF" 4) Measure voltage between terminal of the sensor harness connector and chassis ground, Specification : 4.8V ~ 5.1V. [e-2a11 LMAFS Signal 2MAFS Powor ‘3 Sensor Ground aict SSIATS Signal 5) _ Is the measured voltage within specifications ? : Go to "Component Inspection” procedure. > Check for short to battery or ground in the MAFS power hares. Repair as necessary and go to "Verification of Vehicle Repair” procedure. COMPONENT INSPECTION PSs 4. Visual Inspection 41). lgnition "OFF" & Engine “OFF” 2) Check that arrow mark on the MAFS is indicating correct direction 3) Check any contamination, corriosion or damage on connector. 4) Check that air cleaner is clogged or wet. 5) Check that MAFS cylinder is deformed, blocked by any foreign material or contaminated nore Hot film can be seriously damaged by foreign material or moisture. 6) Is the MAFS visually O.K ? Go to "Check MAFS" as below. > Substitute with a known-good MAFS and check for proper operation, Ifthe problem is corrected, replace MAFS and then go to "Verification of Vehicle Repair" procedure.FUEL SYSTEM FL67 2. Check MAF. » 2) 3) 4) 5) 8) VERIFICATION OF VEHICLE REPAIR = etacieer {0 Engine "ON". Warm up the engine to normal operating temperature. Check any leakage on intake system(Leakage or damage on intercooler hose) Check that EGR operates after sudden accelleration elasped around 90 sec. If necessary, disconnect EGR vaccum hose. Monitor "MASS AIR FLOW’ parameter on the CURRENT DATA. ‘Specification : 500mg/st + SOmgist 1.2 CURRENT DATA >| Sn EGR ACTUATOR IENGINE SPEED VEHICLE SPEED SENSOR @ = Kn/h [FUEL PRESSURE IPFUEL PRESS. REGULATOR 16.8 % [BAROMETRIC PRESS.SNSR 181 kPa CLUTCH SW.CH/T ONLY) ON . [enPH] [HELP| Is the current data displayed correctly ? = > ‘Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deteriora~ tion, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair" procedure. > Substitute with a known-good MAFS and check for proper operation. If the problem is corrected, replace MAFS and then go to "Verification of Vehicle Repair" procedure. After a repair, itis essential to verify that the fault has been corrected. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. 2. Operate the vehicle within DTC Enable conditions in General information. Are any DTCs present ? Goto the applicable troubleshooting procedure. ‘System is performing to specification at this time,DTC TROUBLESHOOTING PROCEDURES DTC P0101 | MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE PROBLEM COMPONENT LOCATION —EssAso7a = = Refer to DTC P0100 DESCRIPTION: “céitsess GENERAL DESCRIPTION, 9 Refer to DTC P0100 DTC DESCRIPTION: If the signal exceeds threshold value, the ECM judged this as a fault and DTC is set. (DTC: DETECTING CONDITION ="eea5xcre> | Item Detecting Condition DTC Strategy PossibleCause '* 2050 < Engine speed < 2600 rpm and injection quantity < 0 Enable Conditions | mgjst, barometric pressure > 750 hpa and -50°C < WTS < 120°C only Threshold Value | Mass air flow > 950 mgist jostic Time | « 5 sec, L "Air Leakage + Short to battery in ~~ signal circuit MIL. Yes Fuel Limit Yes Fuel Cut EGR Off Yes + Faulty MAFS + Faulty EGR + Faulty ECM © EGR valve deactivited Fail safe «Fuel quantity imitation MAFS Idle Position (without EGR) Idle Position (with EGR) ] 460~550 mg/stroke 280-360 mgistroke | SCHEMATIC DIAGRAM E00 Refer to DTC P0100. Refer to DTC P0100. MONITOR SCANTOOL DATA Refer to DTC P0100.FL-69 FUEL SYSTEM. SYSTEMINSPEGTION “eatstio® 4. Check Air Leakage. 41) Check intake and MAFS for source of any air leaks, ‘Check any cracks or deformation on MAFS and check that MAFS is installed in correct position, 2). Verity ol cap and dipstick are property installed and cil cap screwed on completely. 3) Has a problem been found? YES > a” or Replace as necessary and go to "Verification of Vehicle Repair” procedure > Goto "APS Inspection" procedure, 2. Check APS. 1) Ignition OFF. 2) Connect Scantool and monitor Accel Position Sensor parameters on Current Data. Specification : Approx. 0.4 ~ 0.7V(at Idle), 4.4 ~ 4.8V(Wide Open Throttle) 3) Is parameter displayed within specifications? YES } Go to "Check EGR solenoid valve operation" as below. 7 > Go to "APS Inspection" procedure. For more detail inspection, refer to DTC P0120,P0123,P0220,P0223 and P2123 for APS troubleshooting guide. 3. Check EGR solenoid valve operation. 4) Ignition "ON" & Engine "ON". 2) Confirm that EGR solenoid valve Duty i 6% after warming-up Engine 8) Be sure that vacuums fet fer disconnecting vaccum hose from EGR solenoid valve 4) Check that vacuum is felt in idle after sudden accelleration(EGR solenoid vaive Duty : 95%). [ EGROUTY: 5% EGR OUTY: 95% i No Vaccum vacuum '5)_ Is the vaccum felt from vaccum hose according to EGR DUTY? > Go to "WiHamess Inspection’ procedure. > Check EGR solenoid for contamination, deterioration, or damage. Substitute with a known-good EGR and check for proper operation. If the problem is corrected, replace EGR and then go to "Verification of Vehicle Repair" procedure.DTC TROUBLESHOOTING PROCEDURES, FL70 TERMINAL & CONNECTOR INSPECTION 1. Many maifunctions in the electrical system are caused by poor harness and terminals, Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3. Has a problem been found? cay ia as necessary and go to "Verification of Vehicle Repair’ procedure. Go to "Component inspection " procedure. ‘COMPONENT INSPECTION — Eovsse80 41. Visual Inspection 41) Ignition *OFF* & Engine “OFF” 2) Check that arrow mark on the MAFS is indicating correct direction, 3) Check any contamination, corriosion or damage on connector. 4) Check that air cleaner is clogged or wet. 5) Check that MAFS cylinder is deformed, blocked by any foreign material or contaminated. , note . Hot film can be seriously damaged by foreign material or moisture. 6) Is the MAFS visually 0.K ? YES D Go to "Check MAFS" as below. > Substitute with a known-good MAFS and check for proper operation. Ifthe problem is corrected, replace MAFS and then go to "Verification of Vehicle Repair” procedure,FL FUEL SYSTEM fa eK ae 2. Check MAF 1) Engine "ON" 2) Warm up the engine to normal operating temperature, 3) Check any leakage on intake system(Leakage or damage on intercooler hose). 4) Check that EGR operates after sudden accelleration elasped around 90 sec. Ifnecessary, disconnect EGR vaccum hose. 5) Monitor “MASS AIR FLOW’ parameter on the CURRENT DATA. Specification : 500mg/st + 50mgist 1.2 CURRENT DATA > x [EGR ACTUATOR 95.8 % IENGINE SPEED 764 rpm \VEHICLE SPEED SENSOR @ —Kn/h IFUEL PRESSURE 275.bar IFUEL PRESS. REGULATOR 16.0 % [BAROMETRIC PRESS.SNSR 101 kPa lcLUTCH Su.cr/T ONLY) — ON [FIX | [SCRN) [FULL] [PaRT] [GRPH 8) Is the current data displayed correctly ? YES > Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification vehicle Repair” procedure. > Substitute with a known-good MAFS and check for proper operation. If the problem is corrected, replace MAFS and then go to "Verification of Vehicle Repair” procedure. VERIFICATION OF VEHICLE REPAI Refer to DTC P0100.DTC TROUBLESHOOTING PROCEDURES. FL-72 DTC P0102 | MASS OR VOLUME AIR FLOW CIRCUIT LOW VOLTAGE COMPONENT LOCATION: EAé0s5 Refer to DTC P0100 DESCRIPTION © es ‘GENERALDESCRIPTION’ Refer to DTC P0100, DTC DESCRIPTION SS: Ifthe signal is below threshold value, the ECM judged this as a fault and DTC is set. Item Detecting Condition ~ | Possible Cause DTC Strategy _| « Signal check, low Enable Conditions _| ¢ Engine run qi : Threshold Value | ¢ Output signal < - 25 kgih ee Diagnostic Time | « 1 sec. + sshort to ground in es a signal circuit Mit Yes : Fuel Limit Yes ee Fuel Cut #No era ae EGR Off Yes + Faulty ECM © EGR valve deactivited | dicted «© Fuel quantity imitation [ MAS Idle Position (without EGR) ql Idle Position (with EGR) ] Mass air flow 1450~550 mag/stroke 280~360 mg/stroke Refer to DTC P0100, Refer to DTC P0100. ‘MONITOR SCANTOOL Refer to DTC P0100.FL-73 FUEL SYSTEM TERMINAL & CONNECTOR INSPECTION = <0710c8 FS 1. Many malfunctions in the electrical system are caused by poor hamess and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3. Has a problem been found? YES ee as necessary and go to "Verification of Vehicle Repair" procedure. Go to" Power Circuit Inspection * procedure. POWER CIRCUITINSPECTION — Eiers98 4, Check for short in hamess. 1) Ignition "OFF" 2) Disconnect MAF sensor connector. 3) Ignition "ON" & Engine "OFF" 4) Measure voltage between terminal "4" of the sensor hamess connector and chassis ground. “Specification : Approx. B+ 1. MAES Signal 2.MAFS Power 5. Sensor Ground 4101 S.IATS Signal ( J 5) Is the measured voltage within specifications 7 > Go to Signal Circuit Inspection” procedure. Check for open in polwer (IG1) harness Repair as necessary and go to "Verification of Vehicle Repair” procedure.DTC TROUBLESHOOTING PROCEDURES, SIGNAL CIRCUIT INSPECTION= ces2ises ” 4. Ignition “OFF” 2. Disconnect MAF sensor connector and ECM connector. 3. Ignition "ON" & Engine "OFF" 4, Measure voltage between terminal"1" of the MAF sensor hamess connector and chassis ground, Specification : Approx. 4. MAFS Signal 2. MAFS Powor 43. Sensor Ground aig S.IATS Signal 5. Is the measured voltage within specifications 7 5 : > Go to "Ground Circuit Inspection" procedure. Check for short to ground in signal harness. Repair as necessary and go to "Verification of Vehicle Repair” procedure.FL75 FUEL SYSTEM GROUND CIRCUIT INSPECTION ~ 276005 4. Ignition "OFF 2, Disconnect MAF sensor connector and ECM connector. 3. Measure resistance between terminal "3" of the sensor hamess connector and terminal ctor. Specification : Approx. below 19 _ (ozo, 1. MAFS Signal 2.MAFS Powor 3: Sensor Ground 4161 IAT Signal 4, Is the measured resistance within specifications ? YES P Go to "Component inspection” procedure, > Check for open in ground hamess, Repair as necessary and go to "Verification of Vehicle Repair" procedure. ‘COMPONENT INSPECTION £7F88000°° Refer to DTC P0100. VERIFICATION OF VEHICLE REPAIR: Ecsco'a" After a repair, itis essential to verify that the fault has been corrected. 4. Connect scan tool and select “Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. 2. Operate the vehicle within DTC Enable conditions in General information. 3. Are any DTCs present ? YES Goto the applicable troubleshooting procedure. System is performing to specification at this time.DTC TROUBLESHOOTING PROCEDURES [Dtc P0103 | MASS OR VOLUME AIR FLOW CIRCUIT HIGH VOLTAGE } COMPONENT LOCATION ssuaer2e Refer to DTC P0100, DESCRIPTION “eAaciE25 GENERAL DESCRIPTION. © Refer to DTC P0100 DTC DESCRIPTION If the signal is above threshold value, the ECM judged this as a fault and DTC is set. Item Detecting Condition Possible Cause [TC Strategy | « Signal check, high | Enable Conditions | « Engine run Threshold Value | ¢ Output signal > 700 kg/h + Short to battery in © 0.1 sec. ‘signal circuit +- Open in signal hn circuit Fuel Limit | + Faulty MAFS. Fuel Cut [+ Faulty ECM EGR Off | | _FSRON eves _ — | © EGR valve deactivited [see srohecrat — — SPECIICRUGNE Sas SS Se Se Se MAFS: Idle Position (without EGR) Idle Position (with EGR) Mass airflow "450-550 mglstroke 280-360 mgistioke Refer to DTC P0100. Refer to DTC P0100. Refer to DTC P0100.FLTZ, FUEL SYSTEM TERMINAL & CONNECTOR INSPECTION —E90a02000 = BES 4. Many malfunctions in the electrical system are caused by poor harness and terminals, Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3, Has a problem been found? YES ae ‘as necessary and go to "Verification of Vehicle Repair” procedure. Go to" Power Circuit Inspection " procedure. SIGNAL CIRCUIT INSPECTION 1, Check for short to battery in harness 1) Ignition “OFF”. 2) Disconnect MAF sensor connector. 3) Ignition "ON" & Engine "OFF 4) Measure voltage between terminal 1 of the sensor hamess connector and chassis ground. Grecioaion Aproc OV + 4. MAFS Signal 2. MAFS Power 2. Sensor Ground 4161 5.IATS Signal 5) _ Is the measured voltage within specifications? YES P Go to "Check open in signal harness” as below. > Check for short to battery in signal hamess Repair as necessary and go to "Verification vehicle Repair” procedure,DTC TROUBLESHOOTING PROCEDURES, FL-78 2. Check for open in haess 1). Ignition *OFF™ 2) Disconnect MAF sensor and ECM connector. 3) Measure resistance between terminal 1 of the sensor hamess connector and terminal 8 of the ECM harness connector. ‘Specification : Approx. below 10 1. MAFS Signal 2. MAFS Power 53. Sensor Ground a1g1 SLIATS Signal c2a0.2 4) Is the measured resistance within specifications? YES Go to ‘Component Inspection” procedure z > Check for open in signal hares. Repair as necessary and go to “Verification vehicle Repair” procedure. Refer to DTC P0100.FL-79 FUEL SYSTEM DTC P0112 | INTAKE AIR TEMPERATURE LOW INPUT COMPONENT LOCATION co26p473 IATS (Intake Air Temperature Sensor) is intergrated in MAF sensor. This part employs a thermistor (NTC) which is sensitive to changes in temperature. ‘The electric resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases ‘The power source in the ECM is supplied to the IATS via a resistor in the ECM. ‘The ECM judges intake air temperature by the sensor output voltage and is used for injection quantity correction, injection time correction, starting fuel quantity correction as a compensation signal Hf the signal below threshold value, the ECM judged this as a fault and DTC is set, DTC DETECTING CONDITION © cece { ttem Detecting Condition Possible Cause | [bre Strategy | Signal check |" Enable Conditions | « Ignition on | Threshold Value |» Output signal < 112 mV + Short to ground in Diagnostic Time | « 2 sec. signal circuit ML, ‘= No + Faulty ATS Fuel Limit * Faulty ECM. Fuel Cut EGR Off ture is fixed at value of 60°C by ECM Fail safeDTC TROUBLESHOOTING PROCEDURES FL-80 SPECIFICATION «#0s8e90 e ats Temperature (°C) 20 40 Resistance (kQ) 2.29 ~2.55 14-42 SCHEMATIC DIAGRAM ~coaecra => 5 rs 7 [Connection information] (ee 20 aro 1_[c2s02 Terminal | __MAFS signal 1 cae 2_| 62802 Terminal 16] Sensor power KE 4 3 | €230-2 Terminal 7 ‘Sensor ground A 4 Llib 4 ict 1G1 Power 4 2 ssi 5 _| 0230-2 Terminal 5 JAT Signal [eonNECTOR] MAFS Hamoss sie connector EOM sido terminal IATS and ECTS signals should be smooth and continuous without any sudden changes. When the engine is cold, IATS and ECTS signals should look similar, depending on the ambient air temperature. After warmed-up the IATS signal should not have changed less significantly while ECTS signal should have some dropped. ‘This indicates the normal increase of the engine coolant temperature is larger than the normal increase of the intake air temperature as the engine warms up. ‘MONITOR SCANTOOL DATA 4. Ignition “OFF” & Engine "OFF" 2. Install Scantool and Engine "ON". 3. Monitor Intake Air Temperature Sensor on Current data. 1FUEL SYSTEM FIG1 1.2 CURRENT DATA « [EE 713.600 66.4 °C [ENGINE SPEED 756 pe VEHICLE SPEED SENSOR @ =— Koh Fig 1) Signal decreases with Increasing sensor temperature and increases with decreasing sensor temperature : Appr- ox. 2V at 20°C(68°F) Is the Current data displayed correctly ? > Fault is intermittent caused by poor contact in the sensor's and/or ECM’s connector or was repaired and ECM memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair" procedure. > Go to"WiHamess Inspection” procedure, TERMINAL & CONNECTOR INSPECTION = =Azeseas = 1. Many matfunctions in the electrical system are caused by poor hamess and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3. Has a problem been found? YES Repair as necessary and go to "Verification of Vehicle Repair" procedure. Go to "Power Circuit Inspection” procedure,DTC TROUBLESHOOTING PROCEDURES, FL82 a ‘SIGNAL CIRCUIT INSPECTION™= exte1ax 1, Check for short to battery in hamess 1) Ignition “OFF 2). Disconnect IAT sensor connector. 3) Measure voltage between terminal 5 of the sensor hamess connector and chassis ground. ‘Specification : Approx. 5V <0-281> E> 1-MAFS Signal 2. MAFS Powot aTsT2is 3. Sensor Ground aici 5.IATS Signal 4) Is the measured voltage within specifications? ey : Go to "Component inspection” procedure. > Check for short to battery in signal hamess. Repair as necessary and go to "Verification of Vehicle Repaii (COMPONET PECTION — e0rbvHeo procedure. 1. Check IATS 1). Ignition "OFF" & Engine "OFF" 2) Disconnect |ATS connector. 3) Monitor resistance between terminal 3 and 5 of IATS connector(Component Side). SPECIFICATION : _Temperature 7 40 60 [___ Resistance (KO) 2.29~2.55 1A~12 0.56 ~ 0.65FL.83 FUEL SYSTEM. 1. MAES Signal 2. MAFS Power 83. Sensor Ground aici 5.IATS Signal 4) Is the measured resistance within specifications? eS > Substitute with a known-good ECM and check for proper operation. Ifthe problem is corected, replace ECM and then go to "Verification of Vehicle Repair” procedure. > Substitute with a known-good IATS and check for proper operation. If the problem is corrected, replace IATS and then go to "Verification of Vehicle Repair" procedure. ‘After a repair, itis essential to verify that the fault has been corrected. : 4. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. Operate the vehicle within DTC Enable conditions in General information. Are any DTCs present ? YES Go to the applicable troubleshooting procedure. ‘System is performing to specification at this time.DTC TROUBLESHOOTING PROCEDURES, FL84 eeeyeEe—e—eee [DTC P0113 | INTAKE AIR TEMPERATURE HIGH INPUT item Detecting Condition Possible Cause DTC Strategy ‘¢ Signal check, high Enable Conditions | « Ignition on + Short to ground in Threshold Value © Output signal > 4.9V signal circuit Diagnose Tne |» 2 sec. «Open in signal MIL No * Open in ground Fuel Limit lo circuit Fuelcut | ¢No Fay ATS EGR Off Yes + Faulty ECM Fail safe ‘* Engine air temperature is fixed at value of 80°C by ECM. ats "Temperature (0) 20 @ 0 Resistance (kQ) 2.29 ~ 2.55 ante 0.56 ~ 0.65 Refer to DTC P0112.FL85 FUEL SYSTEM TERMINAL & CONNECTOR INSPECTION —_-Ecroar8o 1. Many malfunctions in the electrical system are caused by poor hamess and terminals, Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage, 3. Has a problem been found? YES Repair as necessary and go to "Verification of Vehicle Repair” procedure. Go to "Signal Circuit Inspection” procedure. SIGNAL CIRCUIT INSPECTION 1. Check for short to battery in signal hamess 1) Ignition "OFF". 2) Disconnect IAT sensor connector. 3) Measure voltage between terminal 5 of the sensor harness connector and chassis ground, Specification : Approx. 5V 4. MAFS Signal 2.MAFS Power 13. Sensor Ground 4161 SLIATS Signal 0 1 4) Is the measured voltage within specifications? } Go to "Check for open in signal harness” as below. } Check for short to battery in signal hamess. Repair as necessary and go to "Verification vehicle Repair” procedure,DTC TROUBLESHOOTING PROCEDURES. FL86 2. Check for open in signal hamess 41) Ignition "OFF* 2) Disconnect IAT sensor connector and ECM connector. 3) Measure resistance between terminal 5 of the sensor harness connector and terminal 5 of ECM hamess connector. Specification : Approx. below 10 1. MAES Signal 2. MAFS Power 3, Sensor Ground ait S.IATS Signal 230-2 4) Is the measured resistance within specifications? YES : > Go to "Signal Circuit inspection” procedure. . > Check for open in harness. Repair as necessary and go to "Verification of Vehicle Repair’ procedure. Ignition "OFF Disconnect IAT sensor connector and ECM connector. Measure resistance between terminal 3 of the sensor harness connector and terminal 7 of ECM hamess connecto- f Specification : Approx. below 12 C20 41. MAFS Signal 2.MAFS Power 3. Sensor Ground 4161 S.IATS Signal 230.2FL87 FUEL SYSTEM 4, Is the measured resistance within specifications? YES > Go to "Component Inspection” procedure. Check for open in ground hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure COMPONENT INSPECTION © eebo1As 1, Check IATS 41) Ignition "OFF" & Engine "OFF 2) Disconnect IATS connector. 3) Monitor resistance between terminal 3 and § of IATS connector(Component Side). SPECIFICATION : Temperature (°C) 20 40 60 Resistance (KA) 2.29 ~2.55 0.56 ~ 065 4. MAFS Signal 2. MAFS Powor 53. Sensor Ground 4161 : LIATS Signal 4) Is the measured resistance within specifications? Substitute with a known-good ECM and check for proper operation. Ifthe problem is corrected, replace ECM and then go to "Verification of Vehicle Repair” procedure. > Substitute with a known-good IATS and check for proper operation. If the problem is corrected, replace IATS and then go to "Verification of Vehicle Repair” procedure. VERIFICATION OF VEHICLE REPAI Refer to DTC P0112,DTC TROUBLESHOOTING PROCEDURES, Fi [DTC P0116 | ENGINE COOLANT TEMPERATURE CIRCUIT RANGE/PERFRMANCE ECTS (Engine Coolant Temperature Sensor) located in the engine coolant passage of the cylindes head, It detects the water temperature and relays signals to the ECM. It employs a thermistor, which is sensitive to the changes in the coolant temperature. The electric resistance of a thermistor decreases as the fuel temperature increases, and increases as the fuel temperature decreases. ‘The power source in the ECM is supplied to the ECTS via a resistor in the ECM. ‘The electric resistance of a thermistor decreases in response to the temperature rise. ‘The ECM judges engine coolant temperature by sensor output voltage and provides optimum fuel enrichment when the ‘engine is cold and in order to operate the radiator fan and the A/C condensor fan. Ifthe signal exceeds threshold value, the ECM judged this as a fault and DTC is setFL-89 FUEL SYSTEM i DTC DETECTING CONDITION crear 4 Item Detecting Condition Possible Cause DTC Strategy —_| e Rationality check Enable Conditions | « Ignition on ® Error is reconized when the rising time of coolant temperature up ‘Threshold Value | '©40°C(113°F) is deviated from below data after the engine starting ~40°C(-40°F) @65535 sec. -20°C(-4°F) @760 see. 55°C @S72 sec. | + Open in signal 40°C(113°F) @20 sec, circuit DagrosicTine |eSsen 5 Open mn ground MIL ‘No + Short in signal rualtimt —|2No ove Fuel Cut No + Faulty Thermostat EGR Off No + Faulty ATS —|+ Faulty ECM «Engine temp. is fixed at value of 80°C after cranking and -25°C when cranking by ECM. | « Engine performance is reduced over 120°C Fail safe | » Radiator cooling fan and A/C condensor fan are operated. * Air conditioning system deactivated | © Water heater deactivated ECTS “Temperature (°C) 20 = Resistance (kA) 231-259 031 ~ 0.33 ‘SCHEMATIC DIAGRAM = [Connection information) ors ame 1] 6220-2 Terminala | Sensor signal a al 2 | tnsrument auster | Sensor power By 2 | e2a02 Terminals | Sensor ground 3 + sacrosne Lear ‘SU [eonnecroR] ECTS Hamoss sige connector ECM sie terminal sa TEE = aa Ca [isi hee i ECTS (C208) 230-2 a0DTC TROUBLESHOOTING PROCEDURES FL.90 SIGNAL WAVEFORM —cosccecc = Oo 1-8 § | _IATS and ECTS signals should be smooth and continuous without 7 1.2.0 max: 4.4} anysudden changes. ‘When the engine is cold, JATS and ECTS signals should look sirita, ‘depending on the ambient air temperature, After warmed-up the IATS signal should not have changed less significantly while ECTS signal should have some dropped. This indicates the normal increase of the engine coolant temperature is larger than the normal increase of the intake air temperature as the ‘engine warms up. = wis oc : MONITOR SCANTOOL DATA 1. Ignition “OFF” & Engine "OFF". 2. Install Scantool and Engine "ON’ 3. Monitor Engine Coolant Temperature Sensor on Current data. FIG1 : 3.2 CURRENT DATA x |INT AIR TENP.SNSR 16.8 *C BACOOLANT TENP. SEN Fig 1) Signal decreases with increasing sensor temperature and increases with decreasing sensor temperature |s Current data displayed correctly ? > Fault is intermittent caused by poor contact in the sensor’s and/or ECM’s connector or was repaired and ECM. rmem- ory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair" procedure. > Go to "WiHamess Inspection’ procedureFL91 FUEL SYSTEM TERMINAL & CONNECTOR INSPECTION = =F2e909 4. Many matfunctions in the electrical system are caused by poor hamess and terminals, Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage 3. Has a problem been found? YES Repair as necessary and go to "Verification of Vehicle Repair” procedure. Go to "Signal Circuit Inspection" procedure. SIGNAL CIRCUIT INSPECTION lgnition "OFF". Disconnect ECT sensor connector. Ignition "ON" & Engine "OFF". Measure voltage between terminal 1 of the sensor harness connector and chassis ground. Specification : Approx. SV 1. Sensor Signal (SV) 2. Gauge (12V) 8. Sensor Ground (0¥) 5. Is the measured voltage within specifications? > Goto "Ground Circuit Inspection" procedure. > Check for open or short in the signal harness. Repair as necessary and go to "Verification of Vehicle Repair” procedure. GROUND CIRCUIT INSPECTION 1. Ignition "OFF" 2. Disconnect ECT sensor connector and ECM connector.DTC TROUBLESHOOTING PROCEDURES, FL92 Measure resistance between terminal 3 of the sensor harness connector and terminal 4 of ECM harness connecto- 3 r Specification : Approx. below 12 : <0-234> 4, Sensor Signal (5V) 2. Gauge (12V) 8. Sensor Ground (0V) Is the measured resistance within specifications? 5 Go to “Component Inspection’ procedure ‘Check for open in ground hamess. Repair as necessary and go to "Verification of Vehicle Repair" procedure ‘SOMBDNENT INSPECTIONS RSH cess e err 4. Check MAF 41) Ignition "OFF" 2) Disconnect ECTS connector. 3) Monitor resistance between terminal 1 and 3 of ECTS connector(Component Side). SPECIFICATION ‘Temperature (°C) 20 0 I 20 “40 80 Resistance (KN) | 15482 1.35 578 2a5e01 | 1.148 0.3222 1. Sensor Signal (SV) 2. Gauge (12¥) 8. Sensor Ground (OV)FUEL SYSTEM FL.93 4) Is the measured resistance within specifications? as > Go to "Check thermostat "as below. > Substitute with a known-good ECTS and check for proper operation. Ifthe problem is corrected, replace ECTS and then go to "Verification of Vehicle Repair’ procedure. 2. Check Thermostat 41) Engine "ON" note This test should be performed under cold temperature, 2) Remove radiator cap. 3) Warm up the engine to normal operating temperature. 4) Check that engine cootant circulates. 5) Does engine coolant circulate ? YES > Substitute with a known-good ECM and check for proper operation. Ifthe problem is corrected, replace ECM and then go to "Verification of Vehicle Repair" procedure. > Substitute with a known-good Thermostat and check for proper operation. : Ifthe problem is corrected, replace thermostat and then go to "Veriction of Vehicle Repair” procedure, VERIFICATION OF VEHICLE REPAIF 1 After a repair, itis essential to verify that the fault has been corrected. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. ‘Operate the vehicle within DTC Enable conditions in General information. Are any DTCs present ? eS Go to the applicable troubleshooting procedure, ‘System is performing to specification at this time,DTC TROUBLESHOOTING PROCEDURES [DTC P0117 | ENGINE COOLANT TEMPERATURE CIRCUIT LOW INPUT COMPONENT LOCATION « Refer to DTC P0116. DESCRIPTION — Refer to DTC P0116. DTC DESCRIPTION Ifthe signal exceeds threshold value, the ECM judged this as a fault and DTC is set, Item Detecting Condition Possible Cause DTC Strategy __| « Signal check, low Enable Conditions | « Ignition on Threshold Value | ¢ Output signal < 225 mV Diagnostic Time | ¢ 0.5 sec. . Mit No ; Fuel Limit. | ¢ No + Short to ground in FuelCut |e No signal circut . + Faulty ECTS ee — + Faulty ECM * Engine tern. is fixed value of 80°C after cranking and 25°C ‘when cranking by ECM. Engine performance is reduced over 120°C. Fail sate | Radiator cooling fan and AG condensor fan is operated ‘* Air conditioning system deactivation Water heater deactivation ECTS ] Temperature (°C) 20 80 Resistance (kQ) Refer to DTC P0116. Refer to DTC P0116.Fi FUEL SYSTEM MONITOR SCANTOOL DATA — Eis0azas 5 Refer to DTC P0116. TERMINAL & CONNECTOR INSPECTION Refer to DTC P0116, SIGNAL CIRCUIT INSPECTION &474974 4. Ignition “OFF”. 2. Disconnect ECT sensor connector. 3, Ignition "ON" & Engine "OFF". 4, Measure voltage between terminal 1 of the sensor harness connector and chassis ground. Specification : Approx. SV 7 2a 41. Sensor Signal (5¥) 2 Gauge (12¥) 43 Sensor Ground (OV) 5, Is the measured voltage within specifications? > Go to "Component Inspection" procedure. Check for shor to ground in signal hamess. Repair as necessary and go to "Verification of Vehicle Repair" procedure. Refer to DTC P0116. VERIFICATION OF VEHICLE REPAIR Refer to DTC P0116.DTC TROUBLESHOOTING PROCEDURES. FL-96 DTC P0118 | ENGINE COOLANT TEMPERATURE CIRCUIT HIGH INPUT COMPONENT LOCATION: sties99 Refer to DTC P0116. DESCRIPTION GENERAL DESCRIPTION = Refer to DTC P0116. (DTC DESCRIPTION © If the signal exceeds threshold value, the ECM judged this as a fault and DT‘ Hem Detecting Condition Possible Cause DTC Strategy _| e Signal check, high Enable Conditions _|« Ignition on Threshold Value |e Output signal > 4.97 V Diagnostic Time | « 0.5 sec. + Short to battery in iL No signal circuit FuelLimit | eNo + Open in signal Fuel Cut No ora : . + Open in groune EGRO |e Yes __| circuit ‘« Engine temp. is fixed value of 80°C after cranking and -25°C. + Faulty ECTS + Faulty ECM when cranking by ECM. ‘* Engine performance is reduced over 120°C Fail safe ‘* Radiator cooling fan and A/C condensor fan is operated, | Air conditioning system deactivation | ‘* Water heater deactivation | Temperature (°C) 20 | Resistance (kO) 2.31~259 | 0.31 ~ 0.33 Refer to DTC P0146. Refer to OTC P0116.FL.97 FUEL SYSTEM MONITOR SCANTOOL DATA — Adsacac: Refer to DTC PO116. TERMINAL & CONNECTOR INSPECTION Refer to DTC P0116. SIGNAL CIRCUITINSPECTION | 4. Check for short to battery in signal hamess 1) Ignition “OFF” 2) Disconnect ECT sensor connector. 3). Ignition "ON" & Engine "OFF" 4) Measure voltage between terminal 1 of the sensor hamess connector and chassis ground Specification : Approx. 5V 0-234 4, Sensor Signal (6V) 2. Gauge (12V) 8. Sensor Ground (0V) : eek 5) _ Is the measured voltage within specifications ? Goto " Check for open in hamess" as below. Check for short to battery in signal hamess. Repair as necessary and go to "Verification of Vehicle Repaii procedure.DTC TROUBLESHOOTING PROCEDURES, FL.98 2. Check for open in harness 41). Ignition “OFF* 2). Disconnect ECT sensor connector 3). Ignition "ON" & Engine "OFF" 4) Measure resistance between terminal 1 of the sensor hamess connector and terminal 4 of ECM harness con- rector. "Specification : Approx. below 19 fe Go to "Ground Circuit Inspection" procedure. > Check for open in signal harness. Repair as necessary and go to "Verification of Vehicle Repair” procedure. (GROUND CIRCUIT INSPECTION i 4. lgnition “OFF* 2. Disconnect ECT sensor connector and ECM connector. 3. Measure resistance between terminal 3 of the sensor harness connector and terminal 4 of ECM hamess connector- Specification : Approx. below 12 C2 1. Sensor Signal (SV) 2. Gauge (12V) 3, Sensor Ground (ov) c2a02FL99 FUEL SYSTEM 4, Is the measured resistance within specifications 7 YES > Go to “Component Inspection" procedure. > Check for open in hamess. Repair as necessary and go to "Verification of Vehicle Repair" procedure. COMPONENT INSPECTION — EFACDEAZ — 1. Check MAF 1) Ignition “OFF” 2) Disconnect ECTS connector. 3) Monitor resistance between terminal 1 and 3 of ECTS connector(Component Side). ‘SPECIFICATION : [Temperature () 20 ° 20 0 «| [Resistance (KO) | 15402 1.5 378 24501 i148 aaa | cou 1. Senor Sigal (519 : 2 Sanwa) 43 Sensor Ground (OV) 4) Is the measured resistance within specifications? } Go to "Check thermostat " as below. > Substitute with a known-good ECTS and check for proper operation. Ifthe problem is corected, replace ECTS and then go to "Verification of Vehicle Repair” procedure.DTC TROUBLESHOOTING PROCEDURES FL-100 2. Check Thermostat 1) 2) 3) 4 5) Engine "ON" nore This test should be performed under cold temperature. Remove radiator cap. Warm up the engine to normal operating temperature, Check that engine coolant circulates. Does engine coolant circulate ? YES > Substitute with a known-good ECM and check for proper operation. Ifthe problem is corrected, replace ECM and then go to "Verification of Vehicle Repair" procedure. >> Substitute with a known-good Thermostat and check for proper operation. If the problem is corrected, replace thermostat and then go to "Verification of Vehicle Repair’ procedure. see eee eee After a repair, it is essential to verify that the fault has been corrected. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. Operate the vehicle within DTC Enable conditions in General information, : Are any DTCs present ? Go to the applicable troubleshooting procedure. ‘System is performing to specification at this time.FL-101 FUEL SYSTEM [DTC P0120 | THROTTLE POSITION CIRCUIT MALFUNCTION APS(Acceleration Position Sensor) is measured the driver's acceleration using a potentiometer and APS signal is tran- ‘mitted to the ECM, The pedal's position is calculated from the voltage of potentiometer in the APS. ° ‘The absence of a mechanical link between the accelertor pedal and injection system presents a risk of loss of control of the engine in the event of a failure of the component in the charge of providing the driver's request information to the injection system, ‘Therefore, APS has the two potentiometers whose slides are mechanically solid. APS 1 decides to the fuel quantity and injection timing in the engine. Ifthe signal exceeds threshold value, the ECM judged this as a fault and DTC is set.DTC TROUBLESHOOTING PROCEDURES Item Ea ___ Detecting Condition Possible Cause DTC Strategy _| ¢ Voltage range check Enable Conditions | Ignition on | [Threshold Value | ¢ 4.7 V < Sensor supply voltage < 5.1V. Diagnostic Time | « 0.1 sec. ae a Mit. * Yes circuit Fuel Limit | e Yes + Open in power Fuel Cut @No circuit EGR Off No + Faulty APS |. a + Faully ECM ‘* Engine speed is fixed at 1200 rpm without pedal sensor action, ‘* Engine performance is reduced. Fail safe « Air conditioning system is deactivited as against the vehicle speed and the engine rpm. ‘* Cruise control system inhibited APS ‘Accel pedal position Idle Position (0%) Fully Open Pdsition (100%) Signal votage 06~09V 35-47V APS (0256) ws 7 a ee 1 [ain Terra 2 raps io 2 _ | 0230-1 Terminal 77 2 | APS 1 ground 3 _ | €230-1 Terminal 80 —4 [81 APS 2 power 4 | C230-1 Terminal 78 1 Jo APS 2signas 5 | ©230-1 Terminal 76 ‘ [73 APS 2 ground 8 __| 6230-1 Terminal 79 teonnecrom estes isomer eat en o|=|= Ga ste ‘eB “Ts jHREeie estasece| 100 oP Eg casosFL-103 FUEL SYSTEM SIGNAL'WAVEFORM= | £2A=Fdca = ‘ se 3 nS CH This test should be inspected after depressing the HOLD mode from H run after the sudden acceleration. {As accel pedal is pressed down fly, the intensity ofthe APS 1 & 2 ‘waveform increases individually. APS 1 signal voltage is less than 1V to over 4V and APS 2 is 1/2 voltage as against APS 1 voltage. ‘The waveform pattern become increasing upward rapidly when the tengine speed increases. [> ESR [zon] EME reo] Taco] [ar MONITOR'SCANTOOL DATA™2s702D4_ 1. Ignition "OFF* & Engine "OFF™ 2, Install Scantool and Engine "ON". 3, Monitor Acceleration Position Sensor on Current data. FIG 1 . 1.2 CURRENT DATA % laCcEL. POSITION SENSOR 27.4 [BATTERY VOLTAGE 14.2 Inass AIR FLOU 354 INE.ALR TEMP. SNSR 20.2 \cooLANT TEHP. SENSOR 52.6 JENGINE SPEED 2182 \VEHICLE SPEED SENSOR 8 [scen] [rutt] [parr] [cree Fig 1) Signal increases when depressing accel pedal : Approx. 600 ~900 Mv at idle speed, Is Current data displayed correctly ? > Faults intermittent caused by poor contact in the sensor's andlor ECM's connector or was repaired and ECM mem- cory was rot cleared. Thoroughly check connectors for looseness, poor connection, bending, corrasion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair" procedure. > Go to"WHamess inspection’ procedureDTC TROUBLESHOOTING PROCEDURES FL-104 TERMINAL & CONNECTOR INSPECTION: —Erascsse. wz 4. Many maifunctions in the electrical system are caused by poor hamess and terminals, Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3, Has a problem been found? YES Repair as necessary and go to "Verification of Vehicle Repair” procedure. Go to "Signal Circuit Inspection” procedure. POWER CIRCUIT INSPECTION. EA0ce2s 41. Check for short in harness. 1) Ignition "OFF" 2) Disconnect AP sensor connector. 3) Ignition "ON" & Engine "OFF" 4) Measure voltage between terminal 6 of the sensor harness connector and chassis ground. ‘Specification : 4.7V ~ 5.1V 7 5) Is the measured voltage within specifications ? } Go to "Check for open in hamess" as below. Check for short in the power hamess. Repair as necessary and go to "Verification of Vehicle Repair" procedure,L105 FUEL SYSTEM 2. Check for open in harness 1) 2) 3) 4) Ignition "OFF" Disconnect AP sensor connector and ECM connector Measure resistance between terminal 6 of the sensor harness connector and terminal 78 of ECM hamess co- ‘nector. Specification : Approx. below 1 1. APS 2 Slonal 2.APS 1 Signal 3. APS 2 Power 4. APS 2 Ground 5.APS 1 Ground 6.APS 1 Powor 223041 oe Is the measured voltage within specifications ? . > Go to "Component Inspection" procedure, : } Check for open in the power hamess Repair as necessary and go to "Verification of Vehicle Repair" procedure,FL-106 DTC TROUBLESHOOTING PROCEDURES, COMPONENT INSPECTION” “eox0sHe« 4. Check APS 41) Ignition *OFF* 2) Disconnect APS connector. 3) Check that resistance is getting lower by pressing APS to wide open. 4) Measure resistance between terminal 2 and § of APS connector (Component side). Specification : 1.2kA + 0.4k0 (20°C) 1, APS 2 Signal 2.APS 1 Signal 3. APS 2 Power 4, APS 2 Ground 5.APS 1 Ground 8.APS 1 Power 5) Is the measured resistance within specifications? 3 > Substitute with a known-good ECM and check for proper operation. Ifthe problem is corrected, repiace ECM and then go to "Verification of Vehicle Repair” procedure. > Substitute with a known-good APS and check for proper operation Ifthe probiem is corrected, replace APS and then go to "Verification of Vehicle Repair” procedure. VERIFICATION OF VEHICLE REPAIR = After a repair, itis essential to verify that the fault has been corrected. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" made and then clear DTC. 2. Operate the vehicle within DTC Enable conditions in General information, ‘Are any DTCs present ? Go to the applicable troubleshooting procedure, ‘System is performing to specification at this time.FL-107 FUEL SYSTEM DTC P0123 | THROTTLE/PEDAL POSITION CIRCUIT HIGH INPUT COMPONENT LOCATION | Espsaceo Refer to DTC P0120. DESCRIPTION © eFF2s2Fe GENERAL DESCRIPTION ” Refer to DTC P0120. DTC DETECTING CONDITION: a as DTC Strategy Signal check, high Enable Conditions | « ignition on “Threshold Valve |» Output signal > 4.91V_ Diagnostic Time |» 0.18 sec + Short to battery in il Yes signal circuit FuelLimit | e Yes + Open in ground Fuel Cut No circutt EGR Off #No + Faulty APS. =— + Faulty ECM ‘e Engine speed is fixed at 1200 rpm without pedal sensor action, | « Engine performance is reduced. } Failsafe __| « Airconditioning system is deactvted as against the vehicle speed and the engine rpm. ‘* Cruise control system inhibited. PECIFICATION G0mAseo ECTS Temperature (°C) 20 z 80 Resistance (kQ) 231~2.59 0.31 ~ 0.33 SIGNAL WAVEFORM Refer to DTC P0120 MONITOR SCANTOOL DATA Eveatzio = Refer to DTC P0120,DTC TROUBLESHOOTING PROCEDURES, FL-108, TERMINAL & CONNECTORINSPECTION © «2x73 a Refer to DTC P0120. SIGNAL CIRCUIT INSPECTION =sceies ee 1. Check for short to battery in signal harness 1) Ignition "OFF" 2) Disconnect AP sensor connector. 3) Measure voltage between terminal 2 of the sensor hamess connector and chassis ground. ‘Specification : Approx. below 1V 1.APS 2 Signal 2.APS 1 Signal 3, APS2 Power 4, APS 2 Ground SLAPS 1 Ground 6.APS 1 Power 4) Is the measured resistance within specifications ? YES > Go to" Power Circuit Inspection” procedure. Check for short to battery in harness. Repair as necessary and go to "Verification of Vehicle Repair" procedure.L109 FUEL SYSTEM GROUND CIRCUIT INSPECTION = evs2ac31 2 4, Ignition "OFF" 2. Disconnect AP sensor connector. 3. Measure resistance between terminal 5 of the sensor harness connector and terminal 76 of ECM connector. Specification : Approx. below 12 C25 Ge 1.APS 2 Signal 2.APS 1 Signal 3.APS2 Power 4,APS 2 Ground 5.APS 1 Ground 6.APS 1 Power fe a 230-1 = 4, Is the measured resistance within specifications ? YES > Go to "Component Inspection” procedure, } Check for open in the ground harness. Repair as necessary and go to "Verification of Vehicle Repait” procedure. COMPONENT INSPECTION E0820 Refer to DTC P0120. VERIFICATION OF VEHICLE REPAIR ef Refer to DTC P0120.DTC TROUBLESHOOTING PROCEDURES FL110 DTC P0182 | FUEL TEMP. SENSOR A CIRCUIT LOW INPUT COMPONENT LOCATION _&as38755 ai FTS(Fuel Temperature Sensor) is located in the engine fuel passage from the fuel tank. . It detects the fuel temperature and relays signals to the ECM. Itemploys a thermistor, which is sensitive to changes in the fuel temperature. ‘The electric resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. ‘The power source in the ECM is supplied to the FTS via a resistor in the ECM. itis used during injection control strategies that make corrections depending on the fuel temperature and in order to pr otect the system in event of excessive fuel temperature, {In case of more than FTS 120°C, the engine symptom generates the power loss or poor acceleration. Ifthe signal is below threshold value, the ECM judged this as a fault and DTC is set.FLAN FUEL SYSTEM DTC DETECTING CONDITION «eds: Item Detecting Condition DTC Strategy | Signal check, low | Enable Conditions _| « Ignition on | Threshold Value | ¢ Output signal < 112 mV + Short to ground in Diagnostic Time | « 0.48 sec. cial i No + Faulty FTS | FuelLimit | ¢ No + Faulty ECM | Fuel Cut No EGR Off Yes Fail safe « Engine fuel temperature is fixed at value of 60°C by ECM. SPECIFICATION! = ers?) SSeS [ IATS Temperature (°C) 20 40 ee Resistance (KO) 227 ~278 4.08 ~ 1.28 054 ~065 [Connection information} 7 eee =a + eas 1 | c2a02Terminal2 [Sensor ground Apne 2_[ 230-2 Terminal + FTS signal [CONNECTOR] FTS Harness side connector OM side terminal FTs. 230-2 2304DTC TROUBLESHOOTING PROCEDURES FL112 —_———_—__Ss SIGNAL WAVEFORM Like a ECTS, FTS signals should be smooth and continuous without coarse One any sudden changes. =} When the fuel temperature is cold, FTS output signals increase and when the fuel temperature is hot, FTS output signals decrease. MONITOR'SCANTOOL DATA” Eo7acaes 1. Connect scantoo! to Data Link Cable (DLC) 2. Warm up engine to normal operating temperature. 3. Monitor "Fuel Temperature Sensor” parameter on the scantool. FIG1 . 1.2 CURRENT DATA 7 x [ir.arR TEMP. SNSR 21.6 *C x|cooLANT TEMP. SENSOR 75.5 °C % ENGINE SPEED e2i_rpn * [FUEL PRESSURE 278. 7bar [FUEL PRESS. REGULATOR 16.7 % lecR actuator 5.8 % INLET THROTTLE actu. 5.8 % FIX] [ScRN] [FULL] [Fant] [@RrH] [HELP | Fig 1) Signal decreases with increasing sensor temperature and increases with decreasing sensor temperature Is the Current data displayed correctly ? > Faults intermittent caused by poor contact in the sensor's and/or ECM's connector or was repaired and ECM memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair” procedure. > Go to "WiHarness Inspection” procedure.FL113 FUEL SYSTEM TERMINAL & CONNECTOR INSPECTION —EsroztFs 1. Many maifunctions in the electrical system are caused by poor hamess and terminals, Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3. Has a problem been found? YES past as necessary and go to "Verification of Vehicle Repair” procedure, Go to "Signal Circuit Inspection" procedure. SIGNAL CIRCUIT INSPECTION = Ei7earace 1. Ignition "OFF" 2. Disconnect FT sensor connector. 3. Measure voltage between terminal 2 of the sensor harness connector and chassis ground. Specification : 4.8 ~ 5.1V 0.212 : 1. Sensor ground (ov) 2. Sensor Signal (SV) 7 4. Is the measured voltage within specifications ? > Go to "Component inspectio } Check for short to ground in hamess. Repair as necessary and go to "Verification of Vehicle Repair" procedure " procedure,DTC TROUBLESHOOTING PROCEDURES COMPONENT INSPECTION Ectsscie™ 1. Check Fuel Temperature Sensor 41) Ignition "OFF" 2) Disconnect FTS connector. Measure resistance between terminals 1 and 2 of the FT sensor connector(Component side). 3) SPECIFICATION : Tempore (0) 2m eo Resistance (0) 27-278 ie6-128 = — 1 erage 2. Sensor Signal (6V) (ge 4) Is the measrued resistance within specifications ? : > Substitute with a known-good ECM and check for proper operation, If the problem is corrected, replace ECM and then go to "Verification of Vehicle Repair" procedure, D Substitute with a known-good FTS and check for proper operation. If the problem is corrected, replace FTS and then go to "Verification of Vehicle Repair" procedure. VERIFICATION OF VEHICLE REPAIR= Altera repair itis essential to verify that the fault has been corrected Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. Operate the vehicle within DTC Enable conditions in General information, ‘Are any DTCs present ? YES Go to the applicable troubleshooting procedure. ‘System is performing to specification at this time.FI 15 FUEL SYSTEM [DTC P0183 | FUEL TEMPERATURE SENSOR - HIGH INPUT COMPONENT LOCATION casceaza = Refer to DTC P0182, DESCRIPTION = extssie== GENERAL DESCRIPTION Refer to DTC Pote2. Ss Ifthe signal is above threshold value, the ECM judged this as a fault and DTC is set, DTC DETECTING CONDITION — E07e87#) item Detecting Condition "Possible Gauss DTC Strategy |» Signal check igh Enable Conditons | ignition on Threshold Value | ¢ Output signal > 4.9V_ + Short to ground in eee emen| signal cet __Diagnostic Time | « 0.48 e + Opeft in ground MIL No circuit Fuel Limit No "Pauly FTS FuelGut | 6No + Faulty ECM EGROH |e Yes | Fail safe « Engine fuel temperature is fixed at value of 60°C by ECM. a: SPECIFICATION | ecscaind = = { ats a [Temperature (0) 20 ~ 8 l Resistance (KO) 227~273 1.08 ~ 1.28 0.54 ~ 0.65 SCHEMATIC DIAGRAM “Erocsses Refer to DTC P0182, SIGNAL WAVEFORM — @aXccasb Refer to DTC P0182,DTC TROUBLESHOOTING PROCEDURES FL116 MONITOR SCANTOOL DATA =sFezscs = Refer to DTC P0182. 4. Ignition "OFF" 2. Disconnect FT sensor connector. 3. Measure voltage between terminal 2 of the sensor harness connector and chassis ground. Specification : 4.8 ~ 5.1V C212 4. Sensor ground (ov) 2. Sensor Signal (5V) 4, Is the measured voltage within specifications 7 Go to "Component inspection’ procedure. } Check for short to ground in hamess. Repair as necessary and go to "Verification of Vehicle Repair" procedureFLAN7, FUEL SYSTEM GROUND CIRCUIT INSPECTION = =s2FeA55 sae = 4. Ignition “OFF. Disconnect FT sensor connector and ECM connector. Measure resistance between terminal 1 of the sensor hanes connector and terminal 2 of ECM harness connecto- r O22 1. Sangor ground (OV) 21 Sensor Signal (6V) a caa0.2 4, Is the measured resistance within specifications 7 as > Go to "Component Inspection” procedure. > Check for open in harness, Repair as necessary and go to "Verification of Vehicle Repair" procedure COMPONENT INSPECTION _ cresr7 Refer to DTC P0182. VERIFICATION OF VEHICLE REPAIR: 4 Refer to DTC P0182DTC TROUBLESHOOTING PROCEDURES FL118 DTC P0190 | FUEL RAIL PRESSURE SENSOR CIRCUIT COMPONENT LOCATION =o740e0 RPS (Rail Pressure Sensor) used to transmit to the ECM the pressure value for the rail. The rail is & high pressure accumulator. In order to output a voltage signal to the ECM which is directly proportional to the applied pressure, the rail pressure sensor must measure the instaneous pressure in the rail ‘The fuel flows to the rail pressure sensor through opening in the rail, the end of which is sealed off by the sensor diaphram, Pressurized fuel reaches the sensors diaphram through a blind hole. ‘The sensor element (semi conductor device) for convertering the pressure to an electric signal is mounted on this diaphram, ‘The signal generated by the sensor is inputted to an evaluation circuit which amplifies the measuring signal and sends itto the ECM, This value is used in calculating the flow and injection advance. In case of RPS failure, the engine symptoms will occur the running engine stall and the starting impossible. If the signal exceeds threshold value, the ECM judged this as a fault and DTC is set.FL119 FUEL SYSTEM DTC/DETECTING CONDITION: = essesece Item Detecting Condition il Possible Cause DTC Stategy | Voltage range check |_ Enable Conditions | * Engine run : Threshold Value | « 4.7 V < Sensor supply voltage < 5.1V LD Diagnostic Time |e O.1sec power circuit MIL Yes / + Short to battery in Fuel Limit Yes oc Fuel Cut No Cian EGR Off No » Putt BoM : ‘ Rall pressure is fixed at value of 400 bar by ECM. Fail safe '* Engine shut down « Starting impossible RPS Engine idle state ——+(| Fully acceleration (100%) z Rall Pressure 220 ~ 320 bar (22 ~ 32 Mpa) 1800 bar (180 Mpa) [ ‘Signal Voltage Below 1.7 V Approx. 4.5 V saps sence cox {Connection information] e209 cza0-2 1 | c2s02Termnai9 | APS powor a 8 Serorpoer 2 [6230.2 Terminal 10| PS signal 2 10 Sensor signal z 3 APS gourd ba 1 Sosor ues [CONNECTOR] FPS Hamess side comecior ECM side teminal Rai presure sensor cae aDTC TROUBLESHOOTING PROCEDURES, FL-120 SIGNAL WAVEFORM © ccisroic 4.2 U DE: 420.08nS FRED: Fall acceleration 2.38 He This test should be inspected after depressing the HOLD mode from run after the sudden acceleration. PS signal voltage is less than 1V to over 4.5V “The waveform pattern become increasing upward rapidly when the ‘engine speed increases. Icio state MONITOR SCANTOOL DATA 4. Connect scantool to Data Link Cable (DLC). 2. Warm up engine to normal operating temperature, 3. Monitor "Fuel Pressure Sensor" parameter on the scantool FIG4 : 1.2 CURRENT paTA %|PUEL PRESS. REGULATOR 16.7 % INT. AIR TEMP. SNS wate | |ACCEL. POSITION SENSOR 8.8 % IACCEL. POSITION SENSOR 713. 6n lCOOLANT TENP. SENSOR 78.8 °C [ENGINE SPEED 751 rpn VEHICLE SPEED SENSOR @ —Kn/h v [FIX | [ScRN) [FULL] [PART] [GRPH) [HELP| Fig 1) Normal value at idle speed Is the Current data displayed correctly ? YES Fault is intermittent caused by poor contact in the sensor's and/or ECM’s connector or was repaired and ECM memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair" procedure. > Goto "WiHamess Inspection” procedure.FL121 FUEL SYSTEM TERMINAL & CONNECTOR INSPECTION © =4é2350 1. Many malfunctions in the electrical system are caused by poor hamess and terminals Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3. Has a problem been found? YES Repair as necessary and go to "Verification Vehicle Repair” procedure. Go to "Power Circuit Inspection” procedure. POWER CIRCUIT INSPECTION 1. Check for short in hamess 41) Ignition "OFF" 2) Disconnect FT sensor connector 3) Ignition "ON" & Engine "OFF" 4) Measure voltage between terminal 1 of the sensor harness connector and chassis ground Specification : 5V 1. Sensor Power (5¥) 2. Sensor Signal (€.8¥) 3. Sensor Ground (OV), 5) _Is the measured voltage within specifications ? } Go to "Ground Circuit Inspection” procedure } Check for short to battery in harness. Repair as necessary and go to "Verification vehicle Repair" procedu- te 2. Check for open in harness 1). Ignition "OFF" 2). Disconnect FT sensor connectorDTC TROUBLESHOOTING PROCEDURES FL122 3) Measure resistance between terminal 1 of the sensor harness connector and terminal 9 of ECM hamess connector, Specification : Approx. below 10 41. Sensor Power (SV) 2. Sensor Signal (4.8V) = ‘8. Sensor Ground (OV) 2202 4. Visual inspection 1) Check installation torque and leakage around Fuel Rail Pressure Sensor. 2) Check for damaged hamess and terminals: contact resistance, oxidation, bent or broken terminals. 3) Check deform or crack on Fuel Rail Pressure Sensor. Installation Torque : 35 + 2 Nm 4) Isthe Fuel Rall Pressure sensor visually O.K ? YES > Substitute with @ known-good ECM and check for proper operation, Ifthe problem is corrected, replace ECM and then go to "Verification of Vehicle Repair” procedure. > Substitute with a known-good Fuel Rail Pressure Sensor and check for proper operation. If the problem is corrected, replace Fuel Rail Pressure Sensor and then go to "Verification of Vehicle Repair" procedure. VERIFICATION OF VEHICLE REPAIR After a repair, its essential to verify that the fault has been corrected 4. Connect scan tool and select “Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. 2, Operate the vehicle within DTC Enable conditions in General information, 3. Are any DTCs present ? Goto the applicable troubleshooting procedure System is performing to specification at this time.23, FUEL SYSTEM DTC P0192 | FUEL RAIL PRESSURE SENSOR - LOW INPUT COMPONENT LOCATION 3087040 Refer to DTC P0190 DESCRIPTION ceases, GENERAL DESCRIPTIOI = Refer to DTC P0190. DIC:DESCRIPTION ~ aS a Ifthe signal is below threshold value, the ECM judged this as a fault and DTC is set. { Item Detecting Condition Possible Cause DTC Strategy __| © Signal check, low = Enable Conditions | ¢ Engine run Threshold Value | e Output signal < 180.8 mV Diagnostic Time | « 0.18 sec. + Short to ground in ae over signal circuit uel Limi ° Yes + Faulty RPS fuel i . “ + Faulty ECM EGR ® No « Rall pressure is fixed at value of 400 bar by ECM. Fail safe Engine shut down « Starting impossible SS SPECIFICATION © RPS Engine idle state Fully acceleration (100%) Rail Pressure 220 ~ 320 bar (22 ~ 32 Mpa) 1500 bar (150 Mpa) | Signal Voltage Below 1.7 V ‘Approx. 4.5V ‘SCHEMATIC DIAGRAM ™ “EEE: Refer to OTC O10 SIGNAL WAVEFORM = =6969873 Refer to DTC P0190.DTC TROUBLESHOOTING PROCEDURES Refer to DTC P0190, Ignition "OFF" Disconnect FT sensor connector. Ignition "ON" & Engine "OFF" Measure voltage between terminal 2 of the sensor harness connector and chassis ground. Aenea Specification : 4.8 ~ 5.1V 4. Sensor Power (6V) 2. Sensor Sigal (4:8¥) 43. Sensor Ground (OV) 5. Is the measured voltage within specifications 7 > Go to “Component Inspection” procedure. Check for short to ground in signal hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure. Refer to DTC P0190. ERIFICATION OF VEHICLE REPAIR © Refer to DTC P0190.FL125 FUEL SYSTEM [DTC P0193 | FUEL RAIL PRESSURE SENSOR - HIGH INPUT COMPONENT LOCATION ~ cessicis Refer to DTC P0190. DESCRI Refer to DTC P0190 iene Soe Item = Detecting Condition Possible Cause __DTC Strategy | « Signal check, high le Conditions| « Engine run Threshold Value | » Output signal > 4.8 V Diagnostic Time | « 0.18 sec. + Short to ground in| signal circuit ML ses + Open in signal Fuel Limit hamess Fuel Cut Faulty RPS EGR Off + Faulty ECM Ee fixed at value of 400 bar by ECM. | Fail safe « Engine shut down | « Starting impossible aes RPS | Engine idle state Full acceleration (100%) Rail Pressure 220 ~ 320 bar 22 ~ 82 Mpa) 4500 bar (150 Mpa) Signal Voltage Below 17V = Approx. 45 V Refer to DTC P0190. SIGNAL WAVEFORM © Check for short to battery in harness. Repair as necessary and go to "Verification of Vehicle Repair® procedure.FL-127, FUEL SYSTEM 2. Check for open in harness 41). Ignition *OFF” 2). Disconnect FT sensor connector. 3) Measure resistance between terminal 2 of the sensor harness connector and terminal 10 of ECM hamess connector. ‘Specification : Approx.below 10 <0-208 1. Sensor Power (SV) 2, Sensor Signal (4.8V) 8, Sensor Ground (OV) 4) Is the measured resistance within specifications ? . > Go to "Component Inspection” procedure. . NO > Check for open in hamess. Repair as necessary and go to Verification of Vehicle Repair’ procedure. Refer to DTC P0190, VERIFICATION OF VE Refer to DTC P0190.DTC TROUBLESHOOTING PROCEDURES FL-128 DTC P0220 | ACCELERATOR POSITION SENSOR 2 CIRCUIT ‘APS(Acceleration Position Sensor) is measured the driver's acceleration using a potentiometer artd APS signal is tran- smitted to the ECM. The peda''s position is calculated from the voltage of potentiometer in the APS. The absence of a mechanical link between the accelertor pedal and injection system presents a risk of loss of control of the engine in the event of a failure of the component in the charge of providing the driver's request information to the injection system, ‘Therefore, APS has the two potentiometers whose slides are mechanically solid. APS 2 is for plausibility of load request signal and decide whether or not APS 1 & 2 is malfunctioning. If the signal exceeds threshold value, the ECM judged this as a fault and DTC is set.FUEL SYSTEM Possible Cause Item Detecting Condition DTC Strategy Voltage range check Enable Conditions |e Engine run Threshold Value | « 4.7 V < Sensor supply voltage < 5.1V Diagnostic Time | ¢ 0.1 sec. + Short to ground in | Mi Yes ower circuit Fuel Limit © Yes | + Short to battery in Fuel Cut No | pew souk . pen in power EGR Off No _| creat ‘* Engine speed is fixed at 1200 rpm without accel pedal sensor ]* Faulty APS 2 action + Faulty ECM j | « Engine performance is reduced Fail safe oem « Air conditioning system is deactivted as against the vehicle speed and the engine rpm © Cruise control system inhibited 358. SEE ‘APS ‘Accel pedal position Idle Position (0%) Fully acceleration (100%) [Signalvotage 02~05V 16-25V SCHEMATIC DI 222 Sees Se i rot [Connection Information} S]es6 _ eS hs one 1 [220-1 Terminal 76] APS ground ab rr ars nore 2 [6200 Terminal 77 | APS sonal [u fe 428 goin 2 [620-1 Tominal 76 | APS 1 power co qd i ash “4 [(€230-1 Terminal79 | __APS 2 ground Ay bee 5 [0200-1 Terminal | —_APS-2 etna @_|c200-1 Terminal81 | APS 2power CONNECTOR] [APS Hammess side connector ECM side terminal | | eee q Elele ae Seeiesterast + APS 2002 cza04DTC TROUBLESHOOTING PROCEDURES, SIGNAL WAVEFORM © «sa7sran ‘530, G6nS GHB! 2.2 Y Thistest should be inspected after depressing the HOLD mods from run after the sudden acceleration. ‘As accel padal is pressed down fully the intensity of the APS 1 & 2 wavelorm increases individually ‘APS 1 signal voltage is less than 1V to over 4V and APS 2 is 1/2 vottage as against APS 1 voltage. ‘The waveform pattern become increasing upward rapidly when the engine speed increases. MONITOR 'SCANTOOL DATA 4, Connect scantool to Data Link Cable (DLC) 2. Warm up engine to normal operating temperature. 3. Monitor "Acceleration Position Sensor" parameter on the scantool. FIG 4 . 1.2 CURRENT DATA x |ACCEL.POSITION SENSOR INT ATR TEMP. SNSR lcooLaNT TEMP. IENGINE SPEED VEHICLE SPEED SENSOR Fig 1) Signal increases when depressing accel pedal. Is the Current data displayed correctly ? Faults intermittent caused by poor contact in the sensor's and/or ECM's connector or was repaired and ECM memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair" procedure. > Go to"WiHamess Inspection" procedureFL131 FUEL SYSTEM TERMINAL & CONNECTOR INSPECTION = =8425c0¢. eee eee 4. Many malfunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2, Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3, Has a problem been found? YES Repair as necessary and go to "Verification of Vehicle Repair” procedure. Go to "Power Circuit Inspection” procedure. 4. Check for short in hares 41) Ignition "OFF" 2) Disconnect FT sensor connector. 3) Ignition "ON" & Engine "OFF". 4) Measure voltage between terminal 3 of the sensor hamess connector and chassis ground, Specification :48~5.1V_ C256» 1. APS 2 Signal 3 2.APS 1 Signal 3.APS 2 Power kayeye APS 2 Ground '5.APS 1 Ground 6. APS 1 Power 5) Is the measured voltage within specifications 7 > Go to "Check for open in hamess" procedure Check for short to in harness. Repair as necessary and go to "Verification of Vehicle Repair" procedure.DTC TROUBLESHOOTING PROCEDURES FL132 ———————— 2. Check for open in harness 1) Ignition "OFF". 2) Disconnect FT sensor connector. 3) Measure resistance between terminal 3 of the sensor hamess connector and terminal 81 of ECM hamess co- nector. Specification : Approx below 10. 1. APS 2 Signal 2. APS 1 Signal 3.APS 2 Power 4-APS 2 Ground 5.APS 1 Ground 5.APS 1 Power 220.1 4) Is the measured resistance within specifications 7 Mi > Go to "Component inspection" procedure : > Check for open in harness. Repair as necessary and go to "Verfcation of Vehicle Repair” procedure ‘COMPONENT INSPECTION - 4. Check APS 4) Ignition "OFF 2). Disconnect APS connector. 3) Measure resistance between terminals 3 and 6 of the sensor connector(to IAT sensor side) Specification : 1.7kQ # 0.8k0 (20°C) 4) Is the measured resistance within specifications 7 > Substitute with a known-good ECM and check for proper operation. Ifthe problem is corrected, replace ECM and then go to "Verification of Vehicle Repair" procedure. > Substitute with a known-good APS2 and check for proper operation. If the problem is corrected, replace APS2 and then go to "Verification of Vehicle Repair" procedure.FL133 FUEL SYSTEM VERIFICATION OF VEHICLE REPAIR — «sareceo. on i After @ repair, itis essential to verify that the fault has been corrected. 4. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. 2. Operate the vehicle within DTC Enable conditions in General information. 3. Are any DTCs present ? ey Go to the applicable troubleshooting procedure, ‘System is performing to specification at this time,DTC TROUBLESHOOTING PROCEDURES, FL134 DTC P0223 | ACCELERATION POSITION SENSOR 2 - HIGH INPUT Refer to DTC P0220, Item I Detecting Condition Possible Cause DTC Strategy _| e Signal check, high z Enable Condtions | lgnion on Threshold Vale |» Ouput signal > 2468 Diagnostic Time _ | # 0.18 sec. + Short to battery in | ML «Yes signal circuit Fuel Limit *Yes + Open in signal Fuel Cut No circuit aa oe + Open in ground . circuit ‘» Engine speed is fixed at 1200 rpm without accel pedal sensor + Faulty APS 2 | action, + Faulty ECM * Engine performance is reduced Fail safe ® Air conditioning system is deactivited as against the vehicle speed | and the engine rpm, ‘* Cruise control system inhibited | =e prepay ae SSS Rae Steg 3 a eae. ] ‘Accel pedal position Idle Position (0%) Fully acceleration (100%) Signal votage : 02~05V 16~25V _| ‘SCHEMATIC DIAGRAM = ctssec!? = = = Refer to DTC P0220 SIGNAL WAVEFORM © éhiseabe 7 Refer to DTC P0220.FL135 FUEL SYSTEM MONITOR SCANTOOL DATA © vercr25 ee Refer to DTC P0220, TERMINAL & CONNECTOR INSPECTION EOABEDES © Refer to DTC P0220 SIGNAL CIRCUITINSPECTION — raisscer 4. Check for short to battery in harness 41) Ignition “OFF” 2) Disconnect AP sensor connector. 3). Ignition "ON" & Engine "OFF" 4) Measure voltage between terminal 1 of the sensor hamess connector and chassis ground Specification : 4.8 ~5.1V 1. APS 2 Signal 2.APS 1 Signal Ae 3, APS2 Power 44, APS 2 Ground 5.APS 1 Ground . SLAPS 1 Power 5) Is the measured voltage within specifications ? Go to "Check for open in harness" as below. Oe > ‘check or short to battery n hamess,Repairas necessary and goto "Vercaton of Veni Repair proce- 2, Check for open in harness 4) Ignition “OFF* 2) Disconnect AP sensor connectorDTC TROUBLESHOOTING PROCEDURES FL-136 tance between terminal 4 of the sensor hamess connector and terminal 80 of ECM harness co- Specification : Approx below 10 1. APS 2 Signal 2. APS 1 Signal 3. APS 2 Power 4 APS 2 Ground 5.APS 1 Ground 6.APS 1 Power 2304 4) Is the measured resistance within specifications ? YES } Go to "Ground Circuit Inspection” procedure. 5) > Check for open in harness. Repair as necessary and go to "Verification of Vehicle Repair” procedure. ap GROUND CIRCUIT INSPECTION © Ecirich 4. Ignition "OFF" 2. Disconnect AP sensor connector. 3, Measure resistance between terminal 4 of the sensor harness connector and terminal 79 of ECM hamess connecto- f Specification : Approx.below 12 4. APS2 Signal 2.APS 1 Signal 8.APS 2 Powor 44.APS 2 Ground SLAPS 1 Ground © 8.APS 1 Powor 230-1 et | 4, Is the measured resistance within specifications ? > Go to "Component Inspection" procedure. > Check for open in hamess. Repair as necessary and go to "Verification of Vehicle Repair" procedureFL-137 FUEL SYSTEM Refer to DTC P0220.DTC TROUBLESHOOTING PROCEDURES, FL138 DTC P0231 | ELECTRIC FUEL PUMP CIRCUIT LOW The voltage after the fuel pump relay is used to supply power to the electric fuel pump in the low ptessure line. ‘When the ignition switch isin starting position, the battery voltage is supplied from the fuel pump relay to the ECM. ‘When the ignition switch is turned on, current flows from the ignition switch through the current the fuel pump relay coil to ground by the ECM. And then, the voltage is supplied to the electric fuel pump to drive. In case of the fuel pump relay failure, the engine symptoms will occur the running engine stall and the starting impossible. tem Dateclng Condon Possible Cause re statesy | « Circuit contin check + contact resistance | in connectors eee eee eee —$_$__ + Open in power Ehable Conditions |= Ignitonon |e Threshol Vale | + Open or sto Tor rly conval creu scent Diagnostic Time | » 0.48 see Stel reat we ae + Fuse blown ucllint | 2N ~ Fay iy acu |3Ne EGR Off NoFUEL SYSTEM SCHEMATIC DIAGRAM © ==acbstc sr ime {Connection information) Petey + | eveTernnares | Aaley power a Z| Temina 3 [Ful pu pover op oben male Sea 3 | 200-1 Terminal 2 | Fu pun ea ol + : : _ & [ve Temnal 108 | Ray cope {connec Fuel pump relay Harness side connector ECM side terminal | 2 | ES [ fetetetetatfolr ft aledepderststal| | * sla ale =]*[= C apt 2302 c2a0 Fuel pump relay 1.4 ACTUATION TEST” FUEL PUNE. ‘DURATION [UNTIL STOP KEY ieTHOD _[ACTIUATION ‘CONDITION |G. KEY ON [ENGINE OFF PRESS (STRTJ, IF YOU ARE READY * ‘SELECT TEST ITEM USING UP/DOWN KEY SJ [nano] [Reco] [nenu] [Sra] [stor] This test should be inspected after depressing the HOLD mode after turning the ignition switch ON and OFF several times. When the ground is connected to the terminal 24/C230-1 by the ECM the battery voltage is supplied to the electric fuel pump through the relay terminal 2. Battery voltage is applied to the electrical fuel pump for approx. 3 seconds when the ignition switch is turned on and fuel delivery noise can be heard, For checking the wire and the fuel pump relay with fuse fo the fuel purnp, the START key ‘should be pressed in the scan too! actuation test mode. {And then make sure thatthe relay “click” noise could be heard with the change of the fuel pump pressure. ‘Also, the fuel pressure should be increased above 3.5 bar when turning the ignition switch ON.DTC TROUBLESHOOTING PROCEDURES FL-140 MONITOR SCANTOOL DATA = ©7s8be3 1. Connect scantool to Data Link Cable (DLC), 2. Monitor" Fuel Pump Relay " parameter on the scantool. FIG1 1.2 CURRENT DATA Z FUEL PUMP RELAY on IDOosTER U-OPERAT'G INT 0.6 ¥ |g INILCENGINE CHECK> on lotow RELAY on FUEL quantity 26 nee lren-Lou SPEED orF lren-HIGH SPEED orF bd Fix | [SoRn] [FULL] [Pant] [@ara] [ECP Fig 1) Fuel pump relay ON for approx. 3 seconds when turning the ignition switch ON. Is the Current data displayed correctly ? YES Fault is intermittent caused by poor contact in the sensor's and/or ECM's connector or was repaire and ECM. memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair" procedure. I} > Go to "WiHamess Inspection” procedure. ‘TERMINAL & CONNECTOR INSPECTION ~ 4, Many matfunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3. Has a problem been found? YES Repair as necessary and go to "Verification of Vehicle Repair” procedure. Go to "Power Circuit Inspection" procedure.FL-141 FUEL SYSTEM Sees Ignition “OFF” Disconnect Fuel Pump Relay. Ignition “ON* & Engine "OFF" Measure voltage between terminal 5 of the Fuel Pump Relay harness connector and chassis ground, Rene Specification : 8+ Check for open in power harness. Repair as necessary and go to "Verification of Vehicle Repair” procedure. 1. Check for short to ground in harness 1) Ignition "OFF" 2) Disconnect Fuel Pump Relay and ECM connector.DTC TROUBLESHOOTING PROCEDURES, FL142 3) Measure resistance between terminal 3 of the Fuel Pump Relay harness connector and Chassis ground. Specification : Infinite a 1. From B+ 7 2. Fuel Pump S.ToECM = 5. From B+ ve 4) Is the measured resistance within specifications 7 YES Go to "Check for open in control harness" as below. NO > Check for short to ground in control hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure 2. Check for open in control harness 4) Ignition “OFF. 2) Disconnect Fuel Pump Relay and ECM connector. 3) Measure resistance between terminal 3 of the Fuel Pump Relay hamess connector and terminal 24 of ECM hamess connector. ‘Specification : Approx.below 10 E16 = ne e 5. From B+ ‘ft @ cf 4) Is the measured resistance within specifications ? > Go to "Component Inspection” procedure, > Check for open in control hamess, Repair as necessary and go to “Verification of Vehicle Repair’ procedu- reL143 FUEL SYSTEM COMPONENT INSPECTION — =sce9042 Es 4. Check Fuel Pump Relay 1) 2) 3) 4) Ignition "OFF" & Engine "OFF" Disconnect Fuel Pump Relay Measure resistance between terminals 3 and § of the Fuel Pump Relay connector (Component side), Specification : 90 ~ 1000 (20°C) 1.From B+ = 2. Fuel Pump | BRECM |= 5. From B+ Jena 5] { Is the measured resistance within specifications ? : YES > Go to "Check Electric Fuel Pump Relay "as below. > Substitute with a known-good Electric Fuel Pump Relay and check for proper operation. Ifthe problem is corrected, replace Electric Fuel Pump Relay and then go to "Verification of Vehicle Repair" procedure. 2. Check Electric Feul Pump Relay operation 1) 2) 3) 4) 5) Ignition "OFF" & Engine "OFF". Connect Fuel Pump relay and Disconnect ECM connector. Ignition "ON" & Engine "OFF". Ground terminal 24 of ECM harness connector to operate Fuel Pump Relay. Or, Use Actuator Test mode in scantool to operate Electric Fuel Pump Relay. Is the Fuel Pump Relay operating corretly ? } Go to "Check Fuel Pump Power Circuit’ as below: > Substitute with a known-good Fuel Pump Relay and check for proper operation. Ifthe problem is corrected, replace Fuel Pump Relay and then go to "Verification of Vehicle Repair” procedur- eDTC TROUBLESHOOTING PROCEDURES. FL-144 3, Check Electric Feul Pump Power Circuit 41) Ignition "OFF" & Engine “OFF”. 2) Disconnect Fuel Pump relay. 3) Jump terminal 2 and 4 of Fue! Pump Relay harness connector with jumper wire. 1. From B+ 2 Fuel Pump TR ECM 5. From 84. 4) 1s operating sound of the Fuel Pump heard ? us Substitute with a known-good Fuel Pump Relay and check for proper operation If the problem is corrected, replace Fuel Pump Relay and then go to Verification of Vehicle Repair" procedur- e. > Substitute with a known-good ECM and check for proper operation. Ifthe problem is comected, replace ECM and then go to "Verification of Vehicle Repair” procedure. VERIFICATION OF VEHICLE R After a repair, itis essential to verity that the fault has been corrected. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. 2. Operate the vehicle within DTC Enable conditions in General information. 3. Are any DTCs present ? Go to the applicable troubleshooting procedure. ‘System is performing to specification at this time,L145 2 FUEL SYSTEM [DTC P0232 | ELECTRIC FUEL PUMP RELAY - SHORT CIRCUIT [ Item Detecting Condition Possible Cause DTC Strategy _| » Circuit continuity check Enable Conditions | « Ignition on + Contact resistance Threshold Value _ | « Short for relay control circuit tn connectors (aie ahicid + Short to battery in Diagnostic Time | « 0.48 sec. relay control circuit iL @No + Fuse blown Fuel Limit | ¢ No + Faull relay Fuel Cut #No + Faulty ECM EGR Off #No Refer to DTC P0231 TERMINAL & CONNECTOR INSPECTION Refer to DTC P0231.DTC TROUBLESHOOTING PROCEDURES, CONTROL CIRCUIT INSPECTION © «097678 Ignition "OFF" Disconnect Fuel Pump Relay and ECM connector, Igniton "ON" & Engine "OFF". Measure voltage between terminal 3 of the fuel pump relay hamess connector and chassis ground. Specification : Approx. below 1V <1 1.From Be eae 2.Fuel Pump aToccw = S.rom Be z kh P| 5, Is the measured voltage within specifications 7 eS 5 Go to "Component inspection” procedure. Check for short to battery in control hamess. Repair as necessary and go to "Verification of Vehicle Repair" procedure. (COMPONENT INSPECTI Refer to DTC P0231. (VERIFICATION OF VEHICLE REPAIR Refer to DTC P0231F147 FUEL SYSTEM DTC P0261 | CYLINDER1-INJECTOR CIRCUIT LOW ‘Special injectors with hydraulic servo-system and electical triggering element (solenoid valve) are used'with the common rail system in order to achieve efficient start of injection and precise injected fuel quantity Metering and spray preparation of the diesel fuel, as needed by the engine according to the engine map, Realization Of pilot and main injection and post injection if required. Pllot injection is used to reduce the engine noise and vibration and post injection is used to reduce the NO and NOX in the exhaust ges, Control of injected quantity and injection timing based on the system pressure and enerizing time as actuated by the ECM. The injected fuel quantity is now defined by the injector opening time and rail pressure Injection is terminated when the solenoid valve is no longer triggered and closes as a result In case of more than 2 injectors failure, the engine symptoms will occur the running engine stall and the starting impossible, DTC DESCRIPTION SSeS Ss If the signal exceeds threshold value, the ECM judged this as a fault and DTC is set.DTC TROUBLESHOOTING PROCEDURES, [ Item Detecting Condition Possible Cause DTC Strategy __| e Circuit continuity check Enable Conditions | ¢ Engine run « Overcurrent low side connection: Injector current increases the | * Shortt battery in Threshold Value : tidy ue of 29.5 A~34 A power circu | maximum value power cout [Diagnostic Time |e 0.3 sec. control circuit | + Faulty injector MIL © Yes : Fuel Limit # Yes |+ Fauity EOM | Fuel Cut No | EGR Off No ee [Connection Information} = ES omocttl =r fea ood ois = Samo +, [.6200-2 Terminal 38 | __Iniectoriow side 2 | c230-2 Terminal 36 | injector igh sige [CONNECTOR] Injector Harness side connector ECM side terminal Injector connector 230-2 230-1FL, 149 FUEL SYSTEM SIGNAL WAVEFORM — «ssarao ov wu Inectorboostr cpering watope injector High sice ae Injector booster ‘operating voltage Injector iv En wae [AESIR [zoon]| [ours] [reno] [weco] [reno] | ‘This test should be inspected after depressing the HOLD mode while idling. At first, the waveform observation points is height of injector coil induced voltage (booster voltage) In second place, the injector drive time willbe checked at the high side. ‘When the engine speed is suddenly raced the injector drive time extended at frst, but the drive time will soon match the engine speed MONITOR SCANTOOL DATA © e |FUEL PRESSURE 276. Bhar %|FUEL PRESS. REGULATOR 16.5 % * » |PUEL QUANTITY 8 nec |, ACCEL. POSITION SENSOR 718.5nU COOLANT TEMP. SENSOR 3.9 °C [ENGINE SPEED ‘752 rp r [rrx_] [scan] [ruc] [Parr] [eres] [HELP| Fig 1) Normal value with injector booster operating voltage (above 70V)DTC TROUBLESHOOTING PROCEDURES FL-150 Is the Current data displayed correctly 7 5 Fault is intermittent caused by poor contact in the sensor's and/or ECM's connector or was repaired and ECM memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair" procedure, > Go to ‘WiHamess Inspection" TERMINAL & CONNECTOR INSPECTION” rocedure, 4. Many malfunctions in the electrical system are caused by poor hamess and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3, Has a problem been found? YES Repair as necessary and go to "Verification of Vehicle Repair” procedure. Go to" Power Circult Inspection" procedure : POWER CIRCUIT INSPECTION 1. Injector Control (Low Sida) 2, Injector Power 1 (high Sie)51 FUEL SYSTEM 5. Is the measured voltage within specifications ? > Goto "Control Circuit inspection" procedure. } Check for short to battery in the power hamess. Repair as necessary and go to "Verification of Vehicle Repair’ procedure. CONTROL CIRCUIT INSPECTION — eecced24 Ignition "OFF". Disconnect Injector connector. Ignition "ON" and Engine "OFF". Measure voltage between terminal 1 of the injector harness connector and chassis ground. Specification : Approx. below 1V. C271 1. Injector Contot (Low Side) 2, Injector Power (igh Sido) 5. Is the measured voltage within specifications ? > Got D> Check for short to battery in hares. Repair as necessary and go to "Verification of Vehicle Repair" procedure, ‘Component Inspection’ procedure.DTC TROUBLESHOOTING PROCEDURES ‘COMPONENT INSPECTION eosie188 4. Ignition “OFF” 2. Disconnect Injector connector. 3._ Measure resistance between terminal 1 and 2 of injector connector (Component side) Spetification : 0.3656 5(20°C) C2071 1. Injector Control (Low Side) 2. Injector Power (High Side) 4, Is the measured resistance within specifications ? YES > Substitute with a known-good ECM and check for proper operation Ifthe problem is corrected, replace ECM and then go to "Verification of Vehicle Repair” procedure." Check injector for deterioration, or damage. ‘Substitute with a known-good injector and check for proper operation. Ifthe problem is corrected, replace injector and then go to "Verification of Vehicle Repair" procedure. NOTE Before replacing injector, be sure that grade mark(X, Y,Z) should be satisfied with combination as below. ‘Grade eo) ave ae Remark 1 o | 4 ° 2 1 3 0 | satity with 3 0 3 + _| the number of Grades 4 oleae 0 5 o 2 2 Grade MarkFL-153 FUEL SYSTEM VERIFICATION OF VEHICLE REPAIR £05634 Sees After a repair, itis essential to verity that the fault has been corrected. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. (Operate the vehicle within DTC Enable conditions in General information. ‘Are any DTCs present ? YES Go to the applicable troubleshooting procedure. ‘System is performing to specification at this time,DTC TROUBLESHOOTING PROCEDURES, DTC P0262 | CYLINDER1-INJECTOR CIRCUIT HIGH Refer to DTC P0261 DESCRIPTION — GENERAL DESCRIPTION 0 Refer to DTC Po261 [DTS PERORIETIONG YS a It the signal exceeds threshold value, the ECM judged this as a fault and DTC is set, essibe Cause. DTC Strategy | Circuit continuity check Enable Conditions | e Engine run ‘* Overcurrent high side connection : Injector current increases the Threshold Value | maximum value of 28 A~36 A + Short to battery in ae = potver circuit Diagnostic Time Faulty injector rE a + Faulty ECM | FuelLimit | « Yes FuelCut | eNo EGROF | eNo Refer to DTC P0261 MONITOR SCANTOOL DATA = ccadeieo Refer to DTC P0261 TERMINAL & CONNECTOR INSPECTION = Eo1z08-7 a Refer to DTC P0261FUEL SYSTEM POWER CIRCUIT INSPECTION” “:0rbé00" 4. Ignition "OFF" 2. Disconnect injector connector. 3. Ignition "ON" & Engine “ON” 4. Measure voltage between terminal 2 of the #1 injector and chassis ground. Specification : B+ C23» 1. injactor Control (ow side) 2. Injector Powor (igh Sie) 5, Is the measured voltage within specifications ? 73 >. Goto "Component Inspection” procedure. > Check for short to battery in the power hamess, Repair as necessary and go to "Verification of Vehicle Repair" procedure. ‘COMPONENT INSPECTION ~ €ies8co5 Refer to DTC P0261. VERIFICATIC Refer to DTC P0261DTC TROUBLESHOOTING PROCEDURES FL-156 DTC P0263 | CYL-1 INJECTOR CIRCUIT BALANCE (LOAD DROP IS DETECTED) Refer to DTC P0261 DESCRIPTION. «oie Refer to DTC P0261. Ifthe signal is below threshold value, the ECM judged this as a fault and DTC is set. Item Detecting Condition DTC Strategy | « Circuit continuity check Enable Conditions _| « Engine run + Open in power '* Load drop error : load drop is detected if during energizing the cipcuit minimum currentimin = 3A is not reached ‘Short to ground in Threshold Value |» Fast current decrease error : a fixed time after the energizing | control circuit period the current has to decrease below/min = 3A + Open in control a a a re egy | Diagnostic Time | « 0.3 sec. + Faulty injector MIL aver + Faulty ECM Fuel Limit * Yes | Fuel Cut | EGR Off Injector [ Resistance 0.386 # 0.055 0 at 20°C Refer to DTC P0261. ‘SIGNAL WAVEFORM | E0825si0 Refer to DTC P0261. MONITOR SCANTOOL DATA «2AFs03 Refer to DTC P0261FL-157 FUEL SYSTEM TERMINAL & CONNECTOR INSPECTION Refer to DTC P0261. POWER CIRCUIT INSPECTION — 1. Injector Control (Low Side) 2, Injector Power (High Side) c2a02 4, Is the measured resistance within specifications ? YES P Go to "Control Circuit Inspection" procedure. Check for open in the power harness. Repair as necessary and go to "Verification of Vehicle Repair" procedure. CONTROL CIRCUIT INSPECTION — 4. Check for short to ground in harness 1) Ignition "OFF 2) Disconnect injector connector. 3) _ Ignition "ON" & Engine "OFF”DTC TROUBLESHOOTING PROCEDURES. 4) Measure resistance between terminal 1 of injector harness connector and chassis ground Specification : Infinite C2874» 4. Injector Control (Low side) 2. Injector Power (igh Side) 8) _Is the measured resistance within specifications 7 YES D Go to "Check for open in hamess” as below. > Check for short to ground in the control hamess. Repair as necessary and go to "Verification of Vehicle Repair" procedure. 2. Check for open in hamess : 4) Ignition “OFF” 2) Disconnect injector and ECM connector. 3) Measure resistance between terminal 1 of injector harness connector and terminal 33 of ECM amess connector ‘Specification : Approx. below 10 0x87» 4. Injector Controt (ow Side) 2, Injector Power 2 (High Size) 0280-2 4) Is the measured resistance within specifications 7 > Go to" Component Inspection * procedure. D> Check for open in the control harness. Repair as necessary and go to "Verification of Vehicle Repair” procedure.FL159 FUEL SYSTEM. Refer to DTC P0261DTC TROUBLESHOOTING PROCEDURES FL.160 eee EE DTC P0264 | CYLINDER2-INJECTOR CIRCUIT LOW Refer to DTC P0261 GENERAL DESCRIPTION Item Detecting Condition Possitle Cause DTC Strategy | « Circuit continuity check . “Enable Conditions | » Engine run | Overcurrent iow side connection: injector currentinereases the *_Shortto battery in Threshold Value | maximum value of 28.5 A~ 34 A rae : + Short to battery in [Diagnostic Time _ | « 0.3 sec. control circuit 7 7 = + Faulty injector Mai *Yes Fuel Limit | 6 Yes + Faulty ECM Fuel Cut @No EGR Of No | Resistance | Refer to DTC P0261 Refer to DTC P0261 MONITOR SCANTOOL DATA Ex=Aic20) Refer to DTC P0261 TERMINAL & CONNECTOR INSPECTION 33651899 Refer to DTC P0261FUEL SYSTEM ease 4. Ignition "OFF" 2. Disconnect injector connector. 3. Ignition "ON" & Engine "OFF 4, Measure voltage between terminal 2 of the injector hamess connector and chassis ground. Specification : B+ 0297-25 1. Injector Control (Low Side) 2. Injector Power (high Side) 5. Is the measured voltage within specifications ? YES : > Go to "Control Circuit Inspection" procedure. > Check for open in the power hamess. Repair as necessary and go to "Verication of Vehicle Repair’ procedure. CONTROL CIRCUIT INSPECTION se0*abe: 1. Ignition "OFF" 2. Disconnect injector connector 3. Ignition "ON" and Engine "OFF" 4. Measure voltage between terminal 1 of the injector hamess connector and chassis ground Specification : Approx. below 1V 0207-2 1. Inectar Control {Low Side) 2, Injector Power (High Sice)DTC TROUBLESHOOTING PROCEDURES, 5, Is the measured voltage within specifications ? YES } Go to "Component Inspection'procedure > Check for short to battery in hamess. Refer to DTC P0261FUEL SYSTEM Refer to DTC P0261. Refer to DTC P0261 item Detecting Condition Possible Cause DTC Strategy | « Circuit continuity check Enable Conditions | « Engine run ‘Overcurrent high side connection: injector current increases the Threshold Value | maximum value of 26 A~ 36 A + Short to battery in power Brcuit Diagnostic Time | « 0.3 sec. + Faulty injector ae Sve + Faulty ECM FuelLimit | 6 Yes Fuel Cut. | aNo EGROH — | eNo Injector Refer to DTC P0261 Refer to DTC P0261DTC TROUBLESHOOTING PROCEDURES ‘TERMINAL & CONNECTOR INSPECTION® 4, Many malfunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3, Has a problem been found? 5 Repair as necessary and go to “Verification of Vehicle Repair" procedure. Go to " Power Circuit Inspection " procedure. ‘POWER CIRCUITINSPECTION —EcciAirc Ignition "OFF" Disconnect injector connector. Ignition "ON" & Engine "ON" Measure voltage between terminal 2 of the injector hamess connector and chassis ground, Rena Specification : 8+ 0207-2 1. Injector Controt (Low Side) 2. Injector Power (High Side) 5. Is the measured voltage within specifications ? > Go to” Component Inspectior > Check for short to battery in the power hamess. Repair as necessary and go to "Verification of Vehicle Repair’ procedure. (COMPONENT INSPECTION = Erale336= * procedure, Refer to DTC P0261. VERIFICATION OF VEHICLE REPAIR™ 20-0000 = = Refer to DTC P0261FL165 FUEL SYSTEM DTC P0266 | CYL-2 INJECTOR CIRCUIT BALANCE (LOAD DROP IS DETECTED) COMPONENT LOCATION™ ersosuee Refer to DTC P0261. DESCRIPTION ccirsia’ GENERAL DESCRIPTION © S05 Refer to DTC P0261. DTC DESCRIPTION === If the signal is below threshold value, the ECM judged this as a fault and DTC is set DTC DETECTING CONDITION E76r3985 ee oe Item Detecting Condition | Possible Cause | pc strategy | « Circuit continuity check | Enable Gonsitions |» Engine run + Open in power | © Load drop error: load drop is detected if during energizing the circuit’ minimum currentimin = 3A is not reached + SHlort to ground in Threshold Value | » Fast current decrease error: a fixed time after the energizing control circuit | | period the current has to decrease belowimin = 3A + Open in control = = — circuit circuit Diagnostic Time | « 0.3 sec. : + Faulty injector zi MIL Yes + Faulty ECM | Fueltimt fs Yes Fuel Cut No t EGR Off No ‘SPECIFICATION © =570e00 Injector Resistance SCHEMATIC DIAGRAM ~Exurcae = ae Refer to DTC P0261 SIGNAL WAVEFORM = Ecaczaai a ¥ = Refer to DTC P0261 MONITOR SCANTOOL DATA — EFanercs ey, = Refer to DTC P0261DTC TROUBLESHOOTING PROCEDURES Refer to DTC P0261. POWER CIRCUIT INSPECTION * "ees 1. Ignition "OFF". 2. Disconnect injector and ECM connector. 3. Measure resistance between terminal 2 of injector harness connector and terminal 37 of ECM hamess connector. Specification : Approx. below 19 <0287-2> 4. Injector Contot (ow Side) 2. Injector Power 1 (igh Sie) 230.2 ea a EES 4, Is the measured resistance within specifications ? YES > Go to "Control Circuit Inspection” procedure. > Check for open in the power harness. Repair as necessary and go to "Verification of Vehicle Repair” procedure ‘CONTROL CIRCUIT INSPECTION © =s829:0F 4. Check for short to ground in harness 1) Ignition “OFF. 2), Disconnect injector connector. 3). Ignition "ON" & Engine "OFF*FL167 4) 5) 1) 2) 3) 4) Measure resistance between terminal 1 of injector harness connector and chassis ground FUEL SYSTEM tion: Infinite Go to "Check for open in harness” as below. > Check for short to ground in the control hamess. Repair as necessary and go to "Verification of Vehicle Repair" procedure. Check for open in hamess Ignition "OFF" Disconnect injector and ECM connector. Measure resistance between terminal 1 of injector hamess connector and terminal 40 of ECM hamess connector. Specification : Approx. below 10 1. Injector Control (Low Side) 2. Injector Power (high Size) Is the measured resistance within specifications ? YES > Go to "Component inspection” procedure > Check for open in the control hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedureDTC TROUBLESHOOTING PROCEDURES Refer to DTC P0261. Refer to DTC P0261,FL-169 FUEL SYSTEM DTC P0267 | CYLINDER3-INJECTOR CIRCUIT LOW Refer to DTC P0261. DESCRIP GENERAL DESCRIPTION Refer to DTC P0261 Ifthe signal above threshold value, the ECM judged this as a fault and DTC is set DT¢ DETECTII item Detecting Condition Possible Cause DTC Strategy * Circuit continuity check Enable Conditions | » Engine run ‘© Overcurrent low side connection : injector current increases the + Short to battery in Threshold Value | * Siimtam value of 28.88 ~ 34 A power circuit See sees RRR ‘Sheit to battery in Diagnostic Time 3 sec. contfol circuit Frat injector MIL Yes Fuel Limit Yes eos Fuel Cut No EGRO | eNo SPECIFICATION = E2848 a Injector = ] Resistance 0.365 4 0.086 0 at 20°C | EMATICDIRE Refer to DTC P0261 SIGNAL WAVEFORM 40818 Refer to DTC P0261 MONITOR SCANTOOL DATA — ésiosr21 Refer to DTC P0261 TERMINAL & CONNECTOR INSPECTION —cc0ses28 Refer to DTC P0261DTC TROUBLESHOOTING PROCEDURES POWER CIRCUIT INSPECTION: 4. Ignition “OFF” 2. Disconnect injector connector. 3. Ignition “ON” & Engine *OFF* 4, Measure voltage between terminal 2 of the injector harness connector and chassis ground, Specification : B+ 0257-35 1. Injector Control (Low Sido) 2. Injector Power (High Sie) 5. Is the measured voltage within specifications ? YES > Go to "Control Circuit Inspection” procedure. > Check for open in the power harness. Repair as necessary and go to "Verification of Vehicle Repair” procedure. CONTROL CIRCUIT INSPECTION -Eo:acsce 4. Ignition “OFF” 2. Disconnect Injector connector 3. Ignition "ON" and Engine “OFF” 4 Measure voltage between terminal 1 of the injector hamess connector and chassis ground Specification : Approx. below 1V_ OUT 1. njoctor Contot (Low Side) 2, Injector Power (high Side)74 FUEL SYSTEM 5. Is the measured voltage within specifications 7 as > Go to "Component inspection’ procedure. > Check for shor to battery in hamess. Repair as necessary and go to "Verification of Vehicle Repair’ procedure. Refer to DTC P0261DTC TROUBLESHOOTING PROCEDURES [DTC P0268 | CYLINDER3-INJECTOR CIRCUIT HIGH anne Ee If the signal exceeds threshold value, the ECM judged this as a fault and DTC is set. ‘DTC DETECTING COND Si em eteing Condon [Posse Cause DTC Strategy | « Circuit continuity check Enable Conditions _| ¢ Engine run Threshold Value + Short to battery in power circuit Faulty injector ‘* Overcurrent high side connection : injector current increases the maximum value of 28 A~36 A. | Diagnostic Time | # 0.3 sec. wi] eVes —|+ Fauty Eom Fuallint | Yes roel | so | ccror | Ne | | ‘SPECIFICATION: = ciebse Refer to DTC Po261 ‘SIGNAL WAVEFORM = Refer to DTC Po261 MONITOR SCANTOOL DAT) Refer to DTC P0261. TERMINAL & CONNECTORINSPECTION — =0=s080e Refer to DTC P0261FUEL SYSTEM 4. Ignition “OFF. 2. Disconnect injector connector. 3. Ignition "ON" & Engine "ON" 4, Measure voltage between terminal 2 of the injector hamess connector and chassis ground. Specification : 8+ 0207-2 1. ejector Contat (ow side) 2 Injector Power (high Sie) 5, Is the measured voltage within specifications ? : > Go to "Component inspection” procedure. > Check for short to battery in the power hamess. Repair as necessary and go to "Verification vehicle Repair" procedure. Refer to DTC P0261DTC TROUBLESHOOTING PROCEDURES, L174 DTC P0269 | CYL-3 INJECTOR CIRCUIT BALANCE (LOAD DROP IS DETECTED) Item Detecting Condition Possible Cause DTC Strategy | Circuit continuity check Enable Conditions | * Engine run + Open in power ‘© Load drop error : load drop is detected if during energizing the cirouit minimum currentimin = 3A is not reached + ‘Short to ground in Threshold Value | » Fast current decrease error : a fixed time after the energizing control circuit Period the current has to decrease below/min = 3A + Open in control circuit Diagnostic Time | # 0.3 sec. + Faulty injector MIL Yes + Faulty ECM Fuel Limit Yes Fuel Cut No EGR Off No ‘SIGNAL Refer to DTC P0261 ‘MONITOR SCANTOOL DATA Refer to DTC P0261FUEL SYSTEM FLA75 TERMINAL & CONNECTOR INSPECTION — €s07FA08 Refer to DTC P0261 POWER CIRCUIT INSPECTION © &Ascoeo2 Ignition “OFF”. Disconnect injector and ECM connector. 1 2. 3. Measure resistance between terminal 2 of injector hamess connector and terminal 37 of ECM hamess connector. Specification : Approx. below 19 0297-85 1. Injector Contot (Low Side) 2, Injector Powor (high Side) 230-2 | 4, Is the measured resistance within specifications 7 YES P Goto "Control Circuit Inspection" procedure. > Check for open in the power harness, Repair as necessary and go to “Verification of Vehicle Repair" procedure. CONTROL CIRCUIT INSPECTION — Esxsceed 1. Check for short to ground in harness 4) Ignition “OFF” 2). Disconnect injector connector. 3) Ignition "ON" & Engine “OFF”DTC TROUBLESHOOTING PROCEDURES 4) 5) Measure resistance between terminal 1 of injector harness connector and chassis ground, Specification : Infinite C2873> 1. Injector Controt (Low Side) 2. Injector Power 2 (igh Sico) Is the measured resistance within specifications ? YES } Go to" Check for open in harness” as below. > Check for short to ground in the control hamess. Repair as necessary and go to “Verification of Vehicle Repair” procedure 2. Check for open in harness » 2) 3) 4) Ignition "OFF Disconnect injector and ECM connector. FL176 Measure resistance between terminal 1 of injector harness connector and terminal 39 of ECM hamess connector Specification : Approx. below 10. 0207 1. Injoctor Controt (Low Side) 2, Injector Power 2 (high Side) ‘C2302 Is the measured resistance within specifications ? > Go to "Component inspection" procedure. Check for open in the contro! hamess. Repair as necessary and go to "Verification of Vehicle Repair’ procedureFUEL SYSTEM. Refer to DTC P0261.DTC TROUBLESHOOTING PROCEDURES [DTC P0270 | CYLINDER4-INJECTOR CIRCUIT LOW item Detecting Condition Possible Cause DTC Strategy ® Circuit continuity check Enable Conditions | ¢ Engine run ei + Short to battery in TT Tr sSsS=r * Short to battery in Diagnostic Time © 0.3 sec. control circuit Faulty injector MIL Yes : Fuel Limit Yes Faulty ECM Fuel Cut No EGROF |e No Injector 0.365 + 0.055 0 at 20°C Refer to DTC Po261 MONITOR SCANTOOL DATA” Refer to DTC P0261. TERMINAL & CONNECTOR INSPECTION Refer to DTC P0261FUEL SYSTEM FL-179 POWER CIRCUITINSPECTION: Goto "Control Circuit Inspection” procedure. > Check for short to battery in the power hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure, ‘CONTI IT SN Se 4. Ignition "OFF" 2. Disconnect injector connector. 3. Ignition "ON" and Engine "OFF" 4. Measure voltage between terminal 1 of the injector hamess connector and chassis ground. Specification : Approx. below 1V ee 1. Injector Contot (Low Side) 2. Injector Powor (High Side)DTC TROUBLESHOOTING PROCEDURES 5. Is the measured voltage within specifications ? YES D Go to "Component Inspection" procedure. D> Check for short to battery in hamess. Repair as necessary and go to "Verification of Vehicle Repair procedure. COMPONENT INSPECTION: “ 1: Injector Control (Low Sice) 2 Injector Power (High Size) 5. _ Is the measured voltage within specifications ? ms > Go to "Component inspection” procedure. > Check for shor to battery in the power harness. Repair as necessary and go to "Verification of Vehicle Repai" procedure. (COMPONENT INSPECTION 1. Injector Control (Cow Side) 2. Injector Power 1 (High Slee) 230-2 4, Is the measured resistance within specifications ? as > Go to “Control Circuit Inspection” procedure. D> Check for open in the power hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure.FL185 FUEL SYSTEM CONTROL CIRCUIT INSPECTION 1, Check for short to ground in harness 1) Ignition "OFF 2) Disconnect injector connector. 3) Ignition "ON" & Engine "OFF". 4) Measure resistance between terminal 1 of injector harness connector and chassis ground. ‘Specification : Infinite 0237-4 1. Injector Control (ow Side) 2. Injector Powor (High Sido) 5) _ Is the measured resistance within specifications ? eS } Go to "Check for open in harness” as below. > Check for short to ground in the control harness. Repair as necessary and go to “Verification of Vehicle Repair" procedure. 2. Check for open in harness 1). Ignition “OFF. 2) Disconnect injector and ECM connector. 3) Measure resistance between terminal 1 of injector hamess connector and terminal 38 of ECM hamess connector. ‘Specification : Approx. below 10 (>) _ + Inector contrat (Low side) 2. Injector Power {igh Sice)DTC TROUBLESHOOTING PROCEDURES 4) Is the measured resistance within specifications ? YES } Go to "Component Inspection" procedure. Check for open in the control hamess. Repair as necessary and go to "Verification of Vehicle Repair’ procedure. Refer to DTC P0261. Refer to DTC P0261FL187 FUEL SYSTEM IDTC P0336 | CRANKSHAFT POSITION SENSOR CIRCUIT OUT OF RNAGE ‘The crankshaft angular sensor detects and counts the teeth on the crankshaft and provides ECM with the information on the current position of crank angle and cylinder. This signal is fed to ECM to be used to determine’the engine speed and adjust the fuel injection timing. The camshaft position sensor detects the teeth target wheel and provides ECM with the information on the current position of piston and cylinder. This signal is fed to ECM to be used to determine the sequence of fuel injection. In case of the the crankshaft angular sensor or the camshaft position sensor failure, the engine symptoms will occur ‘running engine stall, starting impossible and rough idle with noise. Ifthe difference between actual CKP value and calculated CKP value is generated, the ECM judged this as a fault and DTC is set Item Detecting Condition Possible Cause DTC Strategy | « Signal check + Open or short to © Engine run signals(+,-) harness “Threshold Value | * C'ank angular with acceleration or deceleration is out of alowed | Open in ground | limits (dynamic plausibility) hamess __ + Faulty CKP Diagnostic Time | « 0.09 sec. + Faulty GKP tone MIL No wheel FuelLimit | ¢ No + Faulty ECM Fuel Cut Yes EGR Off @NoDTC TROUBLESHOOTING PROCEDURES ‘SPECIFICATION Resistance SECTS S [Connection Information) com iteceaas 1 [6290-2 Terminal 20 | _OKP shield wire oa (6280-2 Terminal 19 |_CKP sensor signal + 120, OKP Sensor 2 | 6200-2 Terminal 1@ | CKP sensor signal - [CONNECTOR] (CKP Hamess side connector OM side terminal ‘oKP (C201) 230-2 230-1. 4.8 UF 7.5008 CH B: Zoom 1 “The given data is the normal waveform of the crankshaft postion sensor (CKPS) and the Camshaft position sensor (CMPS). The CKP sinusoidal signal generates continuosly except 2 missing teeth. but the CMP squre waveform signal is output even when the CMP sensor meets the dowel pin of camshaft. Ifthe waveform pattern becomes distorted or generated no signal ‘hile cranking or idling, replace the CKP or the CMP.L189 FUEL SYSTEM ON MONITOR SCANTOOL DATA — «Fecorig = 4. Connect scantoo! to Data Link Cable (DLC). 2. Warm up engine to normal operating temperature, 3, Monitor "Acceleration Position Sensor & Engine Speed’ parameter on the scantool Fie’ 7.3 FLIGiT_BBOORD S498. | MACOEL. POSITION SENSOW no [A fase 2.0 3008 | ENGINE SPEED | Bae 8 ¥ (Terr a-2ar 0.7 s1__ [ri] [won] Fig 1) APS signal and engine speed increase when depressing accel pedal. Is the Current data displayed correctly ? : YES Faultis intermittent caused by poor contact in the sensor's and/or ECM's connector or was repaired and ECM memory was not cleared, Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair" procedure. D Go to "WiHamess Inspection” procedure, TERMINAL & CONNECTOR INSPECTION = FA2Aa7i2 1. Many malfunctions in the electrical system are caused by poor harness and terminals.. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3. Has a problem been found? YES Repair as necessary and go to "Verification of Vehicle Repair” procedure. Go to "Signal Circuit Inspection” procedure.DTC TROUBLESHOOTING PROCEDURES FL-190 ‘SIGNAL CIRCUIT INSPECTION” “Ev asce 4. Check for open or short in signal (+) harness 41) Ignition “OFF & Engine "OFF" 2) Disconnect CKP sensor connector. 3) Ignition "ON" & Engine "OFF". 4) Measure voltage between terminal 2 of the sensor hamess connector and chassis ground. “Specification : Approx. 2.5V 4 Shield ground 2. Sensor signal + 3. Sensor signal - 5) _Is the measured voltage within specifications ? , YES > Goto > Check for open or short in signal(+) hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure. 2. Check for open or short in signal (-) harness 1) Ignition “OFF” & Engine "OFF" 2) Disconnect CKP sensor connector. 3) Ignition "ON" & Engine "OFF". 4) Measure voltage between terminal 3 of the sensor hamess connector and chassis ground. heck for open or short in signal(-) hamess” as below “Specification : Approx. 2.5V 0201» 4.Shield ground 2. Sensor signal + 13. Sensor signalFLA91 FUEL SYSTEM GROUND CIRCUITINSPECTION 1 5) Is the measured voltage within specifications 7 23 > Got > Check for open or short in signal(-) harness. Repair as necessary and go to "Verification of Vehicle Repair” procedure, "Ground Circuit Inspection” Ignition “OFF” & Engine "OFF". Disconnect CKP sensor and ECM connector. ‘Measure resistance between terminal 1 of the sensor hamess connector and terminal 20 of ECM hamess connect- or. Specification : Approx. below 19 4 ‘COMPONENT INSPECTION ® “esto 1 02015 1.Shila ground 2.Sonsor signal + ‘3, Sensor signal - Is the measured resistance within specifications ? YES } Go to "Component Inspection” procedure. } Check for open in hamess. Repair as necessary and go to "Verification of Vehicle Repair" procedure. Se eet Check tone wheel. 1) Ignition "OFF" & Engine “OFF”. 2) Remove CKPS. 3) Visually check that Tone wheel is ©.K through the installation hole for CKPS. 4) Is the Tone wheel installed on the crankshaft O.K 7 } Go to "Check CKPS" as below. Check Tone wheel for contamination, deterioration or damage. Replace Tone wheel on the crankshaft as necessary and go to "Verification of Vehicle Repair” procedure.DTC TROUBLESHOOTING PROCEDURES. FL-192 2. Check CKPS: 4) Ignition "OFF". 2) Remove CKPS and then connect CKPS connector to CKPS. 3) Ignition "ON" & Engine "OFF" 4) Move a metal on the detecting edge of CKPS with monitoring signal waveform, 5) _Isthe signal waveform displayed ? = 6) > Substitute with a known-good ECM and check for proper operation. Ifthe problem is corrected, replace ECM and then go to "Verification of Vehicle Repair” procedure. > Substitute with a known-good CMPS and check for proper operation. If the problem is corrected, replace CMPS and then go to "Verification of Vehicle Repair” procedure. VERIFICATION OF VEHICLE REPAIR) «eata7ec After a repair, its essential to verify that the fault has been corrected. jode and then clear DTC. 4. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" 2. Operate the vehicle within DTC Enable conditions in General information 3, Are any DTCs present ? eS Go to the applicable troubleshooting procedure. ‘System Is performing to specification at this time.FL-193 FUEL SYSTEM DTC P0341 | CAMSHAFT POSITION SENSOR CIRCUIT RANGE/PERFORMANCE COMPONE! ‘The crankshaft angular sensor detects and counts the teeth on the crankshaft and provides ECM with the information on the current position of crank angle and cylinder. This signal is fed to ECM to be used to determine-the engine speed and adjust the fuel injection timing. The camshaft position sensor detects the teeth target wheel and provides ECM with the information on the current position of piston and cylinder. This signal is fed to ECM to be used to determine the sequence of fuel injection. In case of the the crankshaft angular sensor or the camshaft position sensor failure, the engine symptoms will occur a running engine stall, starting impossible and rough idle with noise. 8 =. Ifthe CMP signal is not geneated, the ECM judged this as a fault and DTC is set.DTC TROUBLESHOOTING PROCEDURES DIC DETECTING CONDITION tem ~~ Deteeting Conaition “Possible Cause | DTC Strategy | « Signal check on power circuit +O short [Enable Conatons |» Engine run ae _Cenarstath ‘* Cam signal fails at the condition of crank signal generation. (Cam | * Open in ground Threshold Value | signal static defection) circuit ee Saeeeeaeeeeece — —— + Faulty CMP Diagnostic Time _| @ 0.7 sec. + Faulty CMP dowel MIL No pin. Fuel Limit |e No * Faulty ECM Fuel Cut | Yes, EGROM | #No [Connection Information} foe 1._[c2zsecminal 17 [Control relay power (6280-2 Terminal 22 | CMP sensor signal From onl lay (120) — (6280-2 Terminal 23 | GMP sensor ground [CONNECTOR] ‘CMP Harness sido connector EOM side terminal 230-2 c2304 com (e210) areFL195 FUEL SYSTEM SIGNAL WAVEFORM - Eccavaas (ars ae V bt: —7.5@n8 GH BI-229. onl WAL ASU PIF 6, 50m PREREHA7. 65 ToTDG _}1 ooh = : tnt ‘BTDC 108" : oe cue : : FE ‘ Air gab :1.5 = ‘FEED [20m] FEMS [reer] [Rec | [reno] (_RESIR [oor] REM [reno] [Reco] [rreww] “The given data is the normal waveform of the crankshaft position sensor (CKPS) and the Camshaft position sensor (CMPS). ‘The CKP sinusoidal signal generates continuosly except 2 missing teeth. but the CMP squre waveform signal is output even when the CMP sensor meets the dowel pin of camshaft. Ifthe waveform pattern becomes distorted or generated no signal while cranking or idling, replace the CKP or the CMP. MONITOR'SCANTOOE DATA 4. Connect scantoo! to Data Link Cable (DLC). 2. Warm up engine to normal operating temperature. 3. Monitor "Acceleration Position Sensor & Engine Speed’ parameter on the scantool Fic 1 1,3 FLi@a_micomD 3498, [RACGEL. POSITION SENSOR 5] eo | 608 | “ENGINE SPEED vm] 416 | | | 8 v [uist]er-2e1 6.7 83 [rm ] [We Fig 1) APS signal and engine speed increase when depressing accel pedal.DTC TROUBLESHOOTING PROCEDURES FL-196 Is the Current data displayed correctly ? YES Fault is intermittent caused by poor contact in the sensor's and/or ECM's connector or was repaired and ECM memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair” procedure. > Goto "Witiamess Inspection” procedure ‘TERMINAL & CONNECTOR INSPECTK 4. Many matfunctions in the electrical system are caused by poor hamess and terminals, Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for oeseness, poor connection, bending, coraslon, contamination, deterioration, o jamage. 3. Has a problem been found? YES pon ‘as necessary and go to "Verification of Vehicle Repair” procedure. NO Go to "Power Circuit Inspection" procedure. . Ignition "OFF" & Engine "OFF". Disconnect CMP sensor connector. Ignition "ON" & Engine "OFF". Measure voltage between terminal 1 of the sensor hamess connector and chassis ground. Specification : Approx. B+ <0210> 4. Sensor Power (2) 2, Sensor Signal (aay) 3, Sensor Ground (oy,FL-197 FUEL SYSTEM 5. Is the measured voltage within specifications ? YES > Goto "Signal Circuit Inspection" procedure. > Check for open or short in power hamess. Repair as necessary and go to "Verification of Vehicle Repait” procedure. SIGNAL CIRCUITINSPECTION: 7orAx00= 3 Ignition “OFF” & Engine "OFF* 2. Disconnect CMP sensor connector. 3. Ignition "ON" & Engine "OFF". 4, Measure voltage between terminal 2 of the sensor hamess connector and chassis ground. Specification : Approx. 5V sae 1. Sonsor Power (ev) 2. Sensor Signal Gav) 3. Sensor Ground (ov) 5. Is the measured voltage within specifications ? 5 > Go to "Ground Circuit Inspeciton" procedure. > Check for open or short in hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure,DTC TROUBLESHOOTING PROCEDURES, GROUND CIRCUIT INSPECTION “=u Ignition "OFF" & Engine "OFF". Disconnect CMPS and ECM connector. ‘Measure resistance between terminal 3 of the sensor harness connector and terminal 23 of ECM harness connect- or. Specification : Approx. below 12 <0210> 1. Sensor Power 2y) 2, Sonsor Signal aay) 8. Sensor Ground ov e200.2 4, Is the measured resistance within specifications 7 ey . Go to "Component inspection” procedure. Check for open in hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure. 4. Check Dowel Pin 1) Ignition "OFF" & Engine "OFF" 2) Remove CMPS. 3) Visually check that Dowel Pin is O.K through the installation hole for CMPS. 4) Isthe Tone wheel installed on the crankshaft O.k ? } Go to "Check CMPS" as below. Check Dowel Pin on Camshaft for deterioration or damage. Replace Camshaft as necessary and go to “Verification of Vehicle Repair” procedure. 2. Check CMPS 41) Ignition “OFF” & Engine "OFF" 2) Remove CMPS and then connect CMPS connector to CMPS, 3) Ignition "ON" & Engine "OFF" 4) Move a metal on the detecting edge of CMPS with monitoring signal waveform.FL.199 FUEL SYSTEM 5) _Is the signal waveform displayed correctly? YES > Substitute with a known-good ECM and check for proper operation. If the problem is corrected, replace ECM and then go to "Verification of Vehicle Repair” procedure. i) > Substitute with a known-good CMPS and check for proper operation. If the problem is corrected, replace CMS and then go to "Veriiaton of Vehicle Repal” procedure VERIFICATION OF VEHICLE REPAIR — coss8bsr After @ repair, itis essential to verify thatthe fault has been corrected. 4. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)* mode and then clear DTC. ‘Operate the vehicle within DTC Enable conditions in General information, 3. Are any DTCs present ? 5 Go to the applicable troubleshooting procedure System is performing to specification at this time.DTC TROUBLESHOOTING PROCEDURES DTC P0343 | CAM/ENGINE SPEED SENSOR - HIGH INPUT Item Detecting Condition Possible Cause DTC Strategy ‘¢ Signal check Enable Conditions | Engine run * Short to ground in Threshold Value _ | If the CAM signal frequency detects too many edges signal circuit Diagnostic Tine | = ee cn aaa ona pin ‘hielcut | 3 es "Feu Eo EGR Off eNo Refer to DTC P0341 Refer to DTC P0344 Refer to DTC P0341. Refer to DTC P0341FL201 FUEL SYSTEM SIGNAL CIRCUIT INSPECTION = £b1A8208 Sie 41. Ignition "OFF" & Engine "OFF". 2. Disconnect CMP sensor connector. 3, Ignition "ON" & Engine "OFF" 4. Measure voltage between terminal 2 of the sensor hamess connector and chassis ground. ‘Specification : Approx. 5V_ : 4. Sensor Power aan 2, Sensor Signal «ey 3. Sensor Ground (ov 5. Is the measured voltage within specifications 7 7 . > Go to “Component Inspeciton” procedure. D> Check for open or short in harness. Repair as necessary and go to "Verification of Vehicle Repair" procedure. ‘COMPONENT INSP! IN Refer to DTC P0341 Refer to DTC P0341DTC TROUBLESHOOTING PROCEDURES FL.202 DTC P0401 | EXHAUST GAS RECIRCULATION FLOW INSUFFICIENT DETECTED | COMPONENT LOCATION = GENERAE DESCRIPTION" ‘The EGR (Exhaust Gas Recirculation) system is used to divert some of the exhaust gas to the engine inlet system in order to reduce an excess of air and the temperature in the combustion chamber. This device also significantly reduces emissions of the nitric oxide at the exhaust. ‘The EGR system is composed of a solenoid valve, a proportional pneumatic valve and an air flow meter. ‘The EGR solenoid valve controls the opening and closing the pneumatic valve using the low pressure from the braking assistance circuit. The low pressure is created by the vaccum pump located at the end of the alternator, ‘The duty control of the solenoid valve is determined by the injection computer depending on the air flow requested, In case of EGR solenoid valve failure, the engine performance will be reduced. DTC DESCRIPTION Ifthe signal exceeds threshold value, the ECM judged this as a fault and DTC is setFUEL SYSTEM ae item Detecting Condition Possible Cause _ DTC Strategy _| Rationality check Enable Conditions _| « Engine run TTeshold Vale |, 400 < Engine speed < 2000 rpm and injection quantity < 0.2 |* Faas bee : + Faulty EGR system Diagnostic Time _| « 6 sec. + Faulty Turbo charger system ML * Yes 7 Fuel Limit * Yes oe Fuel Cut No EGR off *Yes | EGR a Resistance Operating Frequency 14~17 at 20°C 300 Hz EGA Solencis [Connection Information} eH zal 2 c2a0-t 1 | 6223Terminal 16 Contol relay power 16 EGR Solenoid valve control 2 | c230-1 Terminal 16 [EGA solenoid valve contol 1 CContrat relay power — {connecron) OR amass comacor EC de taal DD o>] ieeaee { popes [* OR Seno . aDTC TROUBLESHOOTING PROCEDURES ‘SIGNAL WAVEFORM ao 2 TSU BT 2. 10ns PRHRIA.19 Ta ACTUATION TEST IN:-604.Sn VE: 12.0.0 TAK: 14.9.0 FREQ: 333.33 Hz DUTY: 82 % EGR ACTUATOR ahve i usarron [UNTIL STOP KEY ‘ngs wierHiop [activation ‘CoNDITTON |r. KEY On BOR hy ENGINE OFF | Sosed PRESS CSTHTT, TF YOU ARE READY + : SELECT TEST TTEN USING UP/DOWN KEY [iy oon Tao Tasco Seer] [Sram This test should be inspected after depressing the HOLD mode at the operating range of EGR valve. ‘The time T becomes shorter when the EGR valve is opened increasingly For checking the wire from the fuses to the solenoid valve with the ECM circult, he START key should be pressed In the scan tool actuation test mode. ‘And then make sure that the the solenoid valve “click" noise could be heard.FUEL SYSTEM. MONITOR SCANTOOL DATA — esaacach seas! i a6: 1. Connect scantool to Data Link Cable (DLC). 2, Warm up engine to normal operating temperature. Monitor that "Mass Air Flow Sensor" parameter on the scantool is changing without EGR actuator operation or with EGR actuator operation while idling engine speed. Fig4 72 coma bara a x frass at FLOW 469, nara x lence sreeD wt tee x x {RURL quaeriTy oreo |e foosten v-OPERAT’G IMJ 79.9.0 ILCENGINE CHECK) OFF iow RELAY on URL Pune mruae om ' Fix | [scrn] [rut] [Part] [@RPH] [HELP| FIG2 1.2 CURRENT DATA . x |EcR actuaToR 40.8 % |ENGINE SPEED 768 rpn |UEHICLE SPEED SENSOR @ = K/h [rust PRESSURE 228. Thar [FUEL PRESS. REGULATOR 16.2 % [BAROMETRIC PRESS.SNSR 181 kPa. |cLUTCH Su.cH/T ONLY) ON [Fix ] [crn] [rut] [Parr] Fig 1) Normal value without EGR actuator : Approx. 450 ~ 550 mgistroke Fig 2) Normal value with EGR actuator : Approx. 280 ~ 360 mg/stroke Is Current data displayed correctly ? > Faults intermittent caused by poor contact in the sensor's and/or ECM's connector or was repaired and ECM memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair” procedure. > Go to "System Inspection” procedure.DTC TROUBLESHOOTING PROCEDURES. ‘SYSTEM INSPECTIOI 4. Visual Inspect MAFS 1) Check that installation arrow on MAFS is correctly indiated. 2) Check that connector of MAFS is contaminated, deteriorated or damaged. 3) Check that air cleaner is O.K 4) Check that MAFS cylinder is blocked by foreign material, deformed or comtaminated © nore Foreign material or water in intake air makes Hot film in MAFS damage. 5) Isthe MAFS OK? YES Go to "Check MAFS" as below. > Repair or replace as necessary and go to "Verification of Vehicle Repair" procedure. 2. Check MAFS 1) Ignition "ON" & Engine "ON". 2) Check damage or air leakage from Intercooler hose, 3) Check that EGR is off when 90 seconds elasped after acceleration. . 4) Monitor MAFS data when engine idle rpm is approximately 800, ‘Specification : 500mg/st + 50mg/st 5) _ Is the MAFS parameter displayed within specifications ? > Got P Refer to DTC P0100, P0102, P0103 for more detail inspection, Repair or replace as necessary and go to "Verification of Vehicle Repair" procedure, ‘Component Inspection” procedure.FL.207 FUEL SYSTEM COMPONENT INSPECTION Go to "Check EGR solenoid operation” as below. > Check EGR solenoid for contamination, deterioration, or damage. Substitute with a known-good EGR and check for proper operation. If the problem is corrected, replace EGR and then go to "Verification of Vehicle Repair” procedure, 2. Check EGR solenoid valve operation 41) Ignition “ON” & Engine "ON". 2) Confirm that EGR solenoid valve Duty is 5% after warming-up Engine. 3) Be sure that vacuum is felt after disconnecting vaccum hose from EGR solenoid valve. 4) Check that vacuum is felt in ide after sudden accelleration(EGR solenoid valve Duty : 95%) a EGR DUTY : 5% EGRDUTY: 95% l . No Vaccum Vacuum 5) _Is the vaccum felt from vaccum hose according to EGR DUTY ? > Substitute with a known-good ECM and check for proper operation. If the problem is corrected, replace ECM and then go to "Verification of Vehicle Repair” procedure. } Check EGR solenoid for contamination, deterioration, or damage. Substitute with a known-good EGR and check for proper operation. if the problem is corrected, replace EGR and then go to "Verification of Vehicle Repair" procedure,DTC TROUBLESHOOTING PROCEDURES FL-208 VERIFICATION OF VEHICLE REPAIR’ ee2ccaie ‘After a repair, itis essential to verify that the fault has been corrected. ‘Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. 2. Operate the vehicle within DTC Enable conditions in General information, Are any DTCs present ? YES Go to the applicable troubleshooting procedure. ‘System is performing to specification at this time.FUEL SYSTEM tem Detecting Condition Possible Cause DTC Strategy _| Rationality check Enable Conditions | Engine run i + Fuse blown Threshold Value | * 1400 < Engine speed < 2000 rpm and injection quantity < 0.2 ne + Faulty MAFS + Faully EGR system Diagnostic Time | ¢ 6 sec. + Fatty Turbo charger system MIL Yes Fuel Limit Yes een Fuel Cut #No EGR off Yes Resistance 14~17 0 at 20°C 300 Hz Refer to DTC P0401. Refer to DTC P0401.DTC TROUBLESHOOTING PROCEDURES Refer to DTC P0401FUEL SYSTEM. Refer to DTC P0401. Item Detecting Condition Possible Cause DTC Strategy |» Circuit continuity check + Contact resistance connectors + Open or short in Enable Conditions | e Engine run power circuit r + Open in relay ‘Threshold Value _| e Open or short for EGR actuator control circuit Control circuit Diagnostic Time _ | » 0.48 sec. Fuse blown + Faulty EGR ML, Yes Siar Fuel Limit No : Fuel Cut No tee haa EGR Off Yes Refer to DTC P0401. Refer to DTC P0401 TERMINAL AND CONNECTOR INSPECTION = Es#866760 0 Refer to DTC P0401-bro TROUBLESHOOTING PROCEDURES rte POWER CIRCUIT INSPECTION = =S8aD;85. Siege Mi Ignition “OFF” & Engine "OFF". Disconnect EGR solenoid valve connector. Ignition "ON" & Engine "OFF". Measure voltage between terminal 1 of the EGR solenoid valve hamess connector and chassis ground Specification : Approx. B+ Cate 1.GR solenoid valve power 2. EGR Solenoid valve control 5. Is the measured voltage within specifications ? YES . > Goto" Control Circuit inspection * procedure. NO > Check for open or short in power hamess. Repair as necessary and go to "Verification of Vehicle Repair’ procedure. 1. Check for short to ground in control harness, 1) Ignition “OFF” & Engine "OFF" 2) Disconnect EGR solenoid valve connector, 3) Measure resistance between terminal 2 of the EGR solenoid valve hamess connector and chassis ground. Specification : Infinite <0a31> 1. EGR solenoid vate power 2 EGR Solenoid valve controlFL213 FUEL SYSTEM 4) Is the measured resistance within specifications ? YES > Go to "Check for open in harness" as below. > Check for short to ground in hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure. 2. Check for open in control harness 1) Ignition “OFF” & Engine "OFF" 2) Disconnected EGR solenoid valve and ECM connector. 3) Measure resistance between terminal 2 of the EGR solenoid valve hamess connector and terminal 16 of ECM harness connector. ‘Specification : Approx. below 10 <0231> 1.EGR solenoid valve powor 2. EGR Solanoid valve contrat 4) Is the measured resistance within specifications ? YES Go to “Component inspection” procedure. } Check for open in hamess. Refer to DTC P0401. VERIFICATION OF VEHICLE REPAIR — e02ceere Refer to DTC P0401DTC TROUBLESHOOTING PROCEDURES FL.214 [DTC P0406 | EGR SOLENOID VALVE CIRCUIT - SHORT CIRCUIT 7 COMPONENT LOCATION” Refer to DTC P0401 FRIPTION® = 60225846 The EGR (Exhaust Gas Recirculation) system is used to divert some of the exhaust gas to the engine inlet system in order to reduce an excess of air and the temperature in the combustion chamber. This device also significantly reduces emissions of the nitric oxides at the exhaust. ‘The EGR system is composed of a solenoid valve, a proportional pneumatic valve and an air flow meter. ‘The EGR solenoid valve controls the opening and closing the pneumatic valve using the low pressure from the braking assistance circuit. The low pressure is created by the vaccum pump located at the end of the alternator. The duty control of the solenoid valve is determined by the injection computer depending on the air low requested, In case of EGR solenoid valve failure, the engine performance will be reduced. Detecting Condition Possible Cause DTC Strategy | Circuit continuity check 4 ane * Short in power Enable Conditions _| « Engine un circuit aoe ee * Short to battery in Threshold Value | « Shor for EGR actuator control circuit Eee Diagnostic Time © 0.48 sec. + Fuse blown wi] eves « Faull EGR Fuel Limit No — + Faulty ECM FuelCut | @No EGR Off Yes Refer to DTC P0401FL.215 FUEL SYSTEM a al MONITOR SCANTOOL DATA © “€7c7sec2 2 u Refer to DTC P0401 TERMINAL AND CONNECTOR INSPECTION = <2se4047-— Refer to DTC P0401 POWER CIRCUIT INSPECTION © caizcacg 4. Ignition “OFF” & Engine “OFF” 2, Disconnect EGR solenoid valve connector. 3, Ignition "ON" & Engine "OFF" 4. Measure voltage between terminal 1 of the EGR solenoid valve harness connector and chassis ground Specification : Approx. B+ <0231> 1.EGR solenoid valve power 2. EGR Solenoid valve control 5. Is the measured voltage within specifications ? Go to” Control Circuit Inspection " procedure, > Check for open or short in power hares. Repair as necessary and go to "Verification of Vehicle Repai’ procedure.DTC TROUBLESHOOTING PROCEDURES, FL216 CONTROL CIRCUIT INSPECTION «arezAsi eRe 1. Ignition "OFF" & Engine “OFF” 2. Disconnect EGR solenoid valve connector. 3, Measure voltage between terminal 2 of EGR solenoid valve hamess connector and chassis ground. Specification : Approx. below 1V _ C231 1.EGA solenoid valve power 2. EGA” Solenoid valve contro! 4, Is the measured voltage within specifications ? YES > Go to" Component Inspection” procedure a > Check for short to battery in hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure. (COMPONENT INSPECTION= Refer to DTC Po401 VERIFICATION OF VEHICLE REPAIR e008 After a repair, it is essential to verify that the fault has been corrected. Connect scan too! and select “Diagnostic Trouble Codes(OTCs)" mode and then clear DTC. 2. Operate the vehicle within DTC Enable conditions in General information. Are any DTCs present 7 iy Go to the applicable troubleshooting procedure. ‘System is performing to specification at this time,FUEL SYSTEM DTC P0501 | VEHICLE SPEED SENSOR RANGE/PERFORMANCE ‘The VSS (Vehicle Speed Sensor) is a hall sensor type. The vehicle speed sensor is buit into the speedemeter and con- verts the transaxle gear revolutions into the pulse signals, which are sent to ECM. : This pulse signal is fed to ECM to be used to determine the vehicle driving or stop condition including the vehicle spee- ‘The vehicle speed sensor provides ECM with information on the gear position in the manual transmission vehicle and on the gear shifting in the auto transaxle vehicle after computing the engine speed and the vehicle speed signal item Detecting Condition Possible Cause |__DTC Strategy _| » Rationality check, low Enable Conditions |e Engine speed > 3600 rpm and injection quantity > 45 moc Threshold Value | * Vehicle speed signal < 15 Kmih Diagnostic Time |e 4 sec. Opell oc ence power circuit MIL © No + Open or short in | Fuel Limit No Ves circuit Fuel Cut No + Fuse blown | EGRoF No + Faulty VSS L ~ + Faulty ECM «© Clutch error monitoring deactivited Fail safe «© Cruise control system and error monitoring deactivited « Idle compensation deactivited in case of the lack of battery voltagDTC TROUBLESHOOTING PROCEDURES FL-218 SCHEMATIC DIAGRAM Eracesas = {connection information vice — ont Pere 10k tao cove 7 [Gaze Terminals (an) [Vos power ee ou - zou ew Ves ound (oy P 2504) 6) ye opua 2 ean Ves gored e a Cea Terminal WT) Ves power eee . (230-1 Terminal 49 ‘Vs signal [cowecrom) Ves Hamoss sé connector EM io termina vss SIGNAL WAVEFORM — Ecasss077 = WA! 7.60 Di: 47.5008 FREQ: 57.14 1 IIN:=447.200 AVE: 3.5 U Hak: 2.7 U FREQ: 90.91 Hz bury: 40 % 1! 1.5 SIM-SCAN [ENGINE SPEED a lece acruaron Z ren Koh jnnane surrcH ON 95.8% v UBIICLE SPEED STHULATION 53 K/h Courrut to pic > [oon] RENE [nar] [neon] ra] sin += Fix in order to make a simulation vehicle speed. This test should be inspected after depressing the HOLD mode at the vehicle speed of 120 Km. ‘The time T becomes shorter and frequency increases when the engine speed is increased. For checking the wiring ftom the ECM to the speedometer, you should be pressed on the + or - Key ‘And then, check the vehicle speed current data with the speedometer should be changed,FL.219 FUEL SYSTEM MONITOR SCANTOOL DATA — cicscaas 2 cmerappumeres 4. Connect scantoo! to Data Link Cable (DLC). 2. Warm up engine to normal operating temperature. 3. Monitor "Engine Speed & Vehcle Speed Sensor’ parameter on the scantool. FIG4 1.2 CURRENT DATA EAENGINE, SPEED et x |VEHICLE SPEED SENSOR 138 Kn/h IBArTERY VOLTAGE masau |® Inass AIR FLOW 1047 ng/st| INT. AIR TEMP, SNSR 16.0 °C |ACCEL.POSITION SENSOR 54.1 % |ACCEL.POSITION SENSOR 2336. n¥ \COOLANT TEHP. SENSOR 38.2 °C FIR Fig 1) Vehicle speed normal value with engine speed 3550 rpm during driving. Is the Current data displayed correctly ? > Faultis intermittent caused by poor contact in the sensor's and/or ECM’s connector or was repaired and ECM mem- cory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair" procedure. > Go to "WiHarness Inspection" procedure. TERMINAL & CONNECTOR INSPECTION 1, Many malfunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2, Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3. Has problem been found? Repair as necessary and go to "Verification of Vehicle Repair" procedure, Go to "Power Circuit Inspection” procedure. ccDTC TROUBLESHOOTING PROCEDURES FL-220 POWER CIRCUIT INSPECTION — £022082 4. Ignition "OFF" & Engine "OFF" 2. Disconnect VS sensor connector. 3. Ignition “ON” & Engine “OFF” 4, Measure voltage between terminal 1(A/T) or 2(M/T) of the VSS harness connector and chassis ground, Specification Approx. B+ - <0248 1. Power (7) Ground (a7) 2. Ground (WT) Powar (wT) 8, Sonsor Signal 5. Is the measured voltage within specifications ? YES ‘ > Go to "Signal Circuit Inspection” procedure. > Check for open or short in power harness. Repair as necessary and go to "Verification of Vehicle Repair” procedure. ‘SIGNAL CIRCUIT INSPECTION” 1. Ignition “OFF” & Engine "OFF”. 2. Disconnect VS sensor connector. 3. Measure voltage between terminal 3 of VSS hamess connector and chassis ground Specification : Approx. 12V 1. Power (A/T) Ground (wT) 2. Ground (AT) Power (tT) 3, Songor SignalFUEL SYSTEM FL.221 4, Is the measuered voltage within specifications 7 YES Go to "Ground Circuit Inspection” procedure. > Check for open or short to ground in harness. Repair as necessary and go to "Verification of Vehicle Repair" procedure GROUND CIRCUIT INSPECTION” “e~0ox28 aes 4. Ignition "OFF" & Engine "OFF" 2, Disconnect VS sensor and ECM connector. 3, Measure resistance between terminal 2(A/T) or 4(MIT) of VSS hamess connector and terminal 49 of ECM harness connector. Specification : Approx. below 19 es 02402 4. Power (A/T) ‘Ground (wr) 2, Ground (AT) Power (MT) 8. Sensor Signal 4, Is the measured resistance within specifications 7 YES > Go to “Component inspection” procedure. > Check for open in hamess, Repair as necessary and go to "Verification of Vehicle Repair” procedure.DTC TROUBLESHOOTING PROCEDURES FL-222 COMPONENTINSPECTION ~ £4=3e35°°°% Le Ignition "OFF" & Engine “OFF” Disconnect VSS connector. Remove VSS and Driven gear from Transaxle. Visually check that VSS driven gear is in good condition. Monitor signal waveform by rotating VSS driven gear with hand after connect connector to VSS. Is the signal waveform generated from VSS ? YES > Substitute with a known-good ECM and check for proper operation. Ifthe problem is corrected, replace ECM and then go to "Verification of Vehicle Repair" procedure. >. Check VSS for contamination, deterioration, or damage. Substitute with a known-good, \SS and check for proper operation. If the problem is corrected, replace VSS and then go to "Verification of Vehicle Repair" procedure. VERIFICATION OF VEHICLE REPAIR — After a repair, itis essential to verify that the fault has been corrected. 4. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. Operate the vehicle within DTC Enable conditions in General information. 3. Are any DTCs present ? 75 Go to the applicable troubleshooting procedure, ‘System is performing to specification at this time.L223 FUEL SYSTEM [DTC P0503 | VEHICLE SPEED SENSOR - HIGH INPUT COMPONENT LOCATION = cbrass4a ie fas “ Refer to DTC P0501 DESCRIPTION | ©27Fcove ees GENERAL DESCRIPTION” 2 = The VSS (Vehicle Speed Sensor) is a hall sensor type. The vehicle speed sensor is buit into the speedometer and con- verts the transaxle gear revolutions into the pulse signals, which are sent to ECM. This pulse signal is fed to ECM to be used to determine the vehicle driving or stop condition including the vehicle spee- 4. ‘The vehicle speed sensor provides ECM with information on the gear position in the manual transmission vehicle and on the gear shifting in the auto transaxle vehicle after computing the engine speed and the vehicle speed signal DTC DESCRIPTION’ = See Ifthe CMP signal is not geneated, the ECM judged this as a fault and DTC is set. DTC DETECTING CONDITION = Tem Detecting Condon [ Pesstio Gunso] DTC Strategy _| « Rationality check, high Enable Conditions Threshold Value | e Vehicle speed signal > 220 Kmih “Diagnostic Time In driving P| Open or short in * tsec. power circuit : + Open or short to MIL © No Fuel Limit @ No ground in VSS cicuit Fuel Cut © No +, Open ground EGR Off *No rai ee + Faulty ECM ‘© Clutch error monitoring deactivited Fail safe © Cruise control system and error monitoring deactivited « Idle compensation deactivited in case of the lack of battery voltag Refer to DTC P0501 SIGNAL WAVEFORM = &=000874 x Refer to DTC P0501 MONITOR SCANTOOL DATA = “‘e0081a7¢ a e Refer to DTC P0501DTC TROUBLESHOOTING PROCEDURES TERMINAL & CONNECTOR INSPECTION’ © <écroc#ss- Refer to DTC P0501 POWER CIRCUIT INSPECTION &reaspF7. Ignition "OFF" & Engine "OFF". Disconnect VS sensor connector. Ignition "ON" & Engine "OFF". Measure voltage between terminal 1(A/T) or 2(M/T) of the VSS hamess connector and chassis ground. FL224 Specification : Approx. 8+ <0248> 1. Power (&77) Ground (wT) 2. Ground (AT) Bower (MT) 3, Sensor Signal 5. Is the measured voltage within specifications ? eS > Go to "Signal Circuit Inspection" procedure. > Check for open or short in power harness. Repair as necessary and go to "Verification is Vehicle Repair" procedure.FL.225 FUEL SYSTEM SIGNAL CIRCUIT INSPECTION — «sezearr 1. Ignition "OFF" & Engine "OFF" 2. Disconnect VS sensor connector. 3. Measure voltage between terminal 3 of VSS hamess connector and chassis ground, Specification : Approx. 12V 0288 1. Power (77) {Ground (MT) 2, Ground (NT) Power (MT) 8. Sensor Signal 4. Is the measuered voltage within specifications 7 YES : } Go to "Ground Circuit Inspection” procedure. Check for open or short to ground in hamess. Repair as necessary and go to "Verification of Vehicle Repair’ procedure. GROUND CIRCUIT INSPECTION __sF03A01 1. Ignition "OFF" & Engine "OFF" Disconnect VS sensor and ECM connector. Measure resistance between terminal 2(A/T) or (MIT) of VSS harness connector and terminal 49 of ECM hamess connector. Specification : Approx. below 19 ao C248 1. Power (AT) Ground (7) 2. Ground (AT) Powor (MT) 3. Senor SignalDTC TROUBLESHOOTING PROCEDURES, FL.226 4, Is the measured resistance within specifications 7 YES P Go to "Component Inspection” procedure, > Check for open in hamess Repair as necessary and go to "Verification of Vehicle Repair" procedure. COMPONENT INSPECTION _ cs9087A: Refer to DTC P0501. VERIFICATION OF VEHICLE REPAIR Eee Refer to DIC P0501.FL-227 FUEL SYSTEM. ss es a Sele [pTc P0504 | BRAKE SWITCH - RANGE/ PERFORMANCE COMPONENT LOCATION — e2e8c320 WASAE ey GENERAL DESCRIPTION ‘The brake switch has 2 contacts, One allows the stop lights to be supplied and the other is used for firing fault and the correlation between the accelerator pedal position and the brake pedal position. Also, the brake switch has the cancellation of cruise control ‘The ECM senses the state of brake operating through brake switch. The redundant brake circuit is actuated when the accel pedal is depressed and the brake pedal depressed. ‘The ECM will apply a fail safe mode limiting the signal from the accelerator and controlling the injector operation allow- ing the engine to 1200 rpm only when the brake is released, APS signal is returned and injector operation re-instated. DTCDESCRIPTING ae Ifthe brake switch 1 and 2 signal is not geneated normally, the ECM judged this as a fault and DTC is set.DTC TROUBLESHOOTING PROCEDURES DTC DETECTION CONDITION = =Foceaie # lem Detecting Condition Possible Cause DTC Strategy _| « Signal check Enable Conditions | e Ignition on ‘© Case 1: brake switch 1 signal and brake switch 2 signal are abnormally correlated after the ignition switch on. Threshold Value | 6 Case 2: brake switch signal and brake switch 2 signel are + Open in brake abnormally correlated during the driving switch 1 & 2 circuit " a = * Short in brake 3 Gace 1D see switch 1 & 2 circuit | Diagnostic Time | ¢ Ca8e 1:2. sec pen or short in ee power circuit wi = No Fuse blown Fuel Limit | ® No + Faulty brake switch | Fuel Cut No + Faulty ECM EGRO | eNo + Clutch error monitoring deactivted as * Cruise control system and error monitoring deactivited « Idle compensation deactivited in case of the lack of battery vottag SCHEMATIC DIAGRAM eesvikee z an Pon {Connection Information] a en 1 [6250-1 Trina] Brake signal sae cam 2_[_mosrermina20 [Brake power a fo eee 2 _[_c2saTerminal 19 | Broke signal 2 $ bel rater [6230-1 Terminal sa] Wain relay power [conNecToR} Brake switch Hamess side connector ECM sido terminal A 2] |*] gamaame ) ( Cop PEREEREEpe = | « 2 Toye) EEEE tatatstatolataha ster siste ites 3 2302 cza0-1Er SYoreM SIGNAL WAVEFORM — cap2858c [EGR ACTUATOR 95.8% . Sorat MONITOR SCANTOOL DATA = 1. Connect scantoo! to Data Link Cable (DLC) 2. Monitor "Brake Switch” parameter on the scantool FIG4 . 1.2 CURRENT DATA (VEHICLE SPEED SENSOR = @ = Kn/h [FUEL PRESSURE 5.5. har |FUEL PRESS. REGULATOR 1.8 % |EGR ACTUATOR 95.8% |e [BAROMETRIC PRESS.SNSR 181 KPa [CLUTCH SU.cI/T ONLY) ON [BOOSTER U-oPERAT’G INI 8.2 U [etx ][scrn] [runt] [rarer] [enpu] [HELP Fig 1) Normal value when depressing brake pedal. Is the Current data displayed correctly ? > Faults intermittent caused by poor contact in the sensor's and/or ECM's connector or was repaired and ECM memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair” procedure, > Goto "WiHamess inspection” procedure.DTC TROUBLESHOOTING PROCEDURES FL-230 TERMINAL & CONNECTOR INSPECTION © E1sa0acs 4, Many malfunctions in the electrical system are caused by poor hamess and terminals, Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3. Has a problem been found? YES ite ‘as necessary and go to "Verification of Vehicle Repair" procedure. Go to "Power Circuit Inspection” procedure. POWER CIRCUIT INSPECTION 1. Check for open or short in Power hamess 41) Ignition "OFF" & Engine "OFF" 2) Disconnect Brake switch connector. 3) Ignition "ON" & Engine "OFF" 4) Measure voltage between terminal 2 of the Brake switch harness connector and chassis ground. 5) Measure voltage between terminal 3 of the Brake switch hamess connector and chassis ground, Specification : B+ 4. Brake SW 1 signal 2. Powor 4 43. Power from Relay 4. Brake SW2 signal 6) _Is the measured voltage within specifications 7 P Go to "Ground Circuit Inspection" procedure. > Check for open or short in the power hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure,L231 FUEL SYSTEM SIGNAL CIRCUIT INSPECTION | cecanss0, 4. Check for short to battery in Brake SW 1 and 2 signal hamess. 4) Ignition "OFF" & Engine “OFF” 2) Disconnect Brake switch sensor connector. 3) Ignition "ON" & Engine "OFF" 4) Measure voltage between terminal 1 of Brake switch hamess connector and chassis ground 5) Measure voltage between terminal 4 of Brake switch hamess connector and chassis ground ‘Specification : Approx. below 1V. 1. Brake SW 1 signal 2. Power 3. Power trom Relay 2 4, Brake SW? signal CL 6) Is the measured voltage within specifications ? eS > Go to "Check for short to ground in harness" as below. > Check for short to battery in harness. Repair as necessary and go to "Verification of Vehicle Repair” procedure 2. Check for short to ground in hamess. 1) Ignition "OFF" & Engine “OFF”. 2) Disconnect Brake switch and ECM connector. 3) Measure resistance between terminal 4 of Brake switch harness connector and chassis ground.DTC TROUBLESHOOTING PROCEDURES: FL-232 4) Measure resistance between terminal 1 of Brake switch harness connector and chassis ground, ‘Specification : Infinite 1. Brake SW 1 signal 2 Power 3. Power from Relay 4. Brake SW signal 5) _ Is the measured resistance within specifications 7 YES Go to "Check for open in harness" as below. > Check for short to ground in hamess. Repair as necessary and go to "Verification of Vehicle Repair procedure. 3. Check for open in harness 1) Ignition "OFF" & Engine "OFF" 2) Disconnect Brake switch and ECM connector. 3) Measure resistance between terminal 4 of Brake switch harness connector and terminal 54 of ECM harness connector. 4) Measure resistance between terminal 1 of Brake switch hamess connector and terminal 59 of ECM harness connector. Specification : Approx. below 10. 1. Brake SW 1 signal 2. Power 3, Power from Relay 4. Brake SW 2 signalFL-233 FUEL SYSTEM 4, Is the measured resistance within specifications ? Go to "Component Inspection” procedure, > Check for open in harness, Repair as necessary and goto "Verfiaton of Vehicle Repair procedure. 1. Check Brake Switch 41). lanition “OFF” 2). Disconnect Brake Switch connector. 3) Check continuity between terminal 1 and 2 of Brake switch connector (Component side). 4) Check continuity between terminal 3 and 4 of Brake switch connector (Component side) ‘SPECIFICATION : = Brake Pedal OFF Brake Pedal ON Switch 1 = Switch 2 ‘Switch 4 el ‘Switch 2 No continuity Continuity Continuity No continuity | '5) Is the measured continuity status within specifications ? > Substitute with a known-good ECM and check for proper operation If the problem is corrected, replace ECM and then go to "Verification of Vehicle Repair” procedure. D> Check Brake switch for contamination, deterioration, or damage. Substitute with a known-good Brake switch and check for proper operation. If the problem is corrected, replace Brake switch and then go to "Verification of Vehicle Repair” procedure. ‘After @ repair, itis essential to verify that the fault has been corrected, 4. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. 2. Operate the vehicle within DTC Enable conditions in General information. 3. Are any DTCs present ? YES Go to the applicable troubleshooting procedure. ‘System is performing to specification at this time.DTC TROUBLESHOOTING PROCEDURES FL-234 NSN (btc P0562 | SYSTEM VOLTAGE LOW (DESCRIPTION © etseseex ‘The charging system includes a battery, generator with @ built in regulator, the charging indicator light, and connecting wiring. The generator uses diodes to rectify alternating current (AC) to direct current (DC) ‘The ECM provides ground to one side of coil of engine main relay and the other side is connected to battery. ‘The ECM monitors battery voltage and the voltage through engine control relay. Detecting Condition Possible Cause DTC Strategy | » Votage check, low | + Open or short in — power(sensing) Enable Conditions _| « Ignition on circuit Threshold Value | Battery voltage > 6V *-Open or shortin —— Charging warning Diagnostic Time sec circuit i MIL eNO | icharang verng Fuel Limit No Lamp Fuel Cut No + Faulty alternator EGR Off «Yes Ulheeas) Failsafe |e Baty vlogs fee at abaik79.Va8 abasic valeFL-235, FUEL SYSTEM SCHEMATIC DIAGRAM —ccrracss |— Fut pump relay Power, CMP sensor, EGA solooid vale [Connection Information) ecw 1 [6280-1 Terminal 45 | Main relay supply power Mein cso nay [stain selay power ON 2 | Powertuse 30A | Main relay power sa ajen 5 Main rely power ON ; : - 2 (a) ha Main tay conto 4 [0200-1 Terminal 13 | Main relay control one 5 | Poworfuse 30a | Main relay power 1 Power u86 99% in ON sons [CONNECTOR] Main relay Hamess side connector ECM side terminal 1 © |= |* 4. Connect scantool to Data Link Cable (DLC), 2. Monitor "Brake Switch” parameter on the scantool FIG1 1.2 CURRENT DATA * rm |ACCEL.POSITION SENSOR 0.8 % |ACCEL.POSITION SENSOR 728. Sn [COOLANT TEMP. SENSOR 53.3 °C IENGINE SPEED 724 rpm |VEHICLE SPEED SENSOR @ = Kn/h 256. 7har 15.6% 1%] [Scan] [Fut] [Parr] [eRrH] [HELP Fig 1) Normal value atid.DTC TROUBLESHOOTING PROCEDURES FL.236 1 2 3 1 Is the Current data displayed correctly ? YES >> Faults intermittent caused by poor contact in the sensor's and/or ECM's connector or was repaired and,ECM memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to “Verification of Vehicle Repair" procedure. } Go to "WiHamess Inspection" procedure. Many maifunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Has a problem been found? Repair as necessary and go to "Verification of Vehicle Repair" procedure. Go to "Power Circuit Inspection” procedure. : Check for open or short in Power hamess 41) Ignition “OFF”. 2) Disconnect Alternator connector. 3) Ignition "ON" & Engine “OFF”. 4) Measure voltage terminal 1 of Alternator hamess connector and chassis ground, ‘Specification : Approx. 11.5V~13.0V. 4. Sensing 2. Charging warningFL-237, 5) FUEL SYSTEM Is the measured voltage within specifications ? YES } Go to" Check for open or short in Charging warning harness” as below. > Check for open or short in the Chargnig warming harness. Repair as necessary and go to "Verification of Vehicle Repair" procedure. 2. Check for open or short in Charging waming hamess. o) 2) 3) 4) 5) Ignition “OFF” & Engine "OFF". Disconnect Alternator connector. Ignition "ON" & Engine “OFF”. Measure voltage terminal 2 of Alternator namness connector and chassis ground. Specification : Approx. 10.6V~12.0V 1. Sensing 2. Charging warning Is the measured voltage within specifications ? eS } Go to "System Inspection” procedure. > Check for open or short in the Charging waming hamess. Repair as necessary and go to "Verification of Vehicle Repair" procedure.DTC TROUBLESHOOTING PROCEDURES, FL.238 ‘SYSTEM INSPECTION = =s0=0884 4. Check Chargnig warning lamp operation. 41) Ignition “OFF” 2) Disconnect Alternator connector. 3) Jump terminal 2 of Brake switch and chassis ground with jumper wire Specification : Warning Lamp ON when grounding 4.Sensing 2. Charging waming 4) Is the warning lamp turned ON 7 : : > Go to" Check for voltage drop on Alternator B+ Cable" as below. > Check warning lamp and then, repair as necessary and go to "Verification of Vehicle Repair” procedure. 2. Check for voltage drop on Alternator B+ Cable. 41) Ignition "ON" & Engine" ON™ 2) Measure voltage between Battery + and Altemator B+. @ nore + probe: Alternator B+, - probe : Battery + “Specification : Approx. below 0.2V(200mV)FL.239 FUEL SYSTEM 3) Is the measured voltage within specifications 2 YES > Go to" Component Inspection” procedure > Check warning lamp connector for contamination, corrosion or damage warning lamp and then, repair as necessary and go to "Verification of Vehicle Repair” procedure. COMPONENT INSPECTION © EFaArA83 = Z 2 4. Check Charging voltage. 1) Ignition “OFF* & Engine "OFF" 2) Check belt tension for alternator. 3) Check Battery terminal, Fusible Link and Altemator B+ for poor connection and corrosion. 4) Ignition “ON” & Engine "ON" 5) Tum ON electrical Load such as Head Lamp, Blower Motor and Defroster. 6) Measure battery voltage when engien is more than 2000 rpm. “Specification : 12.5 ~ 14.5 7). Is the measured voltage within specifications 7 ic > Substitute with a known-good ECM and check for proper operation, Ifthe problem is corrected, replace ECM and then go to "Verification of Vehicle Repair" procedure. > Check height and condition of Brake switch. Substitute with a known-good Brake switch and check for pr- ‘oper operation. If the problem is corrected, replace Brake switch and then go to "Verification of Vehicle Repa- it procedure, VERIFICATION OF VEHICLE REPAIR — cocica2a — After a repair, itis essential to verify that the fault has been corrected. 1, Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. 2. Operate the vehicle within DTC Enable conditions in General information, 3. Are any DTCs present ? YES Go to the applicable troubleshooting procedure ‘System is performing to specification at this time.DTC TROUBLESHOOTING PROCEDURES DTC P0563 | SYSTEM VOLTAGE HIGH ] DTC DETECTING CONDITION. catsBece Item Detecting Condition Possible Cause DTC Strategy |» Votage check, low = Enable Conditions _| ignition on Threshold Value | « Battery voltage > 17.6V + Open or short in Bs power(sensing) Diagnostic Time | « 5 sec Greuit ae a «arin warning Fuellimt | * No + Faulty altemator FuelCut |e No atone EGR Off ° Yes Fail safe _| « Battery voltage is fixed at about 7.9 V as a basic value Refer to DTC P0562,FL.241 FUEL SYSTEM I POWER CIRCUIT INSPECTION — c0si0e65 7 1. Check for open or short in sensing harness. 1) Ignition “OFF” 2) Disconnect Alternator connector. 3) Ignition “ON* & Engine "OFF". 4) Measure voltage terminal 1 of Alternator hamess connector and chassis ground, Specification : Approx. 11.5V~-13.0V 4. Sensing 2. Charging warming 0 I 5) Is the measured voltage within specifications 7 ms Go to” Check for open or short in Charging warning hamess" as below. > Check for open or short in the Chargnig waming hamess Repair as necessary and go to "Verification of Vehicle Repair" procedure. 2. Check for open or short in Charging warning hamess. 41) Ignition "OFF" & Engine “OFF” 2) Disconnect Alternator connector. 3) Ignition "ON" & Engine "OFF". 4) Measure voltage terminal 2 of Alternator names connector and chassis ground. ‘Specification : Approx. 10.5V~12.0V 1. Seneing 2. Charging warningDTC TROUBLESHOOTING PROCEDURES 5) _ Is the measured voltage within specifications ? YES > Go to "System Inspection” procedure. > Check for open or short in the Charging warning harness Repair as necessary and go to "Verification of Vehicle Repair" procedure ‘SYSTEM INSPECTION © éA2ssvee Refer to DTC P0562, ‘COMPONENT INSPECTION £5 Refer to DTC P0562. VE Refer to DTC P0562,FL243 FUEL SYSTEM DTC P0564 | CRUISE CONTROL SWITCH - LOW & HIGH INPUT, RANGE/ PERFORMANCE eiretato "Sh inn ‘The cruise control system keeps the vehicle running at a fixed speed until a signal celing this fixed speed canceling signalis received ‘When the main switch "AUTO CRUISE” is tured on with vehicle in the running mode, the battery voltage is applied to the ECM. When a signal from the control switch is input to the ECM while the vehicle is in state, the cruise control act- ator is activited to operate the system. Also, while the system is operating, "AUTO CRUISE" indicator lamp in the meter assembly lights up. In case of the cruise control system failure, the engine symptoms will occur acceleration failure and vehicle speed sett- ing failure. ie 2S: ESS If the signal exceeds threshold value, the ECM judged this as a fault and DTC is set,DTC TROUBLESHOOTING PROCEDURES, DTC DETECTING CONDITING toa Detecting Condition * Votage check, low or high Enable Conditions | « Engine run Case 1: Output signal < 250 mV * Case 2 Ouiput signal > 49) ‘Threshold Value | Case 2 ifthe vehicle speed governeris off when the resume inputs or ifthe vehicle speed governer is off when the rise contol SET#/SET- switen inputs i i: ¢ Case 1: 60 sec = Diagnostic Time | # Case 2:0.5 sec 3 Case 3: 1300 [- MIL No Fuellimt | No FuelCut_ | eNo EGROM |e No FL.244 Possible Cause + Open or short in ‘cruise control circuit + Faulty cruise ‘control switch + Faulty ECM SCHEMATIC DIAGRAM © Er00soxe = [Connection Information] 1 _[ 6280-1 Terminal 75 | Cruise Cont! Signal 2 : 3_| 230-1 Terminal 40 | Cruse Control Power 4 | 6230-1 Terminal 74 | Grice Control Ground [connecroR} Mui Functon och ECM side terminal wave «l= [>] peeeeee ) ( oe a . f Eresestaesraa) | La ia a Sts * sspatafe| L| |] fae fa Tse =l*1* as :FL.245 FUEL SYSTEM. TERMINAL AND CONNECTOR INSPECTION — &207900¢ Z 1. Many malfunctions in the electrical system are caused by poor harness and terminals Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3, Has a problem been found? YES Repair as necessary and go to "Verification of Vehicle Repair” procedure. Go to "Power Circuit Inspection" procedure. POWER CIRCUIT INSPECTION: “cossvo1e = 1. Check for open or short in harness 41) Ignition "OFF. 2) Disconnect multi-function switch connector. 3) Ignition "ON" & Engine "OFF" 4) Measure voltage between terminal 3 of the multi-function switch harness connector and chassis ground. Specification : Approx. B+ 203 1.Cruise control signal 2. 3. Cruise contr supply 4 Cruise control ground 5) Is the measured voltage within specifications ? > Go to "Signal Circult nspection* procedure Check fr open or shor to ground in power hamess Repair as necessary and go to "Verification of Vehicle Repair" procedure.DTC TROUBLESHOOTING PROCEDURES FL.246 nent SIGNAL CIRCUIT INSPECTION © «sais700 4. Check for open or short in signal harness 41) Ignition "OFF" & Engine “OFF” 2) Disconnect Multunction switch connector. 3) Measure voltage between terminal 1 of the multi-function switch harness connector and chassis ground. Specificati 1. Cruise contrt signal 2 53. Cruise contol supply 4, Cruise control ground 4) Is the measured voltage within specifications ? YES 7 > Go to "Ground Circuit Inspection” procedure. No > Check for open or short to ground in signal harness, Repair as necessary and go to "Verification of Vehicle Repair" procedure. (GROUND CIRCUIT INSPECTION = eras 1. Ignition “OFF” 2. Disconnect Multi-function switch and ECM connector. 3, Measure resistance between terminal 4 of the multi-function switch connector and terminal 74 of ECM harness connector, ‘Specification : Approx. below 19 $-Crie contol gral Ses 2 rf 5 cise conta spo 4 Ge cata pearFL.247 FUEL SYSTEM. 4 COMPONENT INSPECTION = €062830e = 1 Is the measured resistance within specifications ? 5 > Go to "Component Inspection” procedure. > Check for open in harness. Repair as necessary and go to "Verification of Vehicle Repair” procedure. Check Cruise remote control switch 1) 2) 3) 4) 5) Ignition "OFF" Disconnect ECM connector. Measure resistance between terminal 74 and 75 of ECM hamess connector after Main switch ON. Main switch "OFF" and then measure resistance between terminal 40 and 74 of ECM hamess connector after SETICOAST switch ON, SET/COAST switch "OFF" and then, measure resistance between terminal 40 and 74 of ECM hamess connector after RESUME/ACCEL switch ON, SPECIFICATION : VERIFICATION OF VEHICLE REPAIR ~ ©20c06e 1 2 3 6) Main Switch = ‘SETICOAST Switch RESUME/ACCEL Switch 3900 2200 3100 | Is the measured resistance within specifications ? > Substitute with a known-good ECM and check for proper operation. If the problem is corrected, replace ECM and then go to "Verification of Vehicle Repair” procedure. > Substitute with a known-good Cruise Remote control switch and check for proper operation. If the problem is corrected, replace Cruise Remote control switch and then go to "Verification of Vehicle Repa- ir" procedure. After a repair, it Is essential to verity that the fault has been corrected. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. Operate the vehicle within DTC Enable conditions in General information, ‘Are any DTCs present ? YES Go to the applicable troubleshooting procedure. ‘System is performing to specification at this time,DTC TROUBLESHOOTING PROCEDURES FL.248 DTC P0600 | CAN COMMUNICATION BUS COMPONENT LOCATION —<#Ae2641 z DESCRIPTION =Arsos5 0 = GENERAL DESCRIPTION’ The ECM communicates over the CAN with the EMS(Engine Management System), TCS(TractiomControl System) an- 4d el ‘TCM(Transmission Control Moudle). Through CAN, only two Lines are required to achieve the same function, The info- mation is in digital format . This method does not use a integrated ECM. Input signals to TCM through "CAN communication” are as follows. > Engine rpm, TPS signal, A/C signal, WTS signal, AFS signal, Vs signal, Shift holding signal (FTCS ON) Output signals from TCM through "CAN communication” are as follows, > Request signal for torque reduction, ATF temperature, TCM type, TCM error or not, damper clutch on, offigear position. In case of the CAN failure, the engine symptoms will occur the corrupted torque reduction signal information, shift shock and increasing engine rpm abruptiy. DTC DESCRIPTION== a Ifthe CAN communication is generated threshold value, the ECM judged this as a fault and DTC is set.FL249 FUEL SYSTEM DTC DETECTING CONDITION «s4aaso5 ee [tem Detecting Condition Possible Cause DTC Strategy _| « Signal check, high and low Enable Conditions | « Ignition on a a ———___________} Open in signal Threshold Value communication circuit Diagnostic Time | « 1 sec. + Short to ground in | signal circuit iL = No + Faulty TOM Fuel Limit. | # No + Faulty ECM Fuel Cut No EGR Off No ‘SCHEMATIC DIAGRAM cerscasa Some e ar a ea {Connection information} Paes Eom Function cavcencin 9 10 can oucn (6230-1 Terminal 10 | GAN (gh) caxgom 4 2 caxaom (C224. Terminalé | 200-1 Terminal | CAN (ow) [oonnecroR] ECM sie erminl “TOM Harness side connector al =r a Epistles npolele[7]els aia ia Pets atotete| can02 camoDTC TROUBLESHOOTING PROCEDURES, FL-250 SIGNAL WAVEFORM Esearacs. Tq This test should be inspected after depressing the HOLD mode while idling. In this CAN communication signal waveform, itis impossible to read through by displaying the scantool I unstable waveform pattern with non-uniform frequency or no signal, replace the ECM or the TCM after checking the wiring harness. HA: 3.00 DT: @.t4nS CHB: 1. CAN High side DEY [coor] FET | soo] ra] or) TERMINAL AND'CONNECTOR INSPECTION © = €F7s00E= 1. Many malfunctions in the electrical system are caused by poor harness and terminals, Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3, Has problem been found? YES Repair as necessary and go to "Verification of Vehicle Repair” procedure, Go to "Signal Circuit inspection” procedureFL251 FUEL SYSTEM SIGNAL CIRCUIT INSPECTION — s0ssae0 4, Check for open in harness 1) Ignition "OFF" & Engine "OFF" 2) Disconnect ECM & TCM connector. 3) Measure resistance between terminal 4 of TCM harness connector and terminal 9 of ECM hamess connecto- r 4) Measure resistance between terminal 3 of TCM hamess connector and terminal 10 of ECM hamess connect or. Specification : Approx. below 10. czas c2es 8. CAN HIGH o @ 4. CAN LOW 230-1 9. CANLOW 10. CAN HIGH 200-1 CS a 6) Is the measured resistance within specifications ? YES > Go to"Check for short to ground in hamess” as below. > Check for open in the signal harness. Repair as necessary and go to "Verification of Vehicle Repair” procedure. 2. Check for short to ground in hamess. 41) Ignition "OFF" & Engine "OFF" 2) Disconnect TCM,ECM, TCCU and HCU connector. 3) Measure resistance between terminal 4 of TCM harness connector and chassis ground.DTC TROUBLESHOOTING PROCEDURES, FL-252 4) Measure resistance between terminal 3 of TCM harness connector and chassis ground. 224-3 3.CANHIGH 4.CANLOW 5) _ Is the measured resistance within specificaitons 7 723 } Go to "Component inspection" procedure. > Check for short to ground in signal hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure. ‘COMPONENT INSPECTION: essse004 1. Check resistance 41) Ignition "OFF" & Engine "OFF" 2). Disconnect TCM connector. 3) Measure resistance between terminal 3 and 4 of TCM hamess connector. ‘SPECIFICATION Not TOS, 4WD [ Tes, aw ECM & TCM connected ECM connected only TOM connected only ECM & TCM connected 600 10 4200 #20 | 4200 #20 | 1209 +20 cx243 SLOAN HIGH = ‘S0ANLOWFL-253 FUEL SYSTEM 4) Is the measured resistance within specifications 7 > Go to "Check signal waveform” as below. > Substitute with a known-good ECM and check for proper operation, If the problem is corrected, replace ECM and then go to "Verification of Vehicle Repair" procedure. 2. Check signal waveform 1) Ignition "OFF" & Engine "OFF" 2) Disconnect ECM connector. 3) Monitor signal waveform at terminal 3 and 4 of TCM connector simultaneously fia: 9.@U DI: @.d4nS CHB: 1.1 ‘can}High sige LER AR lll aan cAN|Law sido TEEN [zoon Teno] [RSD] ran] _| 4) Are CAN signals generated correcty 7 > Thoroughly check connectors for looseness, poor connection bending, corrosion, contamination, deteriora tion, or damage. Repair or replace as necessary and then go to "Verification of Vehicle Repair procedure, > Substitute with a known-good ECM and check for proper operation, If the problem is corrected, replace ECM and then go to "Verification of Vehicle Repair" procedure, VERIFICATION OF VEHICLE REPAIR EFemors ‘After a repair, itis essential to verify thatthe fault has been corrected. 4. Connect scan too! and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. Operate the vehicle within DTC Enable conditions in General information, 3. Are any DTCs present ? Go to the applicable troubleshooting procedure, ‘System is performing to specification at this time.DTC TROUBLESHOOTING PROCEDURES FL-254 [DTC P0602 | EEPROM - PROGRAMMING ERROR COMPONENT LOCATION — E#seace= Refer to DTC PO6OO. DESCRIPTION — Eeaseou0 ge GENERAL DESCRIPTION ©) Se) = = pes s ‘The ECM function switches valid for the whole driving cycle ate selected in the initialization of the background test and are made avaliable in the corresponding messages. ‘An ECM ROM malfunction is detected by using a checksum technique for verifying data. Digital data is composed of zeros and ones. A checksum is the total of all ones in a string of data, By comparing the checksum value with a stored value, a malfunction can be detected, In case of the EEPROM error, the engine symptoms will occur the running engine stall and the starting impossible. DTC DESCRIPTION © > © ‘i If the ECM is generated threshold value, the ECM judged this as a fault and DTC is set. DTC DETECTING CONDITIO! item I Detecting Condition DTC Strategy | « ECM check : Enable Conditions _| « ignition on Threshold Value | « EEPROM eae Possible Cause Diagnostic Time | O sec. * Faulty ECM MIL ° Yes Fuel Limit * No FuelCut | Yes EGR Off [eno TERMINAL & CONNECTOR INSPECTION — Replace ECM and then go to "Verification of Vehicle Repair” procedure. > Thoroughly check connectors for looseness, poor connection bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and then go to "Verification of Vehicle Repait” procedure. VERIFICATION OF VEHICLE REPAIR =200514 After a repair, itis essential to verify that the fault has been corrected. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. (Operate the vehicle within DTC Enable conditions in General information. ‘Are any DTCs present ? ms ‘ Go to the applicable troubleshooting procedure. ‘System is performing to specification at this time,DTC TROUBLESHOOTING PROCEDURES, DTC P0603 | EEPROM - COMMUNICATION & MEMORY ERROR Refer to DTC P0600. DESCRIPTION © eroco020 ‘The ECM function switches valid for the whole driving cycle are selected in the initialization of the background test and ate made available in the corresponding messages. a= ‘An ECM ROM matfunction is detected by using a checksum technique for verifying data, Digital data is composed of zeros and ones. A checksum is the total ofall ones in a string of data By comparing the checksum value with a stored value, a malfunction can be detected. In case of the EEPROM error, the engine symptoms will occur the running engine stall and the starting impossible, If the ECM is generated threshold value, the ECM judged this as a fault and DTC is set. lem Detecting Condition Possible Cause DTC Strategy _| « ECM check Enable Conditions | e ignition on * Case 1:EEPROM - communication error Threshold Value | # Case 2:EEPROM - calibration error © Case 3:EEPROM - code word is incorrect or missing © Case 1: 0800 a Diagnostic Time | ¢ Case 2: 0 sec iu # Case 3: 0 sec | MIL ° Yes = Fuel Limit Yes Fuel Cut No EGR Off *NoFL257 FUEL SYSTEM TERMINAL & CONNECTOR INSPECTION = a0FCScE = 2 1. Many matfunctions in the electrical system are caused by poor hamess and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3. Has a problem been found? YES Repair as necessary and go to "Verification of Vehicle Repair” procedure. Go to "Component Inspection” procedure. COMPONENT INSPECTION © essaécce 1. Check ECM, 1) 2) 3) 4) VERIFICATION OF VEHICLE REPAIR © 022101 After a repair, Ignition "OFF" & Engine "OFF" Disconnect ECM from vehicle. ‘Substitute with a known-good ECM and check for proper operation. Is the problem corrected? . > Replace ECM and then go to “Verification of Vehicle Repair” procedure, " > Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and then go to "Verification of Vehicle Repair” procedure. is essential to verify that the fault has been corrected. Connect scan tool and select “Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. (Operate the vehicle within DTC Enable conditions in General information. Are any DTCs present ? 3 Go to the applicable troubleshooting procedure. ‘System is performing to specification at this timeDTC TROUBLESHOOTING PROCEDURES DTC P0650 | MALFUNCTION INDICATION LAMP(MIL) CONTROL CIRCUIT MALFUNCTION 0/5} OF =e Failure diagnosis results are output as diagnosic codes and are displayed on malfuction indicator lamp. When the diagnostic code output terminal is tumed to the ON position, ‘The MIL is the error lamp demanded by the EOBD for exhaust-relevant errors. Energizing by the MIL is done under the MIL lamp test is active or a path with the characteristic "MIL blinking” is prelim- inary entered in the memory. Then the MIL blinks.In case of the engine check failure, the engine check lamp will no ilk Uuminates to notify the driver. If the engine check lamp circuit is generated threshold value, the ECM judged this as a fault and DTC is set. item Detecting Condition Possible Cause DIC Strategy | « Circuit continuity check Enable Conditions _| « Ignition on Threshold Value _ | « Short for engine check lamp control c + Short to MIL Diagnostic Time | 1 sec, control circuit ~ — + Fauity Bulb ie Ae + Faulty ECM Fuel Limit | ¥ No Fuel Cut *No EGR Off © NoFL259 SCHEMATIC DIAGRAM Ess?0ac2 FUEL SYSTEM Instrument cluster [Connection Information] Lorie ores a ace Fuse 6 EK Ol) (Ov reocecs | a | 2 | 36 if tes 1.4 ACTUATION TEST MILCENGINE CHECK) DURATION |UNTIL STOP KEY METHOD ACTIVATION CONDITI ON |1G.KEY ON ENGINE RUNNING PRESS CSTRTJ, IF YOU ARE READY t SELECT TEST ITEM USING UP/DOWN KEY [STRT, STOP] Battery voltage is applied to the engine check lamp By the ECM in ‘order to notify the driver that the ECM is detecting the DTC. For checking short inthe wire between the fuse (10A) and the ECM, the START key should be pressed in the scan tool actuation test mode. ‘And then make sure that the engine check lamp comes ON and stays during the "NOW ACTIVATING indicationDTC TROUBLESHOOTING PROCEDURES FL.260 1. Many malfunctions in the electrical system are caused by poor hamess and terminals, Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage, 3. Has a problem been found? ms ais as necessary and go to "Verification of Vehicle Repair" procedure. Go to " Control Circuit Inspection * procedure. 4. Ignition "OFF" & Engine "OFF". 2. Disconnect ECM connector. 3. Ignition “ON” & Engine "OFF. 4. Measure voltage between terminal 29 of ECM hamess connector and chassis ground. Specification : Approx. 10.8 ~ 13.0V 29. IL contrat 5. Is the measured voltage within specifications 7 } Go to” Component inspection " procedure. > Check for short to battery in control harness. Repair as necessary and go to "Verification of Vehicle Repair" procedureFL-261 FUEL SYSTEM COMPONENT INSPECTION ersozr 4. Check MIL. 41) Ignition "ON" & Engine "OFF" 2) Disconnect ECM connector. 3) Jump terminal 29 of ECM hamess connector and chassis ground with jumper wire. 4) Is the MIL turned ON ? eS > Go to” Check bulb " as below. > Check for short to battery in the signal hamess, Repair as necessary and go to "Verification of Vehicle Repair procedure. 2. Check Bulb. 41) Ignition “OFF” & Engine "OFF" 2) Remove Instrument Panel and then remove bulb from instrument panel. 3) Apply 12 voltage to the bulb and check that bulb is turned ON. 4) Is the bulb turned ON ? ZS > Substitute with a known-good ECM and check for proper operation, Ifthe problem is corrected, replace ECM and then go to "Verification of Vehicle Repair” procedure, > ‘Substitute with a known-good bulb and check for proper operation. Ifthe problem is corrected, replace bulb and then go to "Verification of Vehicle Repair" procedure. VERIFICATION OF VEHICLE REPAIR =<8: After a repair, itis essential to verity that the fault has been corrected, Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. 2. Operate the vehicle within DTC Enable conditions in General information. ‘Are any DTCs present ? YES Go to the applicable troubleshooting procedure, ‘System is performing to specification at this timeDTC TROUBLESHOOTING PROCEDURES FL.262 [DTC P0704 | CLUTCH PEDAL S/W MALFUNCTION Se SS aS eee eee J Signals including de-clutching, first gear, and initial acceleration. The clutch switch also controls cancellation of cruise control. . To prevent engine rpm surging when de-clutching (during gear changes), the ECM adjusts injector operation To check the normal signal from the clutch switch, you should check ON signal current data while depressing the clutch pedal Ifthe clutch switch signal generates, the ECM judged this as a fault and DTC is set. DTC DETECTING CONDITIOI item | Detecting Condition DTC Strategy _| Signal check Enable Conditions | Vehicle speed > 80 Kmih Threshold Value | « No cutch signal + Open or shor in : oo power circu jagnontic Time | Osee. ae “Open in ground iL *No cir FuelLimt | 8 No "Faulty clutch sviteh FuelCut | eNO * Faull ECM EGR Off No Fail safe ‘= Cruise control system deactvitedF263, FUEL SYSTEM SCHEMATIC DIAGRAM — eanipéce peepee ECM [Connection Information} Ctuch sitcn 1 [607 Body ground | _Ctuch switch ground 12 |eas3 290-1 2 | 6230-1 Terminal 61 | _Giutch swich signal [ ‘oo 81 Oltch swten [CONNECTOR] Ciuc switch Hamess side connector EOM side terminal 1 ~[ =I * 2 =[=[=] © im mines 230-2 c2s01 Seems ae After the ignition switch on, the clutch switch is OFF signal to 7] tneech. When depressing the clutch pedal, the clutch switch is ON signal to the ECM. |ACCEL.POSITION SENSOR 728. 3nU To check the normal signal from the clutch switch, you should coon vais cmson? ists te check ON signal current data while depressing the clutch pedal. 1.2 CURRENT DATADTC TROUBLESHOOTING PROCEDURES FL.264 MONITOR SCANTOOL DATA = <2sst3+e = 4, Connect scantoo! to Data Link Cable (DLC). 2. Monitor Clutch Switch " parameter on the scantool. FIG1 1.2 CURRENT DaTA ‘OREN . [ACCEL. POSITION SENSOR 720. 3nU lcooLaNT TEMP. SENSOR 19.3 °C IENGINE SPEED 828 rpa VEHICLE SPEED SENSOR = @ Kn“ | [FUEL PRESSURE 264.8bar [FUEL PRESS. REGULATOR 15.8 % InGR ACTUATOR 95.8 % FIX | [SORN] [FULL] [Part] [eRPH] [HELP Fig 1) Normal value when depressing clutch pedal. Is Current data displayed correctly ? > Fault is intermittent caused by poor contact in the sensor's and/or ECM''s connector or was repaired and ECM memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification vehicle Repair” procedure- } Go to "WiHamess Inspection” procedure. TERMINAL & CONNECTOR INSPECTION = i 4, Many maifunctions in the electrical system are caused by poor hamess and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3. Has a problem been found? YES Repair as necessary and go to "Verification of Vehicle Repair” procedure. Go to" Power Circuit Inspection" procedure.FUEL SYSTEM Ignition "OFF" & Engine "OFF". Disconnect Clutch switch connector. Ignition "ON" & Engine "OFF". Measure voltage between terminal 2 of the clutch hamess connector and chassis ground. Rene Specification : Approx. 11.5V ~ 12.5V 41.Ground 2. Clutch Sulch (12V) 5. Is the measured voltage within specifications ? YES . Go to "Ground Circuit Inspection" procedure. D> Check for short to battery in control harness. Repair as necessary and go to "Verification of Vehicle Repair” procedure GROUND CIRCUIT INSPECTION E S 4. Ignition "OFF" & Engine "OFF". 2. Disconnect Clutch switch connector. 3. Measure resistance between terminal 1 of clutch switch harness connector and chassis ground G21 ecification : Approx. below 19 (0259) 1. Ground 2 Giutch Switeh (12¥) = (G21)DTC TROUBLESHOOTING PROCEDURES FL-266 4, Is the measured resistance within specifications ? 5 > Go to “Component Inspection’ procedure } Check for open in harness. Repair as necessary and go to "Verification of Vehicle Repair” procedure. 4. Check Clutch switch. 1) Ignition "ON" & Engine “OFF”, 2) Disconnect Clutch switch. 3) Measure continuity between terminal 1 and 2 of clutch switch connector (To clutch switch connector) ‘SPECIFICATIONS | eich Pedal OFF Continuity (Below 10) No continuity (O.L Q) 4) Is the measured resistance within specifications ? > Substitute with a known-good ECM and check for proper operation. Ifthe problem is corrected, replace ECM and then go to "Verification of Vehicle Repair" procedure. > Substitute with @ known-good Clutch switch and check for proper operation Ifthe problem is corrected, replace Clutch switch and then go to "Verification of Vehicle Repair’ procedure. After a repair, itis essential to verify that the fault has been corrected. 1. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. 2. Operate the vehicle within DTC Enable conditions in General information. 3. Are any DTCs present? YES Go to the applicable troubleshooting procedure. ‘System is performing to specification at this time.FL-267 FUEL SYSTEM IDTC P1182 | FUEL PRESSURE REGULATOR SHORT SS eee The FPR (Fuel Pressure Regulator) sets the correct pressure in the rail as a function of engine, loading and maintains itat this level. If the rail pressure is excessive, the pressure control valve opens and a portion of the fuel returns from the tank via @ collector line, the fuel If the rail pressure is too low, the pressure control valve closes and seals off the high pressurestage from the low pressure stage. In case of the fuel pressure regulator failure, the engine symptoms will occur the shut down and the starting impossible-. DTC DESCRIPTION: = SS Sh SSeS = Ifthe FPR circuit generates threshold value, the ECM judged this as a fault and DTC is set. DTC DETECTING CONDITION Item Detecting Condition Possible Cause DTC Strategy | « Circuit continuity check Enable Conditions | ¢ Engine run OS orisbaney i Threshold Value _ | ¢ Short for fuel pressure regulator circuit. power circuit Diagnoste Time | « 0.3 sec * Short to battery in | ce $$] contrat ciruit | Mit + Yes Pauly FPR | Fuellimt | No * Faulty ECM Fuelcut | Yes | conor [tne |DTC TROUBLESHOOTING PROCEDURES FL.268 ‘SPECIFICATION ! 2 oycle time T becomes longer when accelerating a pressure regulator is closing to allow a small amount fuel 0 Fetumed to the fuel tank. H position t ' lh | ‘The rail pressure regulator is opening and closing by the ECM duty | control. b : closing position Zon] KEM [nero] [ween] [reno] _|FL269 FUEL SYSTEM MONITOR SCANTOOL DATA © Eiéosse8 © i 2 1. Connect scantool to Data Link Cable (DLC). 2. Warm up engine to normal operating temperature. 3. Monitor that " Fuel Pressure and Fuel Pressure Regulator " parameter on the scantool. FIG 4 1.2 CURRENT DATA z x|nass AIR FLOW 477 ng/st| %|ACCEL.POSITION SENSOR 718.50 x [ENGINE SPEED 749 rpm x |FUEL PRESSURE 270.?bar | : [EAT x EGR ACTUATOR 95.8% » |PUEL QUaNTITY 8 nce [BATTERY VOLTAGE 14.20 v FIA | [SeRN] [FULL] [PART] [GRPH] [HELP] FIG2 : 4.3 FLIGHT RECORD 2008. | XFUEL PRESSURE bar [a frees. 2.8 108.8 | FUEL PRESS. REGULATOR % . fxz.0 0.8 v List |tT-33) 110.6 81 [FIN | [HONE] Fig 1) Normal value with fuel pressure and pressure regulator at idle, Fig 2) Normal value with fuel pressure and engine speed while accelerating and deceleratingDTC TROUBLESHOOTING PROCEDURES: FL270 Is the Current data displayed correctly ? > Faults intermittent caused by poor contact in the sensor's and/or ECM's connector or was fepaired and ECM. memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification vehicle Repair’ procedure. > Go to "WiHamness Inspection” procedure. ‘TERMINAL & CONNECTOR INSPECTION c=ronnza 1. Many malfunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3. Has a problem been found? YES Repair as necessary and go to "Verification of Vehicle Repair” procedure. Go to" Power Circuit Inspection " procedure. : POWER CIRCUIT INSPECTION 4. Ignition "OFF" & Engine “OFF* 2. Disconnect Rail Pressure regulator connector. 3. Ignition "ON" & Engine "OFF". 4, Measure voltage between terminal 1 of the rail pressure regulator harness connector and chassis ground. Specification : Approx. 11.5 ~ 13.5V e202 1. Fuol Prossure regulator High 2. Fuel Prossure regulator LowFL271 FUEL SYSTEM 5. Is the measured voltage within specifications ? YES > Goto" Control Circuit Inspection’ procedure > Check for short to battery in the power hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure. CONTROL CIRCUIT INSPECTION — Ess2esce 1. Check for short to battery in hamess, 1) Ignition "OFF" 2) Disconnect Rail pressure regulator connector. 3) Measure voltage between terminal 2 of rail pressure regulator hamess connector and chassis ground, Specification : Approx. below 1V ae e202} 1. Fuel Pressure regulator High 21 Fual Pressure requiaior Low 4) Is the measured voltage within specifications ? YES > Go to” Component Inspection " procedure. > Check for short to battery in ground hamess. Repair as necessary and go to "Verification of Vehicle Repair" procedure.DTC TROUBLESHOOTING PROCEDURES. FL-272 eee 4. Check Rail Pressure Regulator. 41) Ignition "OFF*. 2). Disconnect Rail Pressure Regulator. 3) Measure resistance between terminal 1 and 2 of rail preussure regulator connecor(Component side). ‘Specification :2.07 ~2.63 0 (20°C) (e202 4. Fuol Pressure regulator High 2. Fuel Pressure regulator Low 4) Is the measured resistance within specifications ? . > Go to” Check regulating pressure" as below. > Substitute with a known-good rail pressure regulator and check for proper operation. Ifthe problem is corrected, replace rail pressure regulator and then go to "Verification of Vehicle Repair” procedure, 2. Check regulating pressure. 41) Ignition “ON” & Engine “O1 2) Monitor signal waveform or graph function of current data by connecting scantool at terminal 2 of Rail preussure regulator. 3) Ignition "OFF" then Igintion "ON" before Main relay OFF. @ sore If Main relay OFF, Monitoring current data is impossible. Because Sensor power is cut and communication between scantool and ECM is off. This test should be done without any leakage from injector nozzle, return line and high pressure line.FUEL SYSTEM FL273 ‘SPECIFICATION ‘Scopemeter [ ‘Scantool ‘Voltage for rail pressure sensor at idle keep up 1.2V~ —_| Pressure detected by Rail pressure sensor keep up 1.4V. | 250bar at idle. Then, the voltage will drop to 0.7V at the point of Key off. | Then, Pressure will drop rapidly upto 100bar at the point Finally Signal waveform shows that voltage is getting | of key off ‘slow down, Finally, Graph shows that pressure is getting slow down, | 4) Does the measured pressure drop rapidly upto 100bar after Key OFF ? YES > Substitute with a known-good rail pressure regulator and check for proper operation. Ifthe problem is corrected, replace rail pressure regulator and then go to "Verification of Vehicle Repair" procedure. NO > Substitute with a known-good ECM and check for proper operation. If the problem is corrected, replace ECM and then go to "Verification of Vehicle Repair” procedure. After a repair, itis essential to verify that the fault has been corrected. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. Operate the vehicle within DTC Enable conditions in General information, ‘Are any DTCs present ? as Go to the applicable troubleshooting procedure. ‘System is performing to specification at this time.DTC TROUBLESHOOTING PROCEDURES [DTC P1183 | RAIL PRESSURE REGULATOR - OPEN OR SHORT CIRCUIT ] Refer to DTC P1182. DICDESCRIPTIONS ees i EE Ifthe FPR circuit generates threshold value, the ECM judged this as a fault and DT Item | Detecting Condition Possible Cause DTC Strategy _| « Circuit continuity check + Open or short in Enable Conditions | e Engine run power cet = Sar crea ee «Open OF Shion! Threshold Value _ | ¢ Open or Short for fuel pressure regulator circuit peed a consi Diagnostic Time | # 0.3 sec. : circuit aE aya Fea | Pau EP + Faulty RPS uel Limit No 2 Fault Bee | Fuel Cut Yes | EGR Off © No 07 ~ 2.530 at 20" Refer to DTC P1182 Refer to DTC P1182 MONITOR SCANTOOL DATA erecacze = me Refer to DIC P1182 TERMINAL & CONNECTOR INSPECTION —Eces9808 Refer to DTC P1182FUEL SYSTEM 4. Ignition “OFF” & Engine "OFF". 2. Disconnect Rail Pressure regulator connector. 3. Ignition "ON" & Engine "OFF". 4, Measure voltage between terminal 1 of the rail pressure regulator harness connector and chassis ground, Specification : Approx. 11.5 ~ 13.5V (e202) 1. Fuel Pressure regulator High 2. Fuel Pressure rogustor Low 5. Is the measured voltage within specifications ? m5 : } Go to" Ground Circuit Inspection” procedure. > Check for short to battery in the power hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure. ea — 1 CTIC 4. Check for short to battery in harness. 1) Ignition "OFF" 2) Disconnect Rail pressure regulator connector. 3) Measure voltage between terminal 2 of rail pressure regulator hamess connector and chassis ground. Specification: Infinite (e202) 1. Fuel Pressure regulator High 2. Fuel Pressure reguator LowDTC TROUBLESHOOTING PROCEDURES, FL.276 4) Is the measured voltage within specifications ? 3 > Goto" Check for open in hamess * as below. > Check for short to ground in ground hamess. Repair as necessary and go to "Verification of Vehicle Repair’ procedure 2. Check for open in harness. 41) Ignition "OFF" 2). Disconnect Rall pressure regulator and ECM connector. 3) Measure registance between terminal 2 of rail pressure regulator hamess connector and terminal 28 of ECM harness connector. ‘Specification : Approx. below 19 (e202 1. Fuel Pressure rogulator High 2 Fuel Pressure regulator Low 4) Is the measured resistance within specifications 7 YES > Go to” Component Inspection " procedure. > Check for open in ground hamess. Repair as necessary and go to "Verification of Vehicle Repair" procedure.FL277, FUEL SYSTEM COMPONENT INSPECTION. Ec#1Asso pipet area y 4. Check Rail Pressure Regulator. 41) Ignition "OFF™ 2) Disconnect Rail Pressure Regulator. 3) Measure resistance between terminal 1 and 2 of rail preussure regulator connecor(Component side) specification : 2.07 ~ 2.639 (20°C) lame, 1. Fuel Pressure regulator High 2. Fusl Pressure regulator Low 4) Is the measured resistance within specifications ? : } Goto” Check regulating pressure" as below. > Substitute with a known-good rail pressure regulator and check for proper operation. Ifthe problem is corected, replace rail pressure regulator and then go to "Verification of Vehicle Repair" procedure. 2. Check regulating pressure. 41) Ignition "ON" & Engine "ON". 2). Ignition "OFF" then Igintion "ON" before Main relay OFF. 3) Monitor signal waveform or graph function of current data by connecting scantool at terminal 2 of Rail preussure regulator. @ nore If Main relay OFF, Monitoring current data is impossible. Because Sensor power is cut and communication between scantool and ECM is off. This test should be done without any leakage from injector nozzle, return line and high pressure line, Time to pressurize upto 250bar is required as shortly as possible after starting but the time to release the pressure to 100 bar after ignition of is required as quickly as passble, However, time to release the pressure from 100bar to Obar is required as slowly as possible. Refer to picture and 2 as below.DTC TROUBLESHOOTING PROCEDURES 4.2 Current Data 250 bar [253.6] ‘580.0 | ¥ Ral Pressire > Fime to 250 bar bar fte.9 TOG. | Rai Presaze regulator valve ee 4.2 Current Data 588.6 | ¥Ral Pressure Bar Pressure retension 2.8 1106.6 | Rai Pressure regulator vale % Voltage Pressure 14V. slow down, Voltage for rail pressure sensor at idle keep up 1.2V~ Then, the voltage will drop to 0.7V at the point of Key off. Finally Signal waveform shows that voltage is getting Pressure detected by Rail pressure sensor keep up 250bar at idle. Then, Pressure will drop rapidly upto 100bar at the point of key off. Finally, Graph shows that pressure is getting slow down, 4) Is the rail pressure data displayed correctly ? > Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification vehicle Repair" procedure > Perform Rail Pressure Sensor & Rall Pressure regulator Inspection procedure, For more detail information, refer to DTC P0192,0193 and P0180 for Rail Pressure sensor and DTC P1182,P1183 and P1184 for Rail Pressure regulator troubleshooting procedure Repair or replace as necessary and go to "Verification of Vehicle Repair’ procedure VERIFICATION OF VEHICLE REPAIR eaba0280 Refer to DTC P1182,FUEL SYSTEM Item Detecting Condition Possible Cause DTC Strategy __| © Rationality check Enable Conditions | e After ignition switch OFF in engine running Threshold Value | © Engine speed > S00rpm within 1.5 sec. + Faulty Injectors Diagnostic Time _| « 0 sec. + Faulty FPR MIL = Yes + Faulty ECM Fuel Limit | ¢ No Fuel Cut Yes EGR Off No Refer to DTC P1182. Refer to DIC P1182. Refer to DTC P1182,DTC TROUBLESHOOTING PROCEDURES, FL-280 eee e—eEe—e—eeyS COMPONENT INSPECTION: Perform injectors & Rall Pressure regulator Inspection procedure. For more detail information, refer to DTC. P0261 to P0272 for Injectors. Repair or replace as necessary and Substitute with a known-good ECM and ccheck for proper operation. Ifthe problem is corrected, replace ECM and then go to “Verification of Vehicle Repair” procedure. > Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deteriora~ tion, or damage. Repair or replace as necessary and go to "Verification vehicle Repair’ procedure. VERIFICATION OF VEHICLE REPAIR Essie et After a repair, it is essential to verify that the fault has been corrected. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. 2. Operate the vehicle within DTC Enable conditions in General information 3. Are any DTCs present ? YES Go to the applicable troubleshooting procedure, ‘System Is performing to specification at this time.FL281 FUEL SYSTEM (DTC P1185 | MAXIMUM PRESSURE EXCEEDED COMPONENT LOCATION ° = 1450 bar (Maxi im pressure exceed) + Faulty RPS Diagnostic Time | 0.24 sec. + Faulty FPR me oe + Faulty ECM FuelLimit | « Yes Fuel Cut Yes EGR Off = NoDTC TROUBLESHOOTING PROCEDURES SPECIFIGATION. =9sareo2 = te i ~ Engine ide stat Fully acceleration (100%) Rail Pressure 220 ~ 820 bar (22 ~ 32 Mpa) 1500 bar (150 Mpa) ‘Signal Voltage Below1.7V Approx. 4.5V SCHEMATIC DIAGRAN gee a ae Fuel prossure reguator [Connection information) (5202 Fuel pressure regulator v1 Fue 27 Fuel pressure regulator (High) | [+ 26 Ful pressure regulator (Low) assure sensor gound }9. Fuel pressure sensor power 10 Fuel pressure sonsor signal (0230-2 Terminal 27 2 | 0290-2 Terminal 26 ‘ce02 Fuel pressure sensor + [0230-2 Terminals Fuel pressure regulator (High) Fuel pressura regulator (Low) Fuel pressure sensor power Fuel pressure sensor signal 2 | ©2902 Terminal 10 2 (62802 Terminal 11 | Fuel prossure sensor ground SIGNAL WAVEFORM excess) Foal pressure sonsor (conNecToR] : FFPRLand RPS Harness side connector ECM side trminal 2302 zat fe 4.2 UV DT:420.0008 FREQ: 2.38 H: Full acceleration Idle state Zoom 1 Zon [ecb] [rNU] Tao] ‘This test should be inspected after depressing the HOLD mode from run after the sudden acceleration. PS signal voltage is less than 1V to over 4.5V. “The waveform pattern become increasing upward rapidly when the engine speed increasesFUEL SYSTEM MONITOR'SCANTOOL'DATA’ —-€s0050:5" z Scasruras 4. Connect scantoo! to Data Link Cable (DLC). 2. Warm up engine to normal operating temperature. 3. Monitor that" Fuel Pressure and Fuel Pressure Regulator " parameter on the scantool FIG 4 1.2 CURRENT Dara a x % |FUEL PRESS. REGULATOR 16.7 % IINr.ALR TEMP. SNSR zaacc | a |ACCEL. POSITION SENSOR 6.8 % JnccrL.PosiTIoN SENSOR 713.600 Jcoovawr ten. sensor 78.8 °C lescine seep 751 vpn JveHICLE SPEED SENSOR 8 Kah 7 Fim] [Sean] [Fu] [PART] [ona] [HELP FIG2 1.3 FLIGHT RECORD 60 | MENGINE SPEED vee [ah - (UNE eo . 2608. | FURL, PRESSURE tar fa. 0.0 v ist tr-ser 134.8 81 [Rie] [non] Fig 1) Normal value with fuel pressure and pressure regulator at idle. Fig 2) Normal value with fuel pressure and engine speed while accelerating and decelerating, Is the Current data displayed correctly ? > Faults intermittent caused by poor contact in the sensor's and/or ECM's connector or was repaired and ECM memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair’ procedure. > Go to"WiHamess Inspection” procedure.DTC TROUBLESHOOTING PROCEDURES. FL.284 TERMINAL & CONNECTORINSPECTION — cssese7r Refer to DTC P1182, COMPONENT INSPECTIOI 4. Check Rail pressure. 41) Ignition "ON" & Engine "ON". 2) Ignition "OFF* then Igintion "ON" before Main relay OFF. 3) Monitor signal waveform or graph function of current data by connecting scantool at terminal 2 of Rail preussure regulator. ( Nore If Main retay OFF, Monitoring current data is impossible. Because Sensor power is cut and communication between scantool and ECM is off This test should be done without any leakage from injector nozzle, return line and high pressure line. Time to pressurize upto 250bar is required as shortly as possible after starting but the time to release the pre- sssure to 100 bar after ignition off is required as quickly as passble. However, time to release the pressure from 100bar to Obar is required as slowly as possible. Refer to picturet and 2 as below. 1.2 Current Data 300.8 bar ‘Time to 250 bar . fs3.9] a0 108-6 | Fal Pressure requatorvaive % fis.9 0.8 Seemiecrat 4-2 Current Data 508.0 | Fas Pressure bar Pressure Bs retension —100 bar ea 108-8 [Fa Prestureroguatorvave % fa DOs fee ‘SPECIFICATION E Voltage ee Pressure ‘Voltage from rail pressure sensor at ile is required to | Pressure detected by Rall pressure sensor is required to keep up with 1.2V ~ 7.4V. keep up with 250bar at idle. Then, the voltage will be drop to 0.7V at the point of Key | Then, Pressure will be drop rapidly upto 100bar at the off point of key off Finally Voltage is getting slowly down | Finally, Pressure is getting slowiy downFL.285 FUEL SYSTEM 4) Is the rail pressure data displayed correctly ? YES > Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to “Verification of Vehicle Repair" procedure. > Perform Rail Pressure Sensor & Rail Pressure regulator Inspection procedure. For more detail information, refer to DTC P0192,P0193 and P0190 for Rail Pressure sensor and DTC P1182,P1183 and P1184 for Rail Pressure regulator troubleshooting procedure. Repair or replace as necessary and go to "Verification of Vehicle Repair” procedure. VERIFICATION OF VEHICLE REPAIR Refer to DTC P1182,DTC TROUBLESHOOTING PROCEDURES. FL.286 ey ———————— Eh DTC P1186 | FUEL PRESSURE MONITORING - MINIMUM PRESSURE AT ENGINE SPEED TOO LOW Ifthe fuel pressure monitoring in engine fuel pressure line generates threshold value, the ECM judged this as a fault and DTC is set tem Detecting Condition Possible Cause DTC Strategy _| e Rationality check ‘© Case 1:0 < Engine speed < 2400 rpm Enable Conditions |, Case 2: Engine speed > 2800 rpm — + Faulty Fuel filter ‘* Case 1: Rall pressure < 120 bar + Faulty Electric fuel Threshold Value | # Case 2: Rail pressure < 200 bar pump (Governor deviation at the high engine speed) Faulty Injector + Faulty FPR Diagnostic Time _ | » 0.0012 sec. + Faulty RPS MIL Yes = hea eo Fuel Limit * Yes Fuel Cut # Yes EGR Off © No Rail Pressure Engine idle state Fully acceleration (100%) Rail Pressure ~220~320 bar (22~32Mpa)—| 11500 bar (150 Mpa) Signal Voltage Approx. 4 5V Refer to DTC P1182.FUEL SYSTEM Refer to DTC P1182. Refer to DIC P1182. Refer to DTC P1182.DTC TROUBLESHOOTING PROCEDURES FL.288 {DTc P1187 | FUEL PRESSURE MONITORING - REGULATOR VALVE STICK | COMPONENT LOCATION —_ «s10ca86 Refer to DTC P1182 DESCRIPTION ™ Gxbai6e" GENERAL DESCRIPTION” © Refer to DTC P1182. DICDESCRIPTION If the fuel pressure monitoring in engine fuel pressure line generates threshold value, the ECM judged this as a fault and DTC is set. tem Detecting Condition DTC Strategy _| « Rationality check Enable Conditions | « Engine run (above 670 rpm) ‘¢ Fuel rail regulator duty ratio < 10% and rail pressure > 250 bar Threshold Value as against actual target rail pressure value. | + Foulty FPR sia Tins |e |r eeu eS, ML * Yes Fuel Limit Fuel Cut EGR Off Cae Rall Pressure = Engine idle state Fully acceleration (100%) __ Rail Pressure 220~ 320 bar (22~32Mpa) | 11500 bar (150 Mpa) Signal Voltage Below 1.7V, ‘Approx 4.5 ‘SCHEMATIC DIAGRAM —e#Fsscec Refer to DTC P1182. ‘SIGNAL WAVEFORM = csecrc05 © pe aera Refer to DTC P1182, MONITOR SCANTOOL DATA = tneiozen © = Refer to DTC P1182,FL.289 FUEL SYSTEM TERMINAL & CONNECTOR INSPECTION — <¢isbe7e Refer to DTC P1182. COMPONENT INSPECTION €Fazever 1, Check Rail pressure. 1) Ignition "ON" & Engine "ON" 2) Ignition “OFF” then Igintion "ON" before Main relay OFF. 3) Monitor signal waveform or graph function of current data by connecting scantool at terminal 2 of Rail preussure regulator. nore If Main relay OFF, Monitoring current data is impossible. Because Sensor power is cut and communication between scantool and ECM is off. This test should be done without any leakage from injector nozzle, return line and high pressure line. Time to pressurize upto 250bar is required as shortly as possible after starting but the time to release the pre~ sure to 100 bar after ignition offis required as quickly as passble. However, time to release the pressure from 4100bar to Obar is required as slowly as possible. Refer to picture? and 2 as below. 1.2 Current Data ‘580.8 | ¥ Fal Prossure Bar "Time to.250 bar 250 bar esa.) a8 180.6 | Ral Pressure regustorvane % fie. 2.8 aa 4.2 Current Data 500.6 | Rail Pressure bar Pressure ratonsion 5s] 108.8 | Fai Pressur eregulator valve % re ee [7 SPECIFICATION vote eee 1 ‘Votage from ral pressure sensor atid is required to | Pressure detected by Rall pressure sensor s required to keep up with 12V = 14V Keep up with 260bar aide ‘Then, the voltage wil be drop o 0.7V atthe point of Key _| Then, Pressure wil be drop rapidly upto 100bar atthe off. point of key off. Finaly Voltage is geting slowly down Finaly, Pressure is geting slowly downDTC TROUBLESHOOTING PROCEDURES 4) Isthe rail pressure data displayed correctly ? YES > Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deteriora~ tion, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair" procedure. > Perform Rail Pressure Sensor & Rail Pressure regulator Inspection procedure. For more detail information, refer to DTC P0192,P0193 and P0190 for Rail Pressure sensor and DTC P1182,P1183 and P1184 for Rail Pressure regulator troubleshooting procedure. Repair or replace as necessary and go to "Verification of Vehicle Repair" procedure. IFICATION OF VEHICLE REPAIR Refer to DTC P1182.FL291 FUEL SYSTEM MONITORING - LEAKAGE DTC P1188 | FUEL PRE: (COMPONENT LOCATION — easrazeg Refer to DTC P1182. Refer to DTC P1182. DTC DESCRIPTION If the fuel pressure monitoring in engine fuel pressure line generates threshold value, the ECM judged this as a fault and DTC Is set. Item Detecting Condition Possible Cause DTC Strategy __| e Rationality check Enable Conditions _| ¢ Engine run (above 670 rpm) « Fuel rail regulator duty ratio 79% and rail pressure < 250 baras | Faulty Fuel fiter ‘Threshold Value | against actual target rail pressure value (Fuel pessure regulator + Faulty Electric fuel leakage), | pump" panna ne [oes ee | ML * Yes + Faulty ECM Fusl Limit | « Yes Fuel Cut + Yes EGR Off #No SPECIFICATION © Esser Rail Pressure Engine idle state Fully acceleration (100%) Rail Pressure 220 ~ 320 bar (22 ~ 32 Mpa) 1500 bar (150 Mpa) Signal Voltage = ‘Approx. 4.5V_ SCHEMATIC DIAGRAM — F2000164 Refer to DTC P1182. ‘SIGNAL WAVEFORM = <008eF27 Refer to OTC P1182. MONITOR SCANTOOL DATA —_ £0s00E36 Refer to DTC P1182DTC TROUBLESHOOTING PROCEDURES FL.292 TERMINAL & CONNECTOR INSPECTION Eags0CCi 1. Many malfunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3, Has a problem been found? YES Repair as necessary and go to "Verification of Vehicle Repair" procedure. Go to" Component Inspection " procedure. COMPONENT INSPECTION = “excaiace) 1. Check Rail pressure. 41) Ignition “ON" & Engine "ON". 2). Ignition” FF” then Igintion “ON” before Main relay OFF. 3) Monitor signal waveform or graph function of current data by connecting scantoo! at terminal 2 of Rall preussure regulator. © note If Main relay OFF, Monitoring current data is impossible. Because Sensor power is cut and communication between scantool and ECM is off This test should be done without any leakage from injector nozzle, return line and high pressure line. Time to pressurize upto 260bar is required as shortly as possible after starting but the time to release the pressure to 100 bar after ignition off is required as quickly as passble. However, time to release the pressure from 100bar to Obar is required as slowly as possible. Refer to picture1 and 2 as below. 4.2 Current Data 500.0 | % ai Pressure > i Time to 250 bar 250 bar [253.2] bar 180.8 | Ral Pressure egulatorvave fis.9FUEL SYSTEM. “180.6 | Rai Pressureregulator valve | fie SPECIFICATION r Valiage Pressure | tage om ral pressure sensor tides requred to | Pressure detected by Rall pressure sensor is equred to | Keep upwih 120 = 14 keep up with 260bar a ile | Then, the voltage will be drop to 0.7V at the point of Key _| Then, Pressure willbe drop rapidly upto 100ber at the oft point of key off l Finally Voltage is getting slowly down ily, Pressure is getting slowly down. 4) Is the rail pressure data displayed correctly ? : > Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deteriora tion, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair’ procedure. > Perform Fuel Pump relay, Injectors, Rail Pressure Sensor and Rail Pressure regulator Inspection procedure, For more detail information, refer to DTC P0232 and P0231 for Fuel pump relay, P0261~0272 for injectors P0192,P0193 and P0190 for Rail Pressure sensor and DTC P1182,P1183 and P1 184 for Rail Pressure regulator troubleshooting procedure. Repair or replace as necessary and go to "Verification of Vehicle Repair" procedure. VERIFICATION OF VEHICLE REPAIR” &7seac05" Refer to DTC P1182.FL.294 DTC TROUBLESHOOTING PROCEDURES DTC P1189 | FUEL PRESSURE MONITORING - GOVERNOR DEVIATION AT ENGINE SPEED TOO HIGH DESCRIPTION (GENERAL DESCRIPTION: ~ Refer to DTC P1182 If the fuel pressure monitoring in engine fuel pressure line generates threshold value, the ECM judged this as a fault and DTC is set so senor seme — ‘item Detecting Condition | [Possible Cause _| DTC Strategy —_| « Rationality check Treble Conone | » Exghe nn above 670m = Fay Eu ter * Rail pressure < 250 bar as against actual target rail pressure | pump Threshold Value | vaiue (Minimum pressure at the low engine speed), + Faulty njactor + Faulty High Diagnosto Tine |» 0.002 seo - pressure pomp ML Yes * Faulty FPR Fuel Limit | « Yes + Faully ECM FuelCut | « Yes EGRO | @No | Rail Pressure | Engine idle state Fully acceleration (100%) Rail Pressure 220 ~ 820 bar (22 ~ 82 Mpa) 4800 bar (150 Mpa) Signal Voltage Below 1.7V Approx. 4.5VFL-295, FUEL SYSTEM SCHEMATIC DIAGRAM — <2ss1c80 = Bais : ‘ Refer to DTC P1182 SIGNAL WAVEFORM = «c4roorr Refer to DTC P1182, MONITOR SCANTOOL DATA = =i0n82F8 Se Refer to DTC P1182, TERMINAL & CONNECTORINSPECTION = c0sciro2 = 4. Many malfunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3. Has a problem been found? aisd Repair as necessary and go to “Verification of Vehicle Repait” procedure. Go to" Component Inspection " procedure. COMPONENT INSPECTION — 240861 4. Check Rail pressure 41). Ignition “ON" & Engine "ON" 2) Ignition "OFF" then Igintion "ON" before Main relay OFF 3) Monitor signal waveform or graph function of current data by connecting scantool at terminal 2 of Rail preussure regulator. W nore If Main relay OFF, Monitoring current data is impossible, Because Sensor power is cut and communication between seantool and ECM is off. “his test should be done without any leakage from injector nozzle, return line and high pressure line. Time to pressurize upto 250bar is required as shortly as possible after starting but the time to release the pressure to 100 bar after ignition off is required as quickly as passble. However, time to release the pressure from 100bar to Obar is required as slowly as possible. Refer to picture1 and 2 as belowDTC TROUBLESHOOTING PROCEDURES FL.296 2 Current Data — bar | [ime to 250 bar sober | | Tm? 8 100.8 | Fai Prossreregutorvave % fe. 0.0 2 Current Data 500.8 | Kai Pisssue bar Prossuro ‘otonsion fs] ea 100-8 | Rai Prosar eopuator vate % ia a0 SPECIFICATION Voltage _ Voltage from rail pressure sensor at idle is required to keep up with 1.2V ~ 1.4V. Then, the voltage will be drop to 0.7V at the point of Key oft. | Finally Vottage is getting stowly down Pressure Pressure detected by Rall pressure sensor is required to keep up with 260bar at idle. ‘Then, Pressure will be drop rapidly upto 100bar at the point of key off, Finally, Pressure is getting slowly down. 4) Is the rail pressure data displayed correctly ? > Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair" procedure > Perform Fuel Pump relay, Injectors, Rail Pressure Sensor and Rail Pressure regulator Inspection procedure. For mare detail information, refer to DTC P0232 and P0231 for Fuel pump relay, PO261~0272 for injectors P0192,P0193 and P0190 for Rail Pressure sensor and DTC P1182,P1183 and P1184 for Rail Pressure regulator troubleshooting procedure Repair or replace as necessary and go to "Verification of Vehicle Repair” procedure.FL.297 FUEL SYSTEM VERIFICATION OF VEHICLE REPAIR = &7000180 a ‘After a repair, itis essential to verify that the fault has been corrected, 4. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. 2. Operate the vehicle within DTC Enable conditions in General information. 3, Are any DTCs present ? YES Go to the applicable troubleshooting procedure. He System is performing to specification at this time.DTC TROUBLESHOOTING PROCEDURES DTC P1190 | INTAKE THROTTLE ACTUATOR - OPEN OR SHORT CIRCUIT COMPONENT LOCATION — Esasazze a, z GENERAL DESCRIPTION = sane By actuating of flaps in the intake passage the passage at the inlet valve of the cylinder can be narrowed. This reduces the air flow. The flaps in the intake passage are controlled by the intake throttle actuator. Calculation of the duty cycle for the inlet passage shut-off can switched on and off by the function switch of the inlet passage shut off. Ifthe engine speed and the demand quantity + low idle governor exceed certain thresholds, also the MAFS signal must be above a threshold. If this is not the case, the error “flap blocked closed is recognized. If the engine speed and the control duty cycle exceed certain thresholds, the digital switch of the inlet passage shut off must be actuated. If it is, the error flap blocked open is recognized In case of the throttle actuator stuck, the engine symptoms will occur a running engine stall and a starting impossible. DTC DESCRIPTION: : If the signal generates threshold value, the ECM judged this as a fault and DTC is set.FUEL SYSTEM DTC DETECTING CONDITION = easz8ec2 = z z Item Detecting Condition Possible Cause [prc strategy | * Circuit continuity check Enable Conditions | ¢ Engine run + Open or short in Threshold Value _| ¢ Open or short for relay control circuit power creas E - + Open or short in Diagnostic Time | 0.48 sec. . control circuit MIL oN + Faulty throttle Fuel Limit No actuator Fuel Cut #No + Faulty ECM EGROM | # Yes SCHEMATIC DIAGRAM cbazrade: [Connection information} Intake throttle Wola Conttot lay power (20) [6228 Terminal 14 Contl relay power — cou 2 | 200-1 Terminal 1@ | _Inlake Bwote actuator contol x coa0-1 t 18 intake tote actuator convot [eonNecroR] Fuel pump relay hamess side connec ECM aie terminalDTC TROUBLESHOOTING PROCEDURES SIGNAL WAVEFORM —&*2ace«7 HA: 13.4.0 DT: 1.948 FREQ: 0.75 Ht IIN:-891.9nU AVE: 12.8.U MAK: 14.2 U REQ: @.81 Hz DUTY: 94 % T k———>! Throttle Throttle operating actuator f range closed position Zoom ‘ 200, [meno] [RECD] [MENU ‘This test should be inspected after depressing the HOLD mode at the operating range of the throttle actuator. The time T becomes shorter when the throttle actuaator is opened increasingly This waveform is funtion to diagnosis the intake throttle actuator rather than operate, or so the intake throttle actuator is not operated actually at engine running MONITOR'SCANTOOL DATA —F#es095x 4. Connect scantool to Data Link Cable (DLC). 2. Warm up engine to normal operating temperature. 3. Monitor that " Intake Throttle Actuator " parameter on the scantool FIG4 1.2 CURRENT DATA 7 x [ENGINE SPEED 816 npn x [EGR acTUATOR 5.8% * [FUEL PRESS. REGULATOR 15.9 % [FUEL TEMP. SENSOR 23.6 °C [BAROMETRIC PRESS.SNSR 769 anntig | @ |VEHICLE SPEED SENSOR 8 =— Kav [FUEL PRESSURE 267.7bar v [Frx_] [ScRN] [FULL] [PaRT] [GRPH] [HELP]FUEL SYSTEM Fic2 4.3 FLIGHT BECORD ‘3000 | MENGINE SPEED ven ]o . fre ee 208.6 | INLET THROTTLE ACTU, —% a0 ’ ist |tr-7i) 123.4 8) [Fim | [none] Fig 1) Normal value with intake throttle actuator at idle, Fig 2) Normal value with intake throttle actuator and engine speed while accelerating and decelerating, Is the Current data displayed correctly ? YES > Fault is intermittent caused by poor contact in the sensor's and/or ECM's connector or was repaired and ECM mem- ‘ory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair" procedure. > Go to"WiHamess Inspection" procedure.DTC TROUBLESHOOTING PROCEDURES TERMINAL & CONNECTOR INSPECTION = EFaaresr a POWER CIRCUIT INSPECTION®= GGaAc500) 1 Many maifunctions in the electrical system are caused by poor hamess and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Has a problem been found? YES Repair as necessary and go to "Verification of Vehicle Repair" procedure. Go to " Power Circuit Inspection * procedure. Check for short in hamess 41) Ignition "OFF" 2) Disconnect MAF sensor connector. 3) Ignition "ON" & Engine "OFF" 4) Measure voltage between terminal of the sensor hamess connector and chassis ground. Specification: 48V ~5.1V 1.MAFS Signal 2MAFS Power ‘3.Sensor Ground aici BIATS Signal 5) _ Is the measured voltage within specifications ? Go to "Component Inspection” procedure. > Check for short to battery or ground in the MAFS power hamess. Repair as necessary and go to "Verification of Vehicle Repair’ procedure,FL-303 FUEL SYSTEM CONTROL CIRCUIT INSPECTION —=2a8a2é4 8 4. Check for short to battery in harness. 41) Ignition “OFF” 2). Disconnect throttle acutator connector. 3) Ignition ON" & Engine " OFF* 4) Measure voltage between terminal 2 of the throttle actuator harness connector and chassis ground. Specification : Approx. below 1V 261 cea 4. Power 2. Thole actuator control 5) Is the measured voltage within specificaitons ? aS } Go to” Check for short to ground in harness " as below. > Check for short to battery in control hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure. 2. Check for short to ground in hamess. 1). Ignition "OFF". 2) Disconnect throttle acutator connector. 3) Measure voltage between terminal 2 of the throttle actuator harness connector and chassis ground, Specification : Infinite (c261 Leva 4. Power 2. Thtle actuator conto!DTC TROUBLESHOOTING PROCEDURES, 4) Is the measured resistance within specifications ? YES > Go to” Check for open in hamess " as below. D> Check for short to ground in control harness. Repair as necessary and go to "Verification of Vehicle Repair’ procedure 3. Check for open in harness. 4) Ignition "OFF" & Engine "OFF" 2). Disconnect Throttle actuator and ECM connector. 3) Measure resistance between terminal 2 of the sensor hamess connector and ECM(37) harenss connector. ‘Specification : Approx. below 10 (e261) 1. Power 2. Trtla actuator control 4) Is the measued resistance within specifications 7 YES > Go to "Component Inspection” procedure. > Check for open in hamess. Repair as necessary and go to "Verification of of Vehicle Repair” procedureFL-305, FUEL SYSTEM 8 COMPONENT INSPECTION — & Substitute with a known-good throttle actuator and check for proper operation. If the problem is corrected, replace throttle actuator and then go to "Verification of Vehicle Repair" procedure 2. Check Throttle actuator Operation. 1). Ignition "ON" & Engine "ON", 2) Check that operating duty of throttle actuator is around 5% at idle. 3) Check that vaccum is felt after disconnecting vaccum hose from throttle actuator valve. 4) Check that vaccum is felt at the moment after ignition off. SPECIFICATION Operating Duty of Throttle actuator : 5% ‘Operating Duty of Throttle actuator : 95% i No vaccum (Close valve) Vaccum (Open valve) 5) _Is the vaccum felt according to the operating duty of throttle actuator ? > Substitute with a known-good ECM and check for proper operation Ifthe problem is corrected, replace ECM and then go to "Verification of Vehicle Repair’ procedure P Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair” procedureDTC TROUBLESHOOTING PROCEDURES FL-306 VERIFICATION OF VEHICLE REPAIR 010570 Alter a repair, itis essential to verify that the fault has been corrected. 4. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. 2. Operate the vehicle within DTC Enable conditions in General information, 3. Are any DTCs present ? a Goto the applicable troubleshooting procedure. System is performing to specication at ths time.FUEL SYSTEM [DTC P1300 | CAM/ENGINE SPEED SENSOR - SYNCHRONIZATION ERROR |(CKP/CMP PLAUSIBILITY) ‘The crankshaft angular sensor detects and counts the teeth on the crankshaft and provides ECM with the information on the current position of crank angle and cylinder. This signal is fed to ECM to be used to determine the engine speed and adjust the fuel injection timing. The camshaft position sensor detects the teeth target wheel and provides ECM with the information on the current position of piston and cylinder. This signal is fed to ECM to be used to determine the sequence of fuel injection. In case of the the crankshaft angular sensor or the camshaft position sensor failure, the engine symptoms will occur ‘a running engine stall, starting impossible and rough idle with noise. Ifthe CMP signal and the CKP signal is out of allowed limits, the ECM judged this as a fault and DTC is set.DTC TROUBLESHOOTING PROCEDURES Possible Cause + Open or short in DTC Strategy | « Signal check | power creat a : | Short to ground in Enable Condions | » Engine cn signal cose Threshold Value | « CMP signal and CKP signal are abnormal corelatvey 1 Open n ground Diagnostic Time | e 0 sec. + Faulty Dowel Pin | MIL + Faulty CMP | * Eau Oke Fuel Limit : uel Gut FauyecM | EGR Off ‘SPECIFICATION [Connection information} ‘cmP (C210) cue = (6223 Teri 7 feria 17 ely power SYPzIO__ 200-2 rena Conia ay pone 7 oe 2 _| 6230-2 Termine 22 | CMP sensor signal 1 3_[(exa0-2 Terminal 25 | CMP sensor ground From cot ey tev) J [CONNECTOR] COMP Harness side connector ECM sie arial | “|> |=) soeeemem ) (oop Fae « [+ x02 casosFL-309) FUEL SYSTEM SIGNAL WAVEFORM =saisse Z see falai= 4.0 VDT: 7.5008 GH B:-229.6ni WAL 4.5 UDF! 6.50n8 FREG?I17.65 Hd ToTOG_|1 teetn=8 : a q BrDC 102 o ‘STDC 108"; Me ° b Aicgab: 1.52 [AEM [Zoor] FMT [reno] [eco] frenu] (_ EE [zon] (SIE [reno] [Reon] [menu] | ‘The given data isthe normal waveform of the crankshaft position sensor (CKPS) and the Camshaft position sensor (CMPS). The CKP sinusoidal signal generates continuosly except 2 missing teeth. but the CMP squre waveform signal is output even when the CMP sensor meets the dowel pin of camshatt. Ifthe waveform pattern becomes distorted or generated no signal while cranking or idling, replace the CKP or the CMP. MONITOR SCANTOOL DATA 4. Connect scantool to Data Link Cable (DLC). 2. Warm up engine to normal operating temperature. 3. Monitor "Acceleration Position Sensor & Engine Speed” parameter on the scantool FIG 1 1.3 FLIGHT RECORD ‘S490, | “ACCEL, POSITION SENSOR aU [A faasr. 0.8 000 [ENGINE SPEED vee | aie a v [eist|tr-201 (0.7 s1__ [Fix | [Hon] Fig 1) APS signal and engine speed increase when depressing accel pedalDTC TROUBLESHOOTING PROCEDURES FL-310 Is the Current data displayed correctly ? YES Fault is intermittent caused by poor contact in the sensor's and/or ECM's connector or was repaired and ECM memory was not cleared, Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or demage. Repair or replace as necessary and go to "Verification of Vehicle Repair” procedure. > Go to "WiHamess Inspection" procedure. TERMINAL & CONNECTOR INSPECTION 4, Many malfunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3. Has a problem been found? =a Repair as necessary and go to "Verification of Vehicle Repair® procedure. Go to "Power Circuit Inspection” procedure. . (POWER CIRCUIT INSI 4. Ignition “OFF" & Engine “OFF” 2. Disconnect CMP sensor connector. 3. Ignition “ON" & Engine “OFF” 4, Measure voltage between terminal 1 of the sensor hamess connector and chassis ground. Specification : Approx. 8+ <0210> 1. Sensor Power (2) 2, Sensor Signal (aay) 8. Sensor Ground ovFL311 FUEL SYSTEM 5, Is the measured voltage within specifications ? YES > Go to "Signal Circuit Inspection” procedure. Check for open or short in power harness. Repair as necessary and go to "Verification of Vehicle Repair" procedure. SIGNAL CIRCUIT INSPECTION © ets7ecs« 2 5 Ignition "OFF" & Engine "OFF" Disconnect CMP sensor connector. Ignition "ON" & Engine "OFF" Measure voltage between terminal 2 of the sensor harness connector and chassis ground. Soecification : Approx. SV calcd 1. Sensor Power (av) 2, Sensor Signal (aay) 8, Sensor Ground (ov) 5. Is the measured voltage within specifications ? YES } Go to "Ground Circuit Inspeciton" procedure. nr Check for open or short in hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure.DTC TROUBLESHOOTING PROCEDURES FL.312 GROUND CIRCUIT INSPECTION — Era4f203° a a si 4. Ignition "OFF" & Engine "OFF" 2. Disconnect CMPS and ECM connector. 3, Measure resistance between terminal 3 of the sensor harness connector and terminal 23 of ECM harness connect- or, Specification : Approx. below 12 <0210> 1. Sensor Power (ey) 2, Sonor Signal (sv) 8, Sensor Ground oy c2a0-2 4. Is the measured resistance within specifications ? . P Go to "Component Inspection" procedure. + Check for open in hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure. COMPONENT INSPECTION = esvsiaa 4, Check Dowel Pin 1) 2) 3) 4) Jgnition "OFF" & Engine "OFF" Remove CMPS. Visually check that Dowel Pin is O.K through the installation hole for CMPS. Is the Phase on the camshaft 0.K ? } Go to "Check CMPS" as below. > Check Dowel Pin on Camshatt for deterioration or damage. Replace Camshaft as necessary and go to "Verification of Vehicle Repair" procedure. 2. Check CMPS 1) 2) 3) 4) 5) Ignition "OFF" & Engine "OFF". Remove CMPS and then connect CMPS connector to CMPS. Ignition "ON" & Engine "OFF" Move @ metal on the detecting edge of CMPS with monitoring signal waveform. Is the signal waveform displayed ?FUEL SYSTEM YES > Substitute with a known-good ECM and check for proper operation. If the problem is corrected, replace ECM and then go to "Verification of Vehicle Repair” procedure. > Substitute with @ known-good CMPS and check for proper operation. If the problem is corrected, replace CMPS and then go to "Verification of Vehicle Repair" procedure. VERIFICATION OF VEHICLE REPAIR = ee7recce = ‘After a repair, itis essential to verify that the fault has been corrected, 4. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. 2. Operate the vehicle within DTC Enable conditions in General information. Are any DTCs present ? YES Go to the applicable troubleshooting procedure ‘System is performing to specification at this time,DTC TROUBLESHOOTING PROCEDURES, FL-314 — eEOe—e—eeE=E—=——EET—™TN TT [DTC P1321 | GLOW INDICATOR LAMP SHORT ‘The glow indicator lamp is used to notify the driver when the glow plug is in operation. The glow indicator lamp are shut off when the battery voltage is low. The duration of preheating and illumination of glow indicator ‘amp are entirely controlled by the injection computer depending on the engine operating conditions. Preheating begins as soon as the ignition is switched on. Postheating consists of alternately supplying the preheating resistors after the engine has been started. But preheating waming lamp is not illuminated during preheating. All glow phases except the pre and the start-ready glow are switched off at engine off. And then the glow indicator lamp is illuminated for at least the time during the pre-glow and start-ready phase by the ECM. Item I Detecting Condition | DTC Strategy | Circuit continuity check Enable Conditions _| « Ignition on Threshold Value _ | e Short for glow indicator lamp control circuit © Open or short i _ lamp control circuit Diagnostic Time | 2 sec. + Fuse iL + Faulty bulb fue + Faulty ECM | Fuel cut No | EGR Off ©NoFL-315, FUEL SYSTEM SCHEMATIC DIAGRAM = =4ecarEE Instrument cluster low ingicatr lamp w [Connection Information] + | _uP-CTerminal2 | Glow indicator lamp power 2 _| ©2302 Terminal 30_| Glow indicator lamp cont a Soe [CONNECTOR] EOM side terminal 230.2 20-41 ‘SIGNAL WAVEFORM. £80305 1.4 ACTUATION TEST ———— ooo GLOW IND. LanP DURATION [UNTIL STOP KEY METHOD [ACTIVATION CONDITION |16.KEY ON ENGINE OFF PRESS ESTRTI, IF YOU ARE READY t SELECT TEST ITEM USING UP/DOWN KEY |_Tsm] [STOP | Battery voltage is applied the glow lamp to the EGM in order to notify the driver that the ECM is preheating it to improve the engine driving performance. For checking open or short in the wire between the fuse (10A) land the ECM, the START key should be pressed in the scan tool ‘actuation test mode. ‘And then make sure thatthe glow indicator lamp comes on stay on ‘during the "NOW ACTIVATING® indication TERMINAL & CONNECTOR INSPECTION — =#etr2ri © 1. Many malfunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Has a problem been found? Repair as necessary and go to "Verification of Vehicle Repair” procedure. ‘Go to " Control Circuit Inspection " procedure.DTC TROUBLESHOOTING PROCEDURES. CONTROL CIRCUIT INSPECTION —EcDazero 4. Check for open or short in hamess. 4) Ignition "OFF" & Engine "OFF* 2) Disconnect ECM connector. 3). Ignition "ON" & Engine "OFF* 4) Measure voltage between terminal 30 of ECM hamess connector and chassis ground, ‘Specification : Approx. 10.8 ~ 13V 30. Glow indicator Control 5) Is the measured voltage within specifications 2 YES Go to” Check Glow indicator lamp circuit " as below. Check for open or short in the contro! harness. Check that 10A Fuse is not install or blown Repair as necessary and go to "Verification of Vehicle Repair" procedure. 2. Operation of Glow indicator lamp circuit. 1). Ignition "OFF" & Engine "OFF. 2) Disconnect ECM connector. 3). Ignition "ON" & Engine "OFF". 4) Jump between terminal 30 of the ECM harness connector and chassis ground with jumper wire. 20, Glow Indeator ControlFL317 FUEL SYSTEM 5) _Is the glow indicator lamp turned ON when jumping ? YES > Go to "Component Inspectio > Check for short to battery between terminal 2 of instrument panel harness and terminal 30 of ECM hamess connector. Repair as necessary and go to "Verification of Vehicle Repair" procedure. COMPONENT INSPECTION €Féi7r9s aS procedure. 4. Check bulb, 4) Ignition "OFF" & Engine “OFF” 2) Remove bulb from instrument panel after removing instrument panel 3) Apply 12 voltage to bulb and ground it so that the bull is tumed on, Specification ; Bulb is turned ON when applying 12V 4) Is the bulb tumed ON? mS > Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair’ précedure > Substitute with a known-good ECM and check for proper operation. Ifthe problem is corrected, replace ECM and then go to "Verification of Vehicle Repair" procedure. VERIFICATION ¢ fi 9 2 = After a repair, itis essential to verify that the fault has been corrected. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. Operate the vehicle within DTC Enable conditions in General information ‘Are any DTCs present ? 5 Go to the applicable troubleshooting procedure. ‘System is performing to specification at this time,DTC TROUBLESHOOTING PROCEDURES [bTc P1322 | GLOW INDICATOR LAMP - OPEN OR SHORT CIRCUIT COMPONENT LOCATION: = E8As6208- =) = Refer to DTC P1321. DESCRIPTION’ esesaig: GENERAL DESCRIPTION@ 9 Refer to DTC P1321 DTC DESCRIPTION. © = Ifthe glow indicator lamp circuit generates threshold value, the ECM judged this as a fault and DTC is set. DTC DETECTING CONDITION. «ie7ee80 Item Detecting Condition Possible Cause TC Strategy | ¢ Circuit continuity check | Enable Conditions |e Ignition on Threshold Value | ¢ Short for glow indicator lamp control circuit + Open or short in | Diagnostic Ti 22 z amp control circuit agnostic Time sec. aa a MIL = No + Faulty ECM Fuel Limit No Fuel Cut *No EGR Off No SCHEMATIC DIAGRAM —Esccisez Refer to DTC P1321 ‘SIGNAL WAVEFORM — eaiiozae Refer to DTC P1321 TERMINAL & CONNECTOR INSPECTION Easauice 0 1. Many malfunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage 3. Has 2 problem been found? Repair as necessary and go to "Verification of Vehicle Repair” procedure. Go to" Control Circuit inspection " procedure.FUEL SYSTEM CONTROL CIRCUIT INSPECTION E2002748 4, Check for open or short in harness. 4) Ignition “OFF” & Engine "OFF". 2) Disconnect ECM connector. 3) Ignition "ON" & Engine “OFF”. 4) Measure voltage between terminal 30 of ECM hamess connector and chassis ground Specicaon Approx 108 18V 30, Glow Ineator Control 5) Is the measured voltage within specifications ? YES Go to" Check Glow indicator lamp circuit " as below. > Check for open or short in the control hamess. Check that 10 Fuse is not install or blown. Repair as necessary and go to "Verification vehicle Repair" procedure 2. Check “operation of Glow indicator lamp circuit’ as below. 4). Ignition "OFF" & Engine "OFF". 2) Disconnect ECM connector. 3) Ignition "ON" & Engine "OFF". 4) Jump between terminal 30 of the ECM hamess connector and chassis ground with jumper wire. 0, Glow indestor Control czaneDTC TROUBLESHOOTING PROCEDURES: FL-320 5) _Is the glow indicator lamp turned ON when jumping ? m2 > Go to “Component Inspection” procedure D> Check for short to battery between terminal 2 of instrument panel harness and terminal 30 of ECM hamess connector. Refer to DTC P1321.FL-321 FUEL SYSTEM IDTC P1326 | GLOW PLUG RELAY SHORT eee ‘The golw plugs are used to heat the inlet air and able to start the engine. . ‘This heating is necessary to allow the diesel fuel to ignite when the temperature low. ‘The ECM controls the feed to preheating resistor via one relay. ‘When the ignition switch is turned on, applies the battery voltage from the heater fuse to the ECM, The glow plug relay coilis energized to turn on the relay switch, which activates the glow plugs by the ECM, according to the signal of water temperature sensor. Feed faults are diagnosed by the ECM via the lines connected to the control terminal of the heater relay. The duration of preheating and illumination of glow indicator lamp are entirely controlled by the injection computer depending on the engine operating conditions. In.case of the glow plug relay failure, the engine symptoms will occur the glow plugs deactivation and the engine starting delayed during the cold condition. Ifthe signal exceeds threshold value, the ECM judged this as a fault and DTC is set.DTC TROUBLESHOOTING PROCEDURES: DTC DETECTING CONDITION — cc2a80e8 tem Detecting Condition FL.322 DTC Strategy |'* Circuit continuity check Enable Conditions * Ignition on Threshold Value _| e Short for glow relay control circuit | sensor action. Diagnostic Time power circuit I MIL = —|+ Short to battery in Fuel Limit | control circuit + Faulty relay Fuel Cut No EGR Off No Faulty ECM ce « Engine speed is fixed as 1200 rpm without the accel postion + Short to battery in ‘SCHEMATIC DIAGRAM = e405". == Gow pug relay relay &tuse box [Connection Information] i) [conNecToR} — contol rtay —— en FHI 5 Glow rlay contot 4 iow plug Relay powor 1 2 Injector tase | Relay power supaly [ 3 | 6230-1 Terminal 18 | Glow relay contro! Glow fusible ink 808 4 Glow fuse Power Injector fuse 152, Glow plug Glow relay harness sido connector OM sie terminal 230-2 230-1FL-323 FUEL SYSTEM ES SIGNAL WAVEFORM © c995 Z Td AGIUATION TEST) For checking the wire and glow relay from the fuses to the glow plug, the START key should be pressed inthe scan tool actuation test moda. And then make sure that the relay "click" noise could Low RELAY be heard Dunatton [UNTIL stoP KEY then cen or ing by angi the cool trpeatue THETHoD [ACTIVATION CONDITION |G. HEY ON ENGINE OFF PRESS COTRTI, IF ¥OU ARE READY SELECT TEST ITEM USING UP/DOUM KEY [str] [Stor] = MONITOR SCANTOOL DATA. ©90s9erA_ 1. Connect scantool to Data Link Cable (DLC). 2. Monitor" Glow Relay " parameter on the scantool FIG1 . 1.2 CURRENT DATA . TE ou [BOOSTER U-OPERAT’G INJ 8.2 VU IMTLCENGINE CHECK > on [FUEL QuaNTITY 29 nce [FUEL PUMP RELAY orF lAN-LOW SPEED orF . IFAN-HIGH SPEED orF lave RELAY OFF iv Frx_| [ScRN] [FULL] [Part] [@RPH] [HELP’ Fig 1) Glow relay ON after the ignition switch ON before coming to the coolant temperature 60°C. Is theCurrent data displayed correctly ? > Fault is intermittent caused by poor contact in the sensor's and/or ECM's connector or was repaired and ECM memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair” procedure } Go to "WiHarness Inspection” procedure.DTC TROUBLESHOOTING PROCEDURES TERMINAL & CONNECTOR INSPECTION —— f0c00uxq> = 4, Many malfunctions in the electrical system are caused by poor hamess and terminals, Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3. Has a problem been found? YES. Bae ‘as necessary and go to "Verification of Vehicle Repair" procedure, Go to" Power Circuit Inspection " procedure. POWER CIRCUIT INSPECTION Ersee28G 4, Ignition "OFF" & Engine "OFF" 2, Disconnect Glow relay. 3. Ignition "ON" & Engine “OFF” 4. Measure voltage between terminal 4 of the relay harness connector and chassis ground. 5. Measure voltage between terminal 2 of the relay harness connector and chassis ground. Specification : Approx. B+ 1. Power (Glow plug sie) — 2. Power (Col side) 3.Coll contro! 4. Main power 6. Is the measured voltage within specifications ? > Go to” Control Circuit Inspection’ procedure. } Check for short to battery in power harness. Repair as necessary and go to "Verification of Vehicle Repair" procedure,FL-325 FUEL SYSTEM CONTROL CIRCUITINSPECTION — F3toi08c 41. Ignition "OFF" & Engine "OFF" 2. Disconnect Glow relay, 3. Measure voltage between terminal 3 of the glow relay connector and chassis ground. Specification : Approx. below 1V 1. Power (Glow plug sae) 2, Power (Col side) 3.Col control 4. Main power it 1 4, Is the measured voltage within specifications ? YES: > Go to” Component Inspection” procedure, Check for short to battery in hamess. Repair as necessary and go to "Verification of Vehicle Repair* procedure. COMPONENT INSPECTION == ex2t0726 4. Check Glow relay 41) Ignition “OFF” & Engine "OFF" 2) Disconnect Glow relay. 3) Measure resistance between terminal 2 and 3 of glow relay. ‘Specification : 55 + 50 Glow plug relay 2, Power (Col side) 3.Col contro! 4 Main powerDTC TROUBLESHOOTING PROCEDURES, FL-326 eRe ee eee 4) Is the measured resistance within specifications ? YES } Go to "Check Glow relay operation” as below. > Substitute with a known-good ECM and check for proper operation. If the problem is corrected, replace ECM and then go to "Verification of Vehicle Repair” procedure. 2. Check Glow relay operation. 1) Ignition "OFF" & Engine "OFF" 2) Connect Glow relay and Disconnect ECM connector. 3) Connect volt mater or test lamp with Glow plug connector (C206), 4) Ignition "ON". 5) Operate Glow relay by grounding terminal 18 of ECM hamess connector or Select actuator test with scantool for operating glow relay. © nore Time to operate glow relay should not be over than 3 sec. Because glow plug can be damaged or Battery can be discharged. Is the glow relay operating correctly ? > Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deteriora tion, or damage. Repair or replace as necessary and go to "Verification vehicle Repair" procedure. > Substitute with a known-good ECM and check for proper operation. tthe problem is corected, replace ECM and then goto "Verication of Vehicle Repair” procedure, VERIFICATION OF VEHICLE REPAIR” After a repair, it is essential to verify that the fault has been corrected, 1. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. 2. Operate the vehicle within DTC Enable conditions in General information. 3. Are any DTCs present ? eS Go to the applicable troubleshooting procedure, ‘System is performing to specification at this time.FL-327, FUEL SYSTEM [DTC P1327 | GLOW RELAY - OPEN OR SHORT CIRCUIT [ Item Detecting Condition Possible Cause DTC Strategy | « Circuit continuity check Enable Conditions | « Ignition on + Open or short to Threshold Value | » Short for glow relay control circuit eee Diagnostic Time _| « 1 sec. + Shertto ground in rain (SE ete Fuel Cut No Seale aa EGR Off *No + Faulty ECM eens '* Engine speed is fixed as 1200 rpm without the accel position sensor action. Refer to DTC P1326. MONITOR SCANTOOL DATA — 009200) Refer to DTC P1326DTC TROUBLESHOOTING PROCEDURES FL.328 ——E—e———————— TERMINAL & CONNECTOR INSPECTION — €Fa0ce76 = 4. Many malfunctions in the electrical system are caused by poor hamess and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3. Has a problem been found? YES a as necessary and go to "Verification of Vehicle Repair” procedure. Go to” Power Circuit Inspection * procedure. POWER CIRCUITINSPECTION #44475 Ignition "OFF" & Engine "OFF Disconnect Glow relay. Ignition "ON" & Engine "OFF". Measure voltage between terminal 4 of the relay harness connector and chassis ground. Measure voltage between terminal 2 of the relay harness connector and chassis ground. oe eNea Specification : Approx. B+ 1. Power (Glow plug size) 7 2. Power (Cal side) 3.Coll contrat 4. Main power 6. Is the measured voltage within specifications ? D Go to" Control Circuit Inspection” procedure. D- Check for short to battery in power harness. Repair as necessary and go to "Verification of Vehicle Repair” procedure.FL.329 FUEL SYSTEM CONTROL CIRCUIT INSPECTION = EescszeF 4. Check for short to ground in harness. 4) Ignition "OFF" & Engine “OFF”. 2) Disconnect Glow relay. 3) Measure voltage between terminal 3 ofthe glow relay connector and chassis ground. ‘Specification: Infinite : 4. Power ie (Giow plug side) af 2 Bower (C03) 8.Colleonol 4. Main power bf 3 1 oi 4) Is the measured resistance within specifications ? 7 YES . } Go to” Check for open in harness " as below } Check for short to ground in harness. Repair as necessary and go to "Verification of Vehicle Repair” procedure. 2. Check for open in harness. 1). Ignition "OFF* & Engine "OFF". 2). Disconnect Glow relay. 3) Measure resistance between terminal 3 of the glow relay connector and terminal 18 of ECM hamess connector. Cy +. Power (Giow tug side kt 2:Powor (Col 0) cs 5.Cot conta ‘Main powerDTC TROUBLESHOOTING PROCEDURES: FL-330 4) Is the measured resistance within specifications 7 YES D Go to” Component Inspection " procedure, > Check for open in control hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure. Refer to DTC P1326. Refer to DTC P1326,FL331 FUEL SYSTEM DTC P1522 | SENSOR SUPPLY VOLTAGE 1 BELOW LOWER LIMIT COMPONENT LOCATION = £25104 = ‘The computer has one of the management functions that is the voltage supply to the sensors. ‘The sensor supply votage 1 Is fed to the APS 1 and MAFS to be used to operate the sensors, Item Detecting Condition Possible Cause | DTC Strategy | « Signal check, low Enable Conditions | e ignition on | Threshold Value | ¢ Output signal < 47V + Open or short to Diagnostic Time | « 0.1 sec. ground in power Mit © No circuit Fuel Limit * Yes + Faulty MAF or APS. Fuel Cut * No + Faulty ECM EGRO No i ® Engine speed is fixed as 1200 rpm without the accel position oe sensor action. SPECIFICATION | <8&cF004 le Voltage 48~5.1V Sensor supply voltage 1 - |DTC TROUBLESHOOTING PROCEDURES FL332 SCHEMATIC DIAGRAM c7xcei= es = # ea {Connection Informat i [Connection information} 4 1 Terminal 80 5 220-t g aps + poner + [e220 Terminai7e [APS 1p 2 | e202 Terminal 16 | _MAFS power Mass ait low sensor (0213. 0290-2I |, Mass airflow sensor power [CoNNecTOR] fees ECM ede terminal Hamess ede connector 243. » fattest fete] 1 [1 fata talslete| | * OO eT) GEEEEBEE! 5 [BSS abate, 2302 cxa04 1.2 CURRENT DATA Tho 5V power source in the ECM is supplied to the Mass Ale TF] Flow Sensor (MAFS), Acceleration Postion Sefisor 1(APS 1) ‘The ECM monitor this sensor supply votage. | incase ofthe sensor supply voltage 1 failure, the engine symptoms is % |ACCEL.POSITION SENSOR 718.50 {as follows. x ENGINE SPEED 750 pn Fas te speed stategy st 1200 rpm whet he scl potion sensor (COOLANT TEMP. SENSOR 83.6 °C VEHICLE SPEED SENSOR 8 = Kn/h [FUEL PRESSURE 270. 7har FUEL PRESS. REGULATOR 16.7 % 95.8 % [eRPH) [HELPFL-333 FUEL SYSTEM MONITOR SCANTOOL DATA = coneA2ec 4. Connect scantool to Data Link Cable (DLC). 2. Monitor" Accel Position Sensor and Mass Air Flow" parameter on the scantoo} FIG1 1.2 CURRENT DATA x |nass AIR FLOW » [ENGINE SPEED INT.@IR TENP-SNSR laCCEL. POSITION SENSOR (COOLANT TEMP. SENSOR \VEHICLE SPEED SENSOR Fig 1) Normal value with mass air flow and accel position sensor at idle. Is the Current data displayed correctly ? > Fault is intermittent caused by poor contact in the sensor's and/or ECM's connector or was repaired and ECM rmem- ory was net cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair” procedure > Go to "WiHarness Inspection” procedure. TERMINAL & CONNECTOR INSPECTION As26085 = 1. Many malfunctions in the electrical system are caused by poor harness and terminals, Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3. Has a problem been found? Repair as necessary and go to "Verifi Go to " Power Circuit Inspection * procedure. jon of Vehicle Repair" procedure.DTC TROUBLESHOOTING PROCEDURES FL.334 OOO POWER CIRCUIT INSPECTION — Go to "Component Inspection” procedure, > Check for open or short to ground in hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure. COMPONENTINSPECTION: =Hscicw" Ignition "OFF" & Engine "OFF" Connect MAFS & Acceleration pedal sensor 1 connector. Ignition * ON” & Engine "OFF" Monitor that DTC P1522 is retrieved again after connecting MAFS & APS. Is the DTC P1822 retrieved again ? > Substitute with a known-good MAFS or/and APS and check for proper operation, Ifthe problem is corrected, replace MAFS or/and APS and then go to "Verification of Vehicle Repair” procedure > Substitute with a known-good ECM and check for proper operation, Ifthe problem is corrected, replace ECM and then go to "Verification of Vehicle Repair" procedureFUEL SYSTEM VERIFICATION OF VEHICLE REPAIR — 5.15V Diagnostic Time | © 0.1 sec. Peddodate MIL + Faulty MAFS or Fue! Limit APS Fuel Cut + Faulty ECM EGR Off No aaa « Engine speed is fixed as 1200 rpm without the accel postion | sensor action, | { Votage aa-5v | Refer to DTC P1522. SIGNAL WAVEFORM F480 Refer to DTC P1522. MONITOR SCANTOOL DATA =ssercrs” Refer to DTC P1522.FUEL SYSTEM. TERMINAL & CONNECTOR INSPECTION = EF0ADE98 = +. Many malfunctions in the electrical system are caused by poor hamess and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3. Has a problem been found? as Repair as necessary and go to "Verification of Vehicle Repair” procedure. Go to" Power Circuit Inspection " procedure. POWER CIRCUIT INSPECTION =COAIFAE 4. Ignition "OFF" & Engine “OFF”. 2. Disconnect MAF and Acceleration pedal sensor connector. 3. Ignition "ON" & Engine "OFF" 4, Measure voltage between terminal 2 of the MAFS harness connector and chassis ground. 5, Measure voltage between terminal 5 of the APS1 harness connector and chassis ground. Specification : Approx. 4.8 ~ 5.1V (0213: AFS Power Mat: APS1 Power 6. Is the measured voltage within specifications ? Go to "Component Inspection” procedure. > Check for open or short to ground in harness. Repair as necessary and go to "Verification of Vehicle Repair” procedure. COMPONENT INSPECTION: “E00se707 ne Refer to DTC P1522 VERIFICATION OF VEHICLE REPAIR = &205F1A Z pcan Refer to DTC P1522.DTC TROUBLESHOOTING PROCEDURES, DTC P1524 | SENSOR SUPPLY VOLTAGE 2 BELOW LOWER LIMIT COMPONENT LOCATION — =7s882er nee ae Refer to DTC P1522 Refer to DTC P1522. If the signal is below threshold value, the ECM judged this as a fault and DTC is set. ‘DTC DETECTING CONDITION sscberse Tem Dateclng Conon Posse Cause DTC Strategy __| ¢ Signal check, low Enable Conditions | « Ignition on Threshold Value | « Output signal < 47 V - "| Engine speed is fixed as 1200 rpm without the accel position a | sensor action. Voltage 48~51V + sShort to battery in — — -| power circuit Mit No f Fuellimt | Yes ‘ FeuyecM Fuel Cut *No EGR Off No : ‘Sensor supply voltage 4 = |FUEL SYSTEM SCHEMATIC DIAGRAM Fotesco S asx ee ma = ee [Connection Information] jozse___0200-1 5 a power 1 [ease Ternnaloi | APS 2 power 2 | czw2Temnaie | _ APS power fa roses sneer T]E2IC200-2|| 5 fal rosue sere rey ower {conneetoR) ae ECM ed torial Varies oe cractr 3 1 ==] Seats C0 Bisham epoeetactaeta [+ 3 (x) LOL Bete P Seseesee ee cao cao SIGNAL WAVEFORM 4s4ar54= fn The 5V power scuce ho ECM ls suppl to th al pressure Z| soncor (PS), aceaaon poston sorwor2 (APS 2) Tho ECM meritee ts eoncor supp vllage Inease oft sooo soppy weap 2 ale th engine symptoms see Feat la speed statogy at 1200 rpm wihou peal pon sensor | ctor |ACCEL. POSITION SENSOR 718.50U lcOOLANT TENP. SENSOR 88.9 °C [ENGINE SPEED 747, xpn \VEHICLE SPEED SENSOR 8 = Ke/h lok ACTUATOR 95.8 % v [PULL] [PART | [GRPH] [HELPDTC TROUBLESHOOTING PROCEDURES MONITOR SCANTOOL DATA Fault is intermittent caused by poor contact in the sensor's and/or ECM's conneclor or was repaired and ECM mem- cory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination. deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair” procedure. Go to "WiHamess Inspection” procedure. ‘TERMINAL & CONNECTOR INSPECTION — ciFFAbSE: 4. Many malfunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3. Has a problem been found? YES Repair as necessary and go to "Verification of Vehicle Repair” procedure. Go to " Power Circuit Inspection " procedure.FL-341 FUEL SYSTEM. POWER CIRCUITINSPECTION = «aese75 Ignition "OFF" & Engine “OFF” Disconnect RPS and Acceleration pedal sensor 2 connector. Ignition "ON" & Engine "OFF" Measure voltage between terminal 1 of the RPS harness connector and chassis ground Measure voltage between terminal 6 of the APS 2 hamess connector and chassis ground. oeene Specification : Approx. 4.8~ 5.1V = (©203 : RPS Power Mat: APS2 Power 6. Is the measured voltage within specifications ? YES > Go to "Component Inspection” procedure. Check for short to battery in harness. Repair as necessary and go to "Verification of Vehicle Repair” procedure. Ignition "OFF" & Engine “OFF” Connect RPS & Acceleration pedal sensor connector. Ignition * ON" & Engine "OFF" Monitor that DTC P1524 is retrieved again after connecting RPS & APS. Is the DTC P1824 retrieved again ? Substitute with a known-good RPS orfand APS and check for proper operation If the problem is corrected, replace RPS or/and APS and then go to "Verification of Vehicle Repair’ procedure. > Substitute with a known-good ECM and check for proper operation. Ifthe problem is corrected, replace ECM and then go to "Verification of Vehicle Repair” procedure. PRONaDTC TROUBLESHOOTING PROCEDURES eee eee WERIFICATION OF VEHICLE REPAIR: €Fe957F2- 0 ‘After a repair, itis essential to verify that the fault has been corrected. 4. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)’ mode and then clear DTC. 2. Operate the vehicle within DTC Enable conditions in General information. 3. Are any DTCs present ? YES Go to the applicable troubleshooting procedure. ‘System is performing to specification at this time.FL-343, FUEL SYSTEM DTC P1525 | SENSOR SUPPLY VOLTAGE 2 - HIGH INPUT COMPONENT L TION © €1787080 Refer to DTC P1522. DESCRIPTION ester GENERAL DESCRIPTION Refer to DTC P1522, DTC DESCRIPTION: Ifthe signal is above threshold value, the ECM judged this as a fault and DTC is set. tem Detecting Condition DTC Strategy _| « Signal check, high Enable Conditions _| e Ignition on Threshold Value | » Output signal > 5.15V. Diagnostic Time | 0.1 sec. + Shot to battery in Te power circuit ual init a + Faulty RPS or APS | Fuel Cut *No + Faulty ECM | EGR Off |e No | Fail safe « Engine speed is fixed as 1200 rpm without the accel position | | sensor action. i Vokase 43-51 | Refer to DTC P1524. SIGNAL WAVEFORM Refer to DTC P1524 MONITOR SCANTOOL DATA — Es2svaae Refer to DTC P1524DTC TROUBLESHOOTING PROCEDURES TERMINAL & CONNECTOR INSPECTION — Ereceec4 1. Many matfunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3, Has a problem been found? YES Repair as necessary and go to "Verification of Vehicle Repair” procedure. Go to" Power Circuit Inspection " procedure, POWER CIRCUIT INSPECTION #908608 70 7 4. Ignition "OFF" & Engine "OFF" 2, Disconnect RPS and Acceleration pedal sensor 2 connector. 3. Ignition "ON" & Engine "OFF" 4, Measure voltage between terminal 1 of the RPS hamess connector and chassis ground, 5. Measure voltage between terminal 6 of the APS 2 hamess connector and chassis ground. Specification : Approx. 4.8 ~ 5.1V_ (0203: RPS Powor Mat: APS 2 Power 6. Is the measured voltage within specifications ? Go to "Component Inspection” procedure. Check for open or short to ground in hamess. Repair as necessary and go to "Verification of Vehicle Repair’ procedure. ‘COMPONENT INSPECTION —“cpFcaaas Refer to DTC P1824 VERIFICATION OF VEHICLE REPAIR = =AAc8ADE j Refer to DTC P1524FL-345 FUEL SYSTEM DTC P1529 | TCU REQUEST FOR MIL ON Auto transaxle failure results are outputs as diagnosic codes by TCM. : In case of auto transaxle failure with locked in 3 rd gear,(AT control relay off) engine malfuntion indicator lamp is displayed by CAN communication between ECM and TCM in order to notify the driver. tem Detecting Condition Possible Cause DTC Strategy | « TCM check Enable Conditions | Engine run Threshold Value _| « Auto transaxle failure with locked in 3rd gear + Faulty auto Diagnose Time |» 05 sec. traneante wi «Yes + Fauly EoM Fualtimt —|2No Fuel Cut No EGR Off °NoDTC TROUBLESHOOTING PROCEDURES FL-346 MONITOR DTG STATUS —“@7racaar 4. Connect scantoo! to Data Link Connector(DLC). 2, Warm up the engine to normal operating temperature. 3, Monitor that DTC P1829 is retrieved on scantool. 4, Isthe DTC P1629 is retrieved on scantool ? m= > This is problem with automatic transaxle. Go to Automatic transaxle troubleshooting procedure. > Faults intermittent caused by poor contact in the ECM's connector or was repaired and ECM memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or repiace as necessary and go to "Verification of Vehicle Repair” procedure. VERIFIC/ ‘OF VEHICLE RE AEBS After @ repair, itis essential to verify that the fault has been corrected, Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. Operate the vehicle within DTC Enable conditions in General information. Are any DTCs present ? : Go to the applicable troubleshooting procedure, ‘System is performing to specification at this time.FL347 FUEL SYSTEM. DTC P1545 | 1ST GEAR RECOGNITION SWITCH - SHORT CIRCUIT DESCRIPTION — Eabisezs Ks se sees 1, GENERAL DESCRIPTION’ Se = ‘1st Gear Recognition Switch is used to control fuel quantity and improving a climb performance when going up a sloping road. This monitoring is to detect the implausible input from 1 st gear recognition switch or neutral switch and carried out only ‘once in the same driving cycle. 2. DTC DESCRIPTION * DTC DETECTING CONDITION © E076a130 Item Detecting Condition Possible Cause DTC Strategy _ | « Circuit continuity check Enabie Conditions | * Engine run - + Short in 1st gear Threshold Value | © Sort fo ft goat recognition swish arcu eee Diagnosis Time |» 1 sec power gout Pauly Tot gear ML " revognivon such Fullimt — | oNo Faulty cM Fuel Cut No EGR Off @No ‘SCHEMATIC DIAGRAM © [Connection Information} S + [6200-2 Terminal 63 [tt gear recognition switch (290-5 Ta gar recogrion 2 2s Grouna ssi oreut fcONNecTOR} "fiaose oe cone EOM sido terminal Ee (CEI) SPEER wal + [+ aD p oe q Glee [ole aieDTC TROUBLESHOOTING PROCEDURES MONITOR DTC STATUS Eros5ses 4. Connect scantoo! to Data Link Cable (DLC). 2. Monitor” 1st Gear Switch " parameter on the scantoo!, FIG4 1.2 CURRENT DATA 7 IACCEL. POSITION SENSOR 728.3aU lcooLaNT TEMP. SENSOR 19.3 °C [ENGINE SPEED 828 pn VEHICLE SPEED SENSOR @ — Kn |™ [FUEL PRESSURE 264.bar |FUEL PRESS. REGULATOR 15.8 % lecr acruaroR 95.8 % ¥ 'FIx | [SCN] [FULL] [Part] [GRPH] [HELP Fig 1) Normal value when shifting 4 st gear. Is the Current data displayed correctly ? > Faults intermittent caused by poor contact in the sensor's and/or ECM's connector or was repaired and ECM ‘memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification vehicle Repair’ procedure- > Go to "WiHamess Inspection” procedure TERMINAL & CONNECTOR INSPECTION | &7e8co: 1. Many malfunctions in the electrical system are caused by poor harness and terminals, Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3. Has problem been found? > Repair as necessary and go to "Verification of Vehicle Repair” procedure. > Go to" Power Circuit Inspection " procedure.FL-349 FUEL SYSTEM EY POWER CIRCUIT INSPECTION — =arecass Ignition "OFF" & Engine "OFF". Disconnect 1st gear recognition switch connector. Ignition "ON" & Engine "OFF" Measure voltage between terminal 1 of the ‘st gear recognition switch harness connector and chassis ground. Specification : Approx. B+ <0250> 4. Power 2.Graund 5, Is the measured voltage within specifications ? : > Go to "Component Inspection" procedure. > Check for short to battery in the power hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure. 1. Check 1st gear recognition switch, 4) Ignition “OFF” & Engine “OFF” 2) Disconnect 1st gear Recognition Switch. 3) Measure continuity between terminal 1 and 2of clutch switch connector (Component side) SPECIFICATIONS ‘ist gear recongnition switch ON ‘1st gear recognition switch OFF Continuity (Below 19) No continuity ( 0) 4) Is the measured resistance within specifications 7 eS > Substitute with @ known-good ECM and check for proper operation. Ifthe problem is corrected, replace ECM and then go to "Verification of Vehicle Repair” procedure. > ‘Substitute with a known-good 1st gear recognition switch and check for proper operation. If the problem is corrected, replace 1st gear recognition switch and then go to "Verification of Vehicle Repair" procedure.DTC TROUBLESHOOTING PROCEDURES VERIFICATION OF VEHICLE REPAIR c28a070 = After @ repair, itis essential to verify that the fault has been corrected. 4. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. 2. Operate the vehicle within DTC Enable conditions in General information 3. Are any DTCs present ? cy Go to the applicable troubleshooting procedure. ‘System is performing to speci tion at this time.FUEL SYSTEM [DTC P1546 | 1ST GEAR RECOGNITION SWITCH - OPEN OR SHORT CIRCUIT DESCRIPTION «1505079 s GENERAL DESCRIPTION 2S Refer to DTC P1845. DTC DESCRIPTION oo If the auto transaxle generates threshold value, the ECM judged this as a fault and DTC is set. DTC DETECTING CONDITION = ESESIASC (ee Detecting Condition Possible Cause | DTC Strategy _| « Circuit continuity check + Open or short to ‘ground in ist gear recognition switch | Enable Conditions | « Engine run power circuit tear aus audl © Sai Eee de aC SG = Open in 1st gear |__Threshold ‘© Short for 1st gear recognition switch circuit __| recognition switch [Diagnostic 1880, ground circuit | - 7 + Faulfy ist gear No recoghition switch Fuel Limit eNo + Faulty ECM | Fuet Cut No EGR Off © No SCHEMATIC DIAGRAM: ebs200rc Refer to DTC P1545, MONITOR:DTC STATUS © coasen8e Refer to DTC P1845, TERMINAL & CONNECTOR INSPECTION ~ FOEA0CAR ia 1. Many malfunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3. Has a problem been found? > Repair as necessary and go to "Verification of Vehicle Repair" procedure. > Goto" Power Circuit Inspection " procedureDTC TROUBLESHOOTING PROCEDURES POWER CIRCUIT INSPECTION —&Fs050:0 = Ignition "OFF" & Engine "OFF" Disconnect 1st gear recognition switch connector. Ignition "ON" & Engine "OFF" Measure voltage between terminal 4 of the 1st gear recognition switch harness connector and chassis ground. Specification : Approx. B+ <0250> 41. Power 2. Ground 5. Is the measured voltage within specifications ? YES > Go to" Ground Circuit Inspection” procedure. > Check for open or short to ground in the power hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure. GROUND CIRCUIT Ignition "OFF" & Engine “OFF” Disconnect ‘st gear recognition switch connector. ‘Measure resistance between terminal 2 of the 1st gear recognition switch harness connector and chassis ground of G24, Specification : Approx. below 12 <0250> 1. Power 2.GroundFL-353 FUEL SYSTEM 4, Is the measured resistance within specifications ? es > Go to "Component Inspection" procedure. > Check for open in hamess, Repair as necessary and go to "Verification of Vehicle Repair” procedure. COMPONENT INSPECTION” Refer to DTC P1546 VERIFICATION OF VEHICLE REPAIR” Refer to DTC P1545.DTC TROUBLESHOOTING PROCEDURES, FL.354 eee ee [DTC P1602 | SERIAL COMMUNICATION PROBLEM WITH TCU (TIME-OUT) ‘The ECM communicate over the CAN are with EMS(Engine Management System), TCS(TractionControl System), TC- M(Transmission Control Moudle). ‘The TCM monitors various information such as vehicle speed , gear position and engine torque during upshif, it reque- sts the ECM to retard ignition timing to decrease torque. This produces small change in torque during upshift, hence smooth shift and increase in shift feeling. In case of the TCM failure, the engine symptoms will occur a corrupted torque reduction signal information,a shift shock, a increasing engine rpm abruptly. Ifthe CAN communication generates threshold value, the ECM judged this as a fault and DTC is set. snceatas ig Detecting Condition Possible Cause | hand low « Signal check, Enable Conditions| Ignition on — + + Open in signal Jue | » No signal through CAN communication lines. circuit sshok ime |e 1sec + Short to ground in —~ signal circuit a joNo + Faulty TCM Fuel Limit. | 6 No + Faulty ECM Fuel Cut *No EGR OffFL-355, FUEL SYSTEM SCHEMATIC DIAGRAM — &2200c54 ies = [Connection information) rom ou coos cot]. ow mua TOM EOM Function can gH 3 a (6224-3 Terminal 3 | 6290-1 Terminal 10 [ GAN (high) caNtuom 4 2 cANgOm (6224-3 Torminal 4 | 0230-1Terminal@ | CAN (ow) [connectoR) ECM sie terminal Tow Harness side connector rm) Se Ese Peers I peepee Te f= aT] | eal perpen neainess zaai| ofa 8 70] |e [a9 [Har 3.8 U DT? e.d4n CHB! 4.1 y __Tis test should be inspected after depressing the HOLD mode while iling, ! In this CAN communication signal waveform, itis impossible to read CAN High side through by displaying the scantool If unstable waveform pattem with non-uniform frequency or no signal, LYN ia if replace the ECM or the TCM after checking the wiring harness. [RS oon RES To] TeDTC TROUBLESHOOTING PROCEDURES. FL-356 TERMINAL AND CONNECTOR INSPECTION — Eiscbesa = 1. Many malfunctions in the electrical system are caused by poor hamess and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3._Has a problem been found? YES Repair as necessary and go to "Verification of Vehicle Repair" procedure. ia Go to "Signal Circuit Inspection” procedure. SIGNAL CIRCUIT IHSPECTION = =a8aic> 4. Check for open in harness 1) Ignition "OFF" & Engine “OFF” 2) Disconnect ECM & TCM connector. 3) Measure resistance between terminal 4 of TCM harness connector and terminal 9 of ECM hamess connecto- 4) Measure resistance between terminal 3 of TCM harness connector and terminal 10 of ECM harness connect or. . ‘Specification : Approx. below 10 czas c2at.3 3. CAN HIGH 4. CANLOW 230-1 9. CANLOW 10.CANHIGH 5) _ Is the measured resistance within specifications ? B Go to "Check for short to ground in harness” as below. Check for open in the signal hamess. Repair as necessary and go to "Verification of Vehicle Repair’ procedure. 2. Check for short to ground in harness. 41) Ignition “OFF” & Engine "OFF" 2) Disconnect TCM,ECM, TCCU and HCU connector. 3) Measure resistance between terminal 4 of TCM harness connector and chassis ground.FL-357, FUEL SYSTEM OT 4) Measure resistance between terminal 3 of TCM harness connector and chassis ground. Specification : Infinite 4.CAN LOW .CAN HIGH 5) Is the measured resistance within specificaitons ? fas > Go to "Component Inspection" procedure, > Check for short to ground in signal hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure. COMPONENTINSPECTION | seciEcs0: ae 1. Check resistance 41). Ignition "OFF" & Engine “OFF 2) Disconnect TCM connector. 3) Measure resistance between terminal 3 and 4 of TCM hamess connector. SPECIFICATION Not TCS.4WD equipped WD equipped | ECM & TCM connected ECM connected only TCM connected only ECM & TCM connected 600 #10 1200 + 20 1200 + 20 12009 +20 4.cantow S.eAN HGH ieDTC TROUBLESHOOTING PROCEDURES, 4) Is the measured resistance within specifications ? YES > Go to "Check signal waveform’ as below. > Substitute with a known-good ECM and check for proper operation. Ifthe problem is corrected, replace ECM and then go to "Verification of Vehicle Repair” procedure. 2. Check signal waveform 4) Ignition “OFF” & Engine “OFF” 2) Disconnect ECM connector. 3) Monitor signal waveform at terminal 3 and 4 of TCM connector simultaneously SPECIFICATION HA: 3.00 DT: @.idns CH CAN High side cAN|Low side [HN oe RENE Tea Te 4) Are CAN signals generated correctly ? 7 > Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and then go to "Verification of Vehicle Repair” procedure. > Substitute with a known-good ECM and check for proper operation. Ifthe problem is corrected, replace ECM and then go to "Verification of Vehicle Repair" procedure. VERIFICATION OF VEHICLE REPAIR After a repair, itis essential to verify that the fault has been corrected. 4. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. 2. Operate the vehicle within DTC Enable conditions in General information. 3. Are any DTCs present ? Go to the applicable troubleshooting procedure System is performing to specification at this time.FUEL SYSTEM {DTC P1603 | CAN COMMUNICATION - BUS ERROR COMPONENT LOCATION © €corara0. GENERAL DESCRIPTION Refer to DTC P1602. DTC DESCRIPTION Ifthe CAN communication generates threshold value, the ECM judged this as a fault and DTC is set, item ‘Detecting Condition Possible Cause DTC Strategy | « Signal check, high and iow Enable Conditions _| « Ignition on 7 - + Open in signal Threshold Value _| ¢ CAN bus error. circuit Diagnostic Time _| # 1 sec. + Short to ground in - - signal circuit Mi #No + Faulty TOM Fuel Limit | «No + Faulty ECM Fuel Cut No { EGR Off #No SCHEMATIC DIAGRAM - Refer to DTC P1602. SIGNAL WAVEFORM © €i877éie Refer to DTC P1602DTC TROUBLESHOOTING PROCEDURES TERMINAL AND CONNECTOR INSPECTION = =PAa0524 1. Many malfunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3, Has a problem been found? eS Repair as necessary and go t ‘Verification of Vehicle Repair” procedure. Go to "Signal Circuit nepection" procedure SIGNAL CIRCUIT IHSPECTION E2608 1. Check for open in harness 41) Ignition “OFF” & Engine "OFF" 2) Disconnect ECM & TCM connector. 3) Measure resistance between terminal 4 of TCM harness connector and terminal 9 of ECM harness connecto- f 4) Measure resistance between terminal 3 of TCM hamess connector and terminal 10 of ECM harness connect- or. ‘Specification : Approx. below 19 aang 2249 L 3. CAN HIGH ERE @ soon y aso S.cAN LOW {0.¢AN HIGH 5) Is the measured resistance within specifications ? Go to "Check for short to ground in harness" as below. Check for open in the signal hamess. Repair as necessary and go to "Verfication of Vehicle Repair” procedure. 2. Check for short to ground in harness. 41) Ignition "OFF" & Engine “OFF” 2). Disconnect TCMECM, TCCU and HCU connector. 3) Measure resistance between terminal 4 of TCM harness connector and chassis ground.FL-361 FUEL SYSTEM es Sl 4) Measure resistance between terminal 3 of TCM hamess connector and chassis ground. ‘Specification : infinite 3.CANHIGH ‘4.CANLOW 5) Is the measured resistance within specificaitons ? YES > Go to "Component Inspection" procedure. > Check for short to ground in signal hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure. : Refer to DTC P1602 Refer to DTC P1602DTC TROUBLESHOOTING PROCEDURES FL362 DTC P1616 | MAIN RELAY - RANGE/PERFORMANCE COMPONENT LOCATION ee#s508 ‘The voltage after the main relay is used to supply power to the sensors and actuators, ECM controls the main relay and its remains ON at key OFF in order to store the adaptaion values and fault status to the memory. ‘When the ignition switch is turned ON, current flows from the ignition switch through the current and the main relay coil to ground by the ECM, ‘And then, the voltage is supplied to the sensors and actuators to drive. In case of the the main relay failure, the engine symptoms will occur a running engine stall, a starting impossible and glow plug deactivation, DIC DESCRIPTION © If the signal exceeds threshold value, the ECM judged this as a fault and DTC is set.FL-363 FUEL SYSTEM DTC DETECTING CONDITION — «5820150 = ne Detecting Condition Possible Cause | DTC Strategy © Circuit continuity check | Enable Conditions | ¢ Ignition on and off « main relay shutoff time is too early or late when comeparing the Threshold Value ignition onfof time with the ECM microcomputer signal + Opne or short in r power circuit Diagnostic Time | « 0 seo : closes | MIL Yes. relay control circuit Fuel Limit No + Faulty relay FuelCut | @ No + Faulty ECM EGROH | eNo | © EGR valve deactivited fae ‘© Fuel quantity limitation SCHEMATIC DIAGRAM. _ Fs par ony oma CA, EGR [Connection Information} a 1 _| 6230-1 Terminal 45 [Relay power supply 2 Power Relay.coll power 3 : : ens cok [6250-1 Terminal 13 [Relay control cout es fone oN sara 5 Power Relay power supply (Gutter ‘ason on son [CONNECTOR] Main telay Harness sie connecter ECM side terminal 1 set [Stan [oselast[ alfa P ale Ja) GeeeitsEety |] [ UStetelsletetelsinistalrdisinbst tn, . 230-2 e204DTC TROUBLESHOOTING PROCEDURES FL-364 eee ee eS MONITOR SCANTOOL DATA Esées0sr 1. Connect scantool to Data Link Cable (DLC). 2. Monitor” Battery Voltage " parameter on the scantool. FIG1 — [ACCEL.POSITION SENSOR 0.8 % laCCEL.POSITION SENSOR 728. 3nU |cooLaNT TEMP. SENSOR 53.3 °C “2 CURRENT DATA =| IENGINE SPEED 774 pn lVEHICLE SPEED SENSOR © @ =—Kn/h IFUEL PRESSURE 256. 7bar IFUEL PRESS. RECULATOR 15.6 % FIR | [SRN] [FULL] [Part] [GRPH] [HELP] Fig 1) Normal value without EGR actuator : Approx. 450 ~ 660 mgistroke Is the Current data displayed correctly ? . > Fault is intermittent caused by poor contact in the sensor's and/or ECM's connector or was repaired and ECM mem- cory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage, Repair or replace as necessary and go to "Verification of Vehicle Repair” procedure > Go to "WiHamess Inspection” procedure. TERMINAL’& CONNECTOR INSPECTION © 8259578 ~~ 1. Many matfunctions in the electrical system are caused by poor hamess and terminals, Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3. Has problem been found? Repair as necessary and go to” Go to" Power Circuit Inspection " procedure. erification of Vehicle Repair" procedure.FL-365 FUEL SYSTEM POWER CIRCUIT INSPECTION = esvsba62 s z Ignition "OFF" & Engine “OFF”. Disconnect Main Relay Ignition "ON" & Engine "OFF" Measure voltage between terminal 2 of the main relay hamess connector and chassis ground, 5. Measure voltage between terminal 5 of the main relay harness connector and chassis ground. Specification : 8+ . : 7 1. PowerlECM.OMP, ete) 2.Power(Coil side) 44.Coll conto! Main powor 6. Is the measured voltage within specifications ? YES > Go to "Control Circuit Inspection” procedure. Ne Check for open or short in the power harness. Repair as necessary and go to "Verification of Vehicle Repair” procedure,DTC TROUBLESHOOTING PROCEDURES FL-366 CONTROL CIRCUITINSPECTION — cc7rsiéa 4. Check for short to ground in hamess. 41) Ignition "OFF" 2) Disconnect Main relay, 3) Measure resistance between terminal 4 of the Main relay harness connector and chassis ground Specification : Infinite 1. Power{ECM.CMP, ete) 2. Power(Col side) '4.Coll conto! 5. Main power 4) Is the measured resistance within specifications 7 m= . P Go to "Check for short to battery in harness” as below. oo > Check for short to ground in harness. Repair as necessary and go to "Verification of Vehicle Repair" procedure. 2. Check for short to battery in hamess 4) Ignition *OFF* 2). Disconnect Main relay. 3). Ignition "ON" & Engine "OFF" 4) Measure voltage between terminal 4 of the Main relay hamess connector and chassis ground. Specification : Approx. below 1V 1. Power(ECM.CME, st.) 2, Power(Coil side) 4, Coll contro! 5. Main powerFL-367 FUEL SYSTEM 5) Is the measured resistance within specifications ? Goto "Check for open in harness" as below. Check for short to ground in hamess, Repair as necessary and go to "Verification of Vehicle Repair” procedure 3, Check for open in hamess. 1) 2) 3) 4) Ignition "OFF" & Engine "OFF" Disconnected MAF sensor connector and ECM connector. Measure resistance between terminal 4 of the Main relay harness connector and terminal 13 of ECM hamess connector. Specification : Approx. below 10 4. Power (ECMOMR, etc) 2, Power(Coil side} 44.Cal contol 5. Main power 200-1 Is the measured resistance within specifications ? > Goto Check for open in harness, Repair as necessary and go to "Verification of Vehicle Repair” procedure. ‘omponent Inspection” procedure.DTC TROUBLESHOOTING PROCEDURES, COMPONENT INSPECTION eicicsed 1. Check Main relay. 1) 2) 3 4) Ignition “OFF” & Engine "OFF" Disconnect Main relay. Measure resistance between terminal 2 and 4 of main relay (Component side). Specification : 70~ 800 (20°C) 4. Powor{EOM.CMP, te) 2. Power(Col side) 44.Coll conto! 55. Main power Is the measured resistance within specifications ? YES > g to heck Main relay operation " as below. D> Substitute with a known-good Main relay and check for proper operation. If the problem is corrected, replace main relay and then go to "Verification of Vehicle Repair" procedure. 2. Check Main relay operation. 1 2) 3 4) 5) 6) Ignition "OFF" & Engine "OFF". Connect Main relay and Disconnect ECM connector. Connect volt meter or test lamp with terminal 4 and 5 of ECM hamess connector. Ignition "ON" & Engine "OFF". Ground terminal 13 of ECM hamess connector so that Main relay operates. Or, ‘Connect ECM harness connector and then, check that main relay operates if 12V is detected at terminal 58 ‘of ECM connector after Ignition ON. Is the 12V detected on voltmeter with operating main relay 7 > Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair” procedure. Substitute with @ known-good ECM and check for proper operation Ifthe problem is corrected, replace ECM and then go to "Verification of Vehicle Repair" procedure.FL.369 FUEL SYSTEM VERIFICATION OF VEHICLE REPAIR = &5777br0 x After a repair itis essential to verify that the fault has been corrected Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. Operate the vehicle within DTC Enable conditions in General information. ‘Are any DTCs present ? a Go to the applicable troubleshooting procedure. ‘System is performing to specification at this time,DTC TROUBLESHOOTING PROCEDURES DTC P1634 | WATER HEATER RELAY MALFUNCTION ‘The direct injection engine is characterised by improved thermodynamic efficiency compared to arvindiret injection engine, due to the reduction in heat loss via the walls. The coolant is used by the passenger compartment heating system- In extream cold conditions, itis therefore difficult to reach a comfortable temperature in the passenger compartment. To reduce the length ofthe increase in the temperature phase, vehicles powered by direct injection engines are fitted ‘with heating resistors located directly in the cooling circu. ‘The electrical power of each water heater component is 300 W. The water heater relay coil is energized to turn on the relay switch, which activates the water heaters by the ECM, according to the signal of water teriperature sensor. ‘The ECM cuts the feed to the water heaters when the period determined by the map has expired or when the coolant temperature exceeds 65 TC. Supply may also be cut for a moment ifthe battery voltage drops below 10 V. If the signal exceeds threshold value, the ECM judged this as a fault and DTC is set.FUEL SYSTEM DTC:DETECTING CONDITION - tem Detecting Condition Possible Cause DTC Strategy _| e Circuit continuity check = Enable Conditions _| Ignition on ‘Threshold Value _| e Open or short for water heater relay control circuit. + Opne or short in : = power circuit Diagnostic Time _| « 1 sec. a P Open o short in ML, No water heater relay Fuel Limit @ No control circuit Fuel Cut @No + Faulty relay EGR Off @ No * Faulty ECM © EGR valve deactivited oe Melts Fuel quantity imitation nt ate Yaerhetr Weert coil [CONNECTOR] Water heater relay Harmass side connector EOM side terminal NsStwe sn NaZhe ath Mat ests [Connection Information} +__[_ 0250 Terminals | Water heater power supply 2_| 6250 Terminal 16 Relay power 3 | 6250-1 Terminal 23 | Water heater relay conto! 4 Fuse 408, PowerDTC TROUBLESHOOTING PROCEDURES FL-372 MONITOR SCANTOOL DATA 4. Connect scantool to Data Link Cable (DLC). 2, Monitor " Water Heater Realy Operation Relay and Coolant Temperature " parameter on the scantool FIG4 -€BOBESE 1.2 CURRENT DATA 7 x [BATTERY VOLTAGE w50 |e lass AIR FLOW 498 ng/s INT ATR TEMP. SNSR 16.6 °C |ACCEL.POSITION SENSOR 8.8 % |ACCEL.POSITION SENSOR 738. Bn. [ENGINE SPEED 813 rpa \VEHICLE SPEED SENSOR © @ =— Kah v [FIX] [SCRN] [FULL] [PART] [GRPH] [HELP Fig 1) Make sure that water heater relay ON before coming to the coolant temperature 60°C. Is the Current data displayed correctly ? : >> Faults intermittent caused by poor contact in the sensor's andlor ECM's connector or was repaired and ECM. memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and goto "Verification of Vehicle Repair" procedure. > Goto “Witiamess Inspection” procedure. TERMINAL & CONNECTOR INSPECTION - 1. Many malfunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. 3. Has problem been found? Repair as necessary and go to "Verification of Vehicle Repair” procedure. Goto” ower Circuit Inspection " procedure.FL.373 FUEL SYSTEM TS POWER CIRCUIT INSPECTION 1. Ignition "OFF" 2, Disconnect Water heater relay 1 3. Ignition "ON" & Engine “OFF” 4, Measure voltage between terminal 2 of the water heater relay and chassis ground. 5, Measure voltage between terminal 4 of the water heater relay and chassis ground, Specification : 11.5V-13.5V_ 4. Power (Glow plug side) 2. Power (Col sie) 3.Cail Contr 4. Main Power 6. Is the measured voltage within specifications ? YES P Go to "Control Circuit Inspection” procedure. i) > Check for open or short in the power harness. Repair as necessary and go to "Verification of Vehicle Repair” procedure.DTC TROUBLESHOOTING PROCEDURES, CONTROL CIRCUIT INSPECTION 1, Check for short to ground in harness. 1) Ignition "OFF 2) Disconnect water heater relay 1 3) Ignition "ON" & Engine "OFF". 4) Measure voltage between terminal 3 of the water relay and chassis ground, Specification : Approx. below 1V 1. Power (Glow plug sie) 2. Power (Col side) 3. colt Contot 4. Main Power 5) Is the measured resistance within specifications ? Go to "Check for short fo ground in harness" as below. ne) Check for short to ground in hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure. 2. Check for short to battery in hamess. 41). Ignition "OFF 2) Disconnect water heater relay 1 3) Measure resistance between terminal 3 of the water heater relay and chassis ground, FL-374 Specification : Infinite 1. Powar (Glow plug side) 2. Power (Col side) 3.Coll Conta 44. Main PowerFL-375 FUEL SYSTEM 4) Is the measured resistance within specifications ? YES > Goto "Check for open in hamess " as below. > Check for short to ground in hamess, Repair as necessary and go to “Verification of Vehicle Repair” procedure. 3. Check for open in hamess. 1) Ignition “OFF” 2) Disconnect water heater relay 1 and ECM connector. 3) Measure resistance between terminal 3 of the water heater relay and terminal 23 of ECM harness connector-. ‘Specification : Approx. below 10. 4. Powar (Giow pug sie) 2. Power (Cal side) 3.Col| Control 4. Main Power oxo NE 4) Is the measured resistance within specifications ? ms > Go to "Component inspection” procedure. NO Check for open in hamess. Repair as necessary and go to "Verification of Vehicle Repair” procedure. Shea?DTC TROUBLESHOOTING PROCEDURES ‘COMPONENT INSPECTION EAiisais Cares gees ees z 4. Check water heater relay 1 41) Ignition "OFF" & Engine "OFF". 2) Disconnect water heater relay. 3) Measure resistance between terminal 2 and 3 of water heater relay connector (Component side). 1. Power (Glow plug side) 2. Power (Col side) 3.Call Control 4. Main Power 4) Is the measured resistance within specifications 7 7 YES > Go to” Check for water heater relay operation " as below. > ‘Substitute with a known-good Main relay and check for proper operation, Ifthe problem is corrected, replace main relay and then go to "Verification of Vehicle Repair" procedure. 2. Check water heater relay operation. 41). Ignition “OF F* & Engine "OFF 2) Connect water heater relay 1,2 and 3 and disconnect ECM connector. 3) Connect volt meter or test lamp with terminal 3 of water heater connector. 4) Ignition "ON" & Engine "OFF" 5) Ground terminal 23 of ECM hamess connector fo operate water heater relay. Or, Check that water heater relay operates after Engine starts(Perform this test under 60°C). © nore Time to operate water heater relay should not be over than 3 sec. Because water heater plug can be damaged or Battery can be discharged 6) Is the power supplied to water heater plug by operating water heater relay ? > Substitute with a known-good ECM and check for proper operation. If the problem is corrected, replace ECM and then go to "Verification of Vehicle Repair" procedure. > Substitute with a known-good ECM and check for proper operation. Ifthe problem is corrected, replace ECM and then go to "Verification of Vehicle Repair" procedure.FL377, FUEL SYSTEM VERIFICATION OF VEHICLE REPAIR — § ‘After a repair, itis essential to verify that the fault has been corrected. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC Operate the vehicle within DTC Enable conditions in General information. Are any DTCs present ? YES Go to the applicable troubleshooting procedure. ‘System is performing to specification at this time.DTC TROUBLESHOOTING PROCEDURES FL.378 DTC P1636 | VOLTAGE REGULATOR MALFUNCTION ‘The Engine control module (ECM) is installed in the passenger compartment, . ‘The ECM is a solid state device that uses intemal circuitry to process the input signals according to control algorithms ‘A voltage regulator inside the ECM controls power supply to output transistor. Item Detecting Condition Possible Cause DTC Strategy __| e Rationality check | Enable Conditions _| * When Ignition switch is off Threshold Value | » Engine < 600 rpm within 1.5 Diagnostic Time | » 0 sec. ao + Faulty ECM MIL. No FuelLimit | e No Fuel Cut No EGR Off ‘@ NoFUEL SYSTEM FL-379 MONITOR DTC STATUS = ee A x 4. _Igintion" OFF " 2. Connect scantool and select Diagnostic Trouble Code(DTC). 3. Clear DTC and then, Monitor DTC status. 4, Is the DTC P1636 is retreived again ? YES ‘Substitute with a known-good ECM and check for proper operation Ifthe problem is corrected, replace ECM and then go to "Verification of Vehicle Repair" procedure. Faultis intermittent caused by poor contact in the sensor's and/or ECM's connector or was repaired and ECM mem- ‘ory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contaminati- ‘on, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair” procedure. After @ repair, itis essential to verify that the fault has been corrected. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. 2. Operate the vehicle within DTC Enable conditions in General information, ‘Are any DTCs present ? : YES Go to the applicable troubleshooting procedure. ‘System is performing to specification at this time,DTC TROUBLESHOOTING PROCEDURES [DTC P1638 | MICROCONTROLLER MALFUNCTION Malfunctions are detected using checksum techniques for verifying data. . Digital data is composed of zeros and ones. A checksum is the total of all ones in a string of data, By comparing the checksum value with a stored value, a malfunction can be detected. fan overrun occurs during normal operation, the microcontroller will be monitored when the following test conditions have been fulfled 41. Ignition start has not occurred 2. Accelerator pedal not actuated. 3. Cruise control is not active, 4. No increase in external fuel quantity command If the ECM microcontroller generates threshold value, the ECM judged this as a fault and DTC is set.FL-381 FUEL SYSTEM DTC DETECTING CONDITION = E=siss95 3 ttem Detecting Condition Possible Cause DTC Strategy | ¢ Rationality check Enable Conditions | « Ignition on ‘* Case 1: microcontroller is reported as defective (recovery occurred (new program start)) '* Case 2: injector is energized as engine while engine speed above Threshold Value | 2050 rpm and APS is 0 % (fuel cut range) '* Case 3: engine speed has not dropped below 500 rpm within 1.5 sec. affer turning the igintion switch off (Watchdog post-run test) © Case 4: Gate array communication error occurs |. Fauty Eo * Case 1: 0 sec. = . + Case 2: AT 0.84 sec. MT 0.49 sec. Diagnostic Time | Case 3:0 sec © Case 4; 0.3 sec. ML [ene Fuel Limit * Yes (case3) Fuel Cut © Yes (case 1,2,4) EGR Off © No MONITOR'DTC STATUS extesess = 4. Igintion * OFF" 2. Connect scantool and select Diagnostic Trouble Code(DTC). 3. Clear DTC and then, Monitor DTC status. 4, Is the DTC P1638 is retreived again 7 m= ‘Substitute with a known-good ECM and check for proper operation If the problem is corrected, replace ECM and then go to "Verification of Vehicle Repair" procedure, Fault is intermittent caused by poor contact in the sensor's and/or ECM’s connector or was repaired and ECM mem- ‘ory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contaminati- (on, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair” procedure. VERIFICATION OF VEHICLE REPAIR © ecczteas™ = After a repair, itis essential to verify that the fault has been corrected. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. (Operate the vehicle within DTC Enable conditions in General information. ‘Are any DTCs present ? Go to the applicable troubleshooting procedure ‘System is performing to specification at this time.DIC TROUBLESHOOTING PROCEDURES FL-382 DTC P1639 | A/D CONVERTER MONITORING MALFUNCTION ] COMPONENT LOCATION © @) Pull up current —+ Charge (7A) — @) Hold in current (121A) —» ©) Charge ((6),@) Hold in control current). DTC DESCRIPTION 2am es If the signal above threshold value, the ECM judged this as a fault and DTC is set. DTC DETECTING CONDITION ce Item Detecting Condition Possible Cause _ | DTC Strategy _| ¢ Signal check, high | Enable Conditions | « Engine run Threshold Value | « Injector booster voltage > 95.V (More than 7 tines) Diagnostic Time © 0 sec, + Faulty ECM mit * No FuelLimit | No Fuel Cut Yes EGROP — | eNoFUEL SYSTEM 4. Connect scantoo! to Data Link Cable (DLC). 2. Monitor Injector Booster Operating Voltage " parameter on the scantool. FIG1 1.2 CURRENT Data 7 x |Mass AIR FLOW 473 ag/st| » |FUEL PRESSURE 276. Bbar X|FUEL PRESS. REGULATOR 16.5 % > | OUTROS TR a » |FUEL QUANTITY. Bo meo lACCEL. POSITION SENSOR 718.50 COOLANT TEMP. SENSOR 83.9 °C [ENGINE SPEED 752 npn v FIX | [ScRN] [FULL] [PaRT] [GRPH] [HELP Fig 1) Normal value with injector booster operating voltage sensor at idle. |s Current data displayed correctly ? : YES >> Faults intermittent caused by poor contact in the sensor's and/or ECM's connector or was repaired and ECM memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair" procedure. > Substitute with a known-good ECM and check for proper operation. Ifthe problem is corrected, replace ECM and then go to "Verification of Vehicle Repair” procedure. After @ repair, it is essential to verify that the fault has been corrected Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. 2. Operate the vehicle within DTC Enable conditions in General information, 3. Are any DTCs present ? Goto the applicable troubleshooting procedure ‘System is performing to specification at this time.DTC TROUBLESHOOTING PROCEDURES FL386 [DTC P1647 | CAPACITOR VOLTAGE - TOO LOW Item Detecting Condition Possible Cause DTC strategy |» Signal check, tow Enable Conaltions | « Engine run ‘Threshold Value © Injector booster voltage < 10 V (More than 7 times) Diagnostic Time | « 0 sec. + Faully EoM iL = No Fuel Limit | 3 No Fuel Cut | Yes EGR Off No Refer to DTC P1646.Fl 87, FUEL SYSTEM [DTC P1661 | CRUISE CONTROL LAMP-OPEN OR SHORT CIRCUIT ‘GENERAL DESCRIPTION ‘The eruise control system keeps the vehicle running at a fixed speed until a signal canceling this fixed speed is receive- 4 ‘When the main switch "AUTO CRUISE” is turned on with vehicle in the running mode, the battery voltage is applied to the ECM. When a signal from the control switch is input to the ECM while the vehicle is in state, the cruise control actuator is activited to operate the system. ‘Also, while the system is operating, "AUTO CRUISE” indicator lamp in the meter assembly lights up. In case of the cruise control system failure, the engine symptoms will occur acceleration failure and vehicle speed sett- ing failure, tem Detecting Condition Possible Cause DTC Strategy __| « Votage check, low or high [Enable Conditions |» Engine run | ‘* Case 1 : Short for cruise control lamp circuit. ‘© Case 2 : Open for cruise control lamp circuit Threshold Value + Open or short in cruise control circuit ; * Case 1:05 00 "Faulty cruise Disgaoese 1a | Case 2: 1.2 sec control switch Senn +T EEE PTs REE —— + Faulty ECM MIL No ty Fuel Cut je No | EGROM | 4No SCHEMATIC DI sess Refer to DTC P0564DTC TROUBLESHOOTING PROCEDURES TERMINAL AND CONNECTOR INSPECTION ~~ FsAc085 is 1. Many malfunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. : 3. Has a problem been found? YES ay as necessary and go to "Verification of Vehicle Repair" procedure. Go to "Control Circuit Inspection” procedure. ‘CONTROL CIRCUIT INSPECTION® Esie0as0= 1. Ignition “OFF” & Engine "OFF" 2. Disconnect ECM connector. 3. Ignition "ON" & Engine "OFF" 4. Measure voltage between terminal 14 of ECM hamess connector and chassis ground. Specification : Approx. 10.8 ~ 13.0V 14. Crise Indication lamp 5. Is the measured voltage within specifications 7 > Go to "Component Inspection’ procedure, > Check for open or short in control harness. Repair as necessary and go to "Verification of Vehicle Repair” procedure.FUEL SYSTEM 1. Check Cruise control indication lamp 4) Ignition "ON" & Engine "OFF". 2) Disconnect ECM connector. 3) Jump terminal 24 of ECM hamess connector and chassis ground with jumper wire. 4) Is the Cruise control indication lamp tumed ON ? YES Go to "Check bulb” as below. > Check for open or short in signal harness. Repair as necessary and go to "Verification vehicle Repair’ procedure. 2. Check Bulb 1) Ignition “OFF” & Engine "OFF. 2) Remove Instrument Panel and then remove bulb from instrument panel 3) Apply 12 voltage to the bulb and check that bulb is turned ON. 4) Isthe bulb tumed ON ? m2 > Substitute with a known-good ECM and check for proper operation. Ifthe problem is corrected, replace ECM and then go to "Verification of Vehicle Repair" procedure. > Substitute with a known-good bulb and check for proper operation. Ifthe problem is corrected, replace bulb and then go to "Verification of Vehicle Repair” procedure. ERIFICATION OF VEHICLE REPAIR © sbeiiek® SSS After a repair, itis essential to verify that the fault has been corrected, Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. 2. Operate the vehicle within DTC Enable conditions in General information. ‘Are any DTCs present ? YES Go to the applicable troubleshooting procedure. ‘System is performing to specification at this time,DTC TROUBLESHOOTING PROCEDURES FL.390 DTC P1765 | TORQUE REDUCTION SIGNAL - MAL ‘The ECM communicate over the CAN are the EMS(Engine Management System), TCS(Traction Control System) TCM- (Transmission Control Moudle). With the introduction of a CAN, only two Lines are required to achieve the same function. The information is in digital format . This method does not use a integrated ECM Input signals to TCM through " CAN communication " are as follows. > Engine pm, TPS signal, AIC signal, WTS signal, AFS signal, Vss signal, Shift holding signal (FTCS ON) ‘Output signals from TCM through" CAN communication "are as follows. > Request signal for torque reduction, ATF temperature, TCM type, TCM error or not, damper clutch on, offigear position. In case of the CAN failure, the engine symptoms will occur the corrupted torque reduction signal information, shift shock and increasing engine rpm abruptly. If the CAN communication generates threshold value, the ECM judges this as a fault and DTC is set.FL-391 FUEL SYSTEM DTC DETECTION CONDITION = Go to "WiHamess inspection" procedure,FL-397 FUEL SYSTEM TERMINAL & CONNECTOR INSPECTION = &*e2Fc2e = = 1. Many maifunctions in the electrical system are caused by poor hamess and terminals. Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage. 2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage 3. Has a problem been found? eS a” necessary and go to "Verification of Vehicle Repair" procedure. Go to "Signal Circuit Inspection” procedure. SIGNAL'CIRCUIT INSPECTION. “ea4rAt85 Z 4. Check for open or short in APS 2 Signal harness 4) Ignition "OFF" 2). Disconnect APS sensor connector. 3) Ignition "ON" & Engine "OFF. 4) Measure voltage between terminal 1 of the sensor harness connector and chassis ground ‘Specification : 4.8 ~ 5.1V : 1.APS 2 Signal 2.APS 1 Signal 3. APS 2 Power 44,APS 2 Ground 5.APS 1 Ground 6.APS 1 Power 5) _Is the measured voltage within specifications 7 } Go to "Check for open or short in APS1 Signal hamess" as below. } Check for open or short in APS2 signal harness. Repair as necessary and go to "Verification vehicle Repa- ir" procedure,FL-398 DTC TROUBLESHOOTING PROCEDURES 2. Check for open or short in APS1 signal hamess, 1) Ignition "OFF" 2) Disconnect AP sensor connector 3) Measure voltage between terminal 2 of the sensor harness connector and chassis ground, 4) 5) GROUND CIRCUIT INSPECTION — Go to "Ground Circuit Inspection" procedure. NO > Check for open or shor in APS1 harness. Repair as necessary and go to "Verification of Vehicle Repair” procedure. 4, Check for open in APS2 hamess. y 2) 3) Ignition "OFF" Disconnect AP sensor and ECM connector. Measure resistance between terminal 4 of the sensor hamess connector and terminal 79 of ECM hamess connector Specification : Approx.below 10 0-256 De 060 1. APS 2 Signal 2.APS 1 Signal 3. APS 2 Power 4, APS 2 Ground '5,APS 1 Ground 6. APS 1 Power 0230-1FL.399 FUEL SYSTEM 4) Is the measured resistance within specifications ? eS D Go to "Check for open in APS1 ground harness” as below. > Check for open in APS2 ground harness. Repair as necessary and go to “Verification of Vehicle Repair” procedure. 2, Check for open in APS1 hamess 1). Ignition "OFF" 2) Disconnect AP sensor and ECM connector. 3) Measure resistance between terminal 5 of the sensor harness connector and terminal 79 of ECM hamess co- nestor. Specification : Approx below 10. na 1. APS 2 Signal 2°4PS 1 Signal 5:APS2 Power 4.APS 2 Ground 5.APS 1 Ground 8.APS 1 Power 4) Is the measured resistance within specifications 7 YES > Go to "Component Inspection” procedure. >. Check for open in APS1 ground harness. Repair as necessary and go to "Verification vehicle Repair" proc- cedure.DTC TROUBLESHOOTING PROCEDURES FL-400 COMPONENT INSPECTION Se0eAEDAE = 1, Check APS 4) Ignition "OFF". 2) Disconnect APS connector. 3) Measure resistance between terminals 3 and 6 of the sensor connector(to IAT sensor side). Spectcaion 170080) 4. APS 2 Signal 2.APS 1 Signal 3. APS 2 Powor 4, 4PS 2 Ground 55, APS 1 Ground GAPS 1 Power ers 4) Isthe measured resistance within specifications ? YES > Substitute with a known-good ECM and check for proper operation. If the problem is corrected, replace ECM and then go to "Verification of Vehicle Repair” procedure. > Substitute with a known-good APS2 and check for proper operation. Ifthe problem is corrected, replace APS2 and then go to "Verification of Vehicle Repair” procedure. VERIFICATION OF VEHICLE REPAIR técaso07 After a repair, its essential to verify that the fault has been corrected. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. Operate the vehicle within DTC Enable conditions in General information. ‘Are any DTCs present ? Go to the applicable troubleshooting procedure. ‘System is performing to specification at this time,FL-401 FUEL SYSTEM. DTC P2228 | ATMOSPHERIC PRESSURE SENSOR - LOW INPUT ABA ASS COMPONENT LOCATION ‘An atmospheric pressure sensor is used to detect changes in barometric pressure that can alter the ihtake air density, resulting in improper air-fuel ratio. ‘i’ To compensate for this type of deviation, the amount of fuel injected is controlled. For example, the amount of fuel injected is decreased to compensate for the lower intake air density caused by the de- ‘creased barometric pressure.(high altitude) The atmospheric pressure sensor is located in the ECM. Possible Cause | Item DTC Strategy Enable Conditions _| « ignition on |” Threshold Value © Output signal < 0.15V Diagnostic Time | « 2 sec. ia fio) + Faulty ECM Fuel Limit NO Fuel Cut NO. EGR Off NO "Fail safe '» Barometric pressure is fixed at a value of 900 hPa by the ECM.DTC TROUBLESHOOTING PROCEDURES FL402 SPECIFICATION — E0scosee {mospheric Pressure SensoR Pressure ‘Approx. 1000 + 30 hPa MONITOR SCANTOOL DATA &sAsz1e0 ss é 1. Connect scantool to Data Link Cable (DLC). 2. Monitor" Barometric Pressure Sensor " parameter on the scantool FIG1 1.2 CURRENT DATA ra » (SST ET VEHICLE SPEED SENSOR = 8) Knvh |™ |FUEL PRESSURE 276.8bar IFUEL PRESS. REGULATOR 16.6 % leeR ACTUATOR 95.8 % ICLUTCH SW.cM/T ONLY) ON [BRAKE SUITCH orF v - Fr | [scan] [runt] [parr] [enpu] [WeLP) Fig 1) Normal value with barometric pressure sensor sensor at idle speed Is Current data displayed correctly ? YES > Fault is intermittent caused by poor contact in the sensor's and/or ECM's connector or was repaired and ECM memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair” procedure. > Substitute a known-good ECM and check for proper operation, Ifthe problem is corrected, replace ECM and then go to "Verification of Vehicle Repair” procedure.FL403 FUEL SYSTEM VERIFICATION OF VEHICLE REPAIR = £”0986°3 After @ repair, itis essential to verify that the fault has been corrected. Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. Operate the vehicle within DTC Enable conditions in General information. Are any DTCs present ? YES Go to the applicable troubleshooting procedure. ‘System is performing to specification at this time.DTC TROUBLESHOOTING PROCEDURES L404 DTC P2229 | ATMOSPHERIC PRESSURE SENSOR - HIGH INPUT _ ‘An atmospheric pressure sensor is used to detect changes in barometric pressure that can alter the intake air density, resulting in improper air-fuel ratio. . To compensate for this type of deviation, the amount of fuel injected is controlled. For example, the amount of fuel injected is decreased to compensate for the lower intake air density caused by the decreased barometric pressure. (high altitude) The atmospheric pressure sensor is located in the ECM. DTC Strategy _| « Signal check, low |_Enable Conditions | « Ignition on Threshold Value | Output signal < 4.9V Diagnostic Time | # 2 sec. MIL Fuel Limit Fuel Cut EGR Off + Faulty ECM Fail safe ‘* Barometric pressure is fixed at a valueFL-405 FUEL SYSTEM SPECIFICATION erasriA > © = s i AS) { : _ Atmospheric Pressure Sensor = E Pressure ~ aprox 10002 30 nPa ITOOL DATA ecosdoab = Connect scantool to Data Link Cable (DLC), Monitor " Barometric Pressure Sensor " parameter on the scantool 1 2. FIG4 4.2 CURRENT DATA a » ENGINE SPEED 751 rpn VEHICLE SPEED SENSOR = 8) Xnvh |™ |FUEL PRESSURE 276.8bar |FUEL PRESS. REGULATOR 16.6 % EGR ACTUATOR 95.8 % CLUTCH SW.CIT ONLY) — ON IBRAKE SWITCH OFF v FIX | [cen] [FuLt] [Parr] [GRPH] [HELP Fig 1) Normal value with barometric pressure sensor sensor at idle speed Is the Current data displayed correctly ? ms > Faults intermittent caused by poor contact in the sensor's and/or ECM! 's connector or was repaired and ECM memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of Vehicle Repair” procedure. > Substitute with a known-good ECM and check for proper operation If the problem is corrected, replace ECM and then go to "Verification of Vehicle Repair” procedure.DTC TROUBLESHOOTING PROCEDURES VERIFICATION OF VEHICLE REPAIR &c3i After a repair, itis essential to verify that the fault has been corrected, Connect scan tool and select "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC. ‘Operate the vehicle within DTC Enable conditions in General information ‘Are any DTCs present ? Go to the applicable troubleshooting procedure. ‘System is performing to specification at this time,FL-407 FUEL SYSTEM FUEL DELIVERY SYSTEM-DIESEL COMPONENTS | exesa030 1) injector [B] High Pressure (HP) Pump [3] Common Fal [4] High Pressure Pipe (Irjector-Common Rai) [5] High Pressure Pipe (HP Pump—»Common Rail) [Fuel Fiter Fuel Pump (Low Pressure) (5) Fuel TankFUEL DELIVERY SYSTEM-DIESEL & caution ‘Common Rail Fuel Injection System is subject to extremely high pressure (Approximately 1,350 bar) Never perform any work on injection system with engine running or within 30 secods after the engine stops. Always pay attention to safety precaution. Ensure the absolute cleanliness It is not recommanded to remove the injectors without any notice, FL.408FL-409 EO FUEL LINE SCHEMATIC DIAGRAM oonens ee290937 FUEL SYSTEM. Fuel Tank Pre-fiter Fuel Pump (Low pressure) Fuel Filter Low Pressure Fuel Line High Pressure Pump High Pressure Fuel Line Common Rail Injector Fuel Return Line ECMFUEL DELIVERY SYSTEM-DIESEL, LOW PRESSURE FUEL SYSTEM COMPONENTS, FUEL PUMP ‘The fuel pump is either an electric fuel pump with pre-fiter, or a gear-type fuel pump. The pump draws the fuel from the fuel tank and continually delivers the required quantity of fuel in the direction of the high-pressure pump, FUEL FILTER Inadequate fitering can lead to damage at the pump components, delivery valves, and injector nozzles. The fuel fi- Iter cleans the fuel before it reaches the high-pressure pump, and there by prevents premature wear at the pump's sensitive components, HIGH PRESSURE FUEL SYSTEM COMPONENTS HIGH PRESSURE PUMP The high-pressure pump pressurizes the fuel to a system pressure of up to 1,350bar. This pressurized fuel then pa- ses through a high-pressure line and into the tubular common rail COMMON RAIL (HIGH PRESSURE ACCUMULATOR) Even after an injector has taken fuel from the rail in order to inject it, the fuel pressure inside the rail remains practi- ly constant. This is due to the accumulator effect arising from the fue's inherent elasticity. Fuel pressure is measured by the rail pressure sensor and maintained at the des- ired level by the pressure-control valve. INJECTORS ‘The nozzles of these injectors open when the solenoid va- Ive is triggered and permit the flow of fuel. They inject the fuel directly into the engine's combustion chamber. The ‘excess fuel which was needed for opening the injector nozzles flows back to the tank through a collector line. The return fuel from the fuel pressure control valve and from the low-pressure stage is also led into this collector line together with the fuel used to lubricate the high-pressure pump. FL.410 HIGH PRESSURE PIPE ‘These High Pressure Pipes carry the high-pressure fuel. ‘They must therefore be able to permanently withstand the maximum system pressure and, during the pauses in injection, the sometimes high-frequency pressure fluctuations which occur. They are therefore manufactured from steel tubing. Normally, they have an outside diameter of 6 mm. and an intemal diameter of 2.4 mm. The injection lines be- {ween the common rail and the injectors must all be of the same length, The differences in length between the common rail and the individual injectors are compensated for by Using slight or pronounced bends in the individual lengths of tubing. Nevertheless, the injection lines should be kept as short as possible.FLA11 FUEL SYSTEM INJECTOR DESCRIPTION | casoieae ‘The start of injection and the injected fuel quantity are ad- justed by electrically triggered injectors. These injectors supersede the nozzle-and-holder assembly (nozzle and nnozzle-holder). Similar to the already existing nozzle-holder assemblies in direct-injection (D1) diesel engines, clamps are preferably used for installing the injectors in the cylinder head. This means that the Common Rail injectors can be installed in already existing DI diese! engines without ma- jor modifications to the cylinder head. tune Injector comoctor Fangio Fuel et om al) Fring bot nectar lane Seal og ~The hole-type nozzle - The hydraulic servo-system ~The solenoid valve Fuel is fed from the high-pressure connection to the nozzle through the passage, and to the control chamber through the feed orifice. The control chamber isconnected to the fuel return via a bleed orifice which is opened by the sole- noidvalve ‘With the bleed orifice closed, the hydraulic force applied to the valve controlplunger exceeds that at the nozzle-needie pressure shoulder. As a result the needle is forced into its seat and seals off the high-pressure passageffom the co- ‘mbustion chamber. When the injector's solenoid vaive is triggered, the bleed orifice is opened. This leads to a drop in control-chamber pressure and, as a result, the hydraulicpressure on the plunger also drops. As soon as the hydraulic force drops. belowthe force on the nozzle-needle pressure shoulder, the nozzle needle opensand fuel is injected through the spray holes into the combustion chamber. This indirect control of the nozzle needle using a hydraulic force-amplific- ationsystem is applied because the forces which are necessary for opening the needlevery quickly cannot be directly generated by the solenoid valve. The so-calledcontrol quantity needed for opening the nozzle needle is in adalt- ion to thefuel quantity which is actually injected, and it is led back to the fuel-returniine via the control chamber’s orifices, In addition to the contro! quantity, fuel is also lost at the nozzle-needleand valve-plunger guides. These control and leak-off fuel quantities are retumedto the fuel tank via the fuel return and the collector line to which overflow valve, high-pressure pump, and fuel pressure control valve and also connected,FUEL DELIVERY SYSTEM-DIESEL FL412 METHODD OF OPERATION = esocrese Injector (schematic) A 6. Bleed orifice B. Injector opened (injection) 7. Feed orifice 1, Fuel return 8. Valve control chamber 2. Electrical connection 8. Valve control plunger 3. Triggering element (solenoid valve) 10. Feed passage to the nozzle 4. Fuel inlet (high pressure) from the rail 11. Nozzle needle 5. Valve ballFL413 FUEL SYSTEM ‘The injactor’s operation can be subdivided into four operating states withthe engine running and the high-pressure pump generating pressure: 1. Injector closed (with high pressure applied) 2. Injector opens (start of injection) 3, Injector opened fully 4, Injector closes (end of injection) These operating states result from the distribution of the forces appliedto the injector's components. With the engine at stand stil and no pressurein the rail, the nozzle spring closes the injector. 4, INJECTOR CLOSED (AT-REST STATUS) In the at-rest state, the solenoid valve is not energized and is thereforeclosed (See "A" IN Figure). With the bleed orifice closed, the valve springforces the armature's ball ont- othe bleed orifice seat. The rail’ high pressurebuilds up in the valve control chamber, and the same pressure is also presentin the nozzle's chamber volume. The rail pressure applied at the control plunger'send face, together with the force of the nozzle spring, maintain the nozzlein the closed positionagainst the opening forces applied to its pressure stage. 2, INJECTOR OPENS (START OF INJECTION) The injector isin its at-rest position. The solenoid valve is energized withthe pickup current which serves to ensure that it opens quickly (See "B” inFigure). The force exerted by the triggered solenoid now exceeds that of thevalve sp- fing and the armature opens the bleed orfce. Almost imm- ediately.the high-level pick-up current is reduced to the lower holding current requiredfor the electromagnet. This is possible due to the magnetic circuit's airgap now being smaller. When the bleed orifice opens, fuel can flow from thevalve-control chamber into the cavity situated above it, and from there viathe fuel return to the fuel tank, The bleed orifice prevents complete pressurebalance, and the press- ture in the valve control chamber sinks as 2 result This leads to the pressure in the vaive-control chamber being lower than thatin the nozzle's chamber causes a reduction in the force exerted on the controlplunger, the nozzle needle opens as a result, and injection starts. The nozzleneedie’s opening speed is determined by the difference in the flow rate throughthe bleed and feed orifices. The control plunger reaches its upper stop whereit remains supported by a cu- shion of fuel which is generated by the flow offuel between the bleed and feed orifices. The injector nozzle has now ‘openedfully, and fuel is injected into the combustion chamber at a pressure almostequal to that in the fuel rail. Force distribution in the injector is similarto that during the opening phases 3. INJECTOR CLOSES (END OF INJECTION) ‘As soon as the solenoid valve is no longer triggered, the valve spring forcesthe armature downwards and the ball closes the bleed orifice. The armatureis a 2-piece design, Her, although the armature plate is guided by a driversho- tlderin its downward movement, it can “over spring" with the return springso that it exerts no downwards-acting for- ‘ces on the armature and the ball. This closing of the bleed orifice leads to pressure build up in the controlchamber via the input from the feed orifice. This pressure is the same asthat in the rail and exerts an increased force on the con- ‘rol plunger throughits end face. This force, together with that of the spring, now exceeds theforce exerted by the ‘chamber volume and the nozzle needle closes. The nozz- leneedle's closing speed is determined by the flow through the feed ofifice Injection ceases as soon as the nozzle needle comes up against its bottoristop again, CLEANING | coai7iog & caution + Common Rail Fuel Injection System is subject to extrembly high pressure (Approximately 1,350 bar) + Never perform any work on injection system with engine running or within 30 seconds after the engine stops. + Always pay attention to safety precaution. + Ensure the absolute cleantiness. + tis not recommended to remove the injectors without any notice It must be needed to clean the injector when injector is used again, 4. Clean the injector in vertical position in an ultra-sound bath. 2. Ifnecessary, clean the injector body and sealing surface on the nozzle retaining nut also, using a fine cleaning cloth to remove any ditt residue Do not remove the protection caps to do that. 3. The nozzle-shaft must only be cleaned in an ultraso- und bath and in a vertical position, ‘A mechanical cleaning of the nozzie-shafft by wire-t rush is not permitted.FUEL DELIVERY SYSTEI FL414 REMOVAL csosoros 4. Unfasten the high-pressure pipe (A) connecting the common rail and the injector. & caution + Common Rail Fuel Injection System is subject to extremely high pressure (Approximately 1,350 bar) + Never perform any work on injection system with engine running or within 30 seconds after the engine stops. + Always pay attention to safety precaution. + Ensure the absolute cleanliness. + Itis not recommended to remove the injectors without any notice. 1. Tur ignition swithe to OFF position. 2. Disconnect the negative battery (-) terminal and wait for about 30 seconds. 3. Pull off the injector electric connector (A). oeon0u 5. Remove the injector return hose (A) by pulling the fixing-clip (B). & caution + Plugs must be installed and/or uninstalled only with the ignition switch tumed OFF. + Do not extremely bend or squeeze the cable, do not bring them in contact with sharp edges, and also secure cables against vibrations.FL415 FUEL SYSTEM 6. After pulling the injector plug cap (A) vertically, rotate. = REPLACEMENT — esesso7a itclockwise and remove it. & caution + Common Rail Fuel Injection System is subject to extremely high pressure (Approximately 1,350 bar) + Never perform any work on injection system with ‘engine running or within 30 seconds after the engine stops. + Always pay attention to safety precaution. + Ensure the absolute cleantiness + Itis not recommended to remove the injectors without any notice. 4. Remove the injector according to removal procedur- e 2. Check the injector grade on top of the injector, and then replace the used injector with a new one in same Lvaenoco grade with used one. 7. Remove injector by unscrewing injector clamp bolt © nore a If itis impossible to replace the used injector with @ @ caution ‘new injector in same grade, replace:it with the new one in different grade according to the table below. Before re-installing injector, clean the cylinder head bore and sealing surface. 1. Insert the brush 2. Clean the sealing surface and blow out. Grade Combination 1 coer Combination 2 Combination 3 Combination 4 Combination 5 Combination 6 |u| +lols)olx n|r|w)olola|< lee etelelarFL416 FUEL DELIVERY SYSTEI Install the injector by installing the clamp with clamp bolt INSTALLATION — escezcre & caurion + Common Rail Fuel injection System is subject ni ies Injector Clamp Bolt installation to extremely high tly 1,350 ete tet 25 ~ 29 N-m (18.44 ~ 21.39 lb-ft) * Never perform any work on injection system with engine running or within 30 seconds after the 5. Install the injector plug cap (A) by rotating it counter engine stops. clockwise. + Always pay attention to safety precaution. + Ensure the absolute cleanliness. + Its not recommended to remove the injectors without any notice. 1. Insert the new seal ring, eumne Inoctorennector Peng lt eo at) Fan bot snthor Selina 6. Install the high pressure pipe (A) connecting the inje~ ctor and the common rail, ne & caution + Whenever using the old injector again, the clamp fixing bolt and seal-ring are replaced with a new one, + Before re-installing injector, clean the cylinder head bore and sealing surface. 2, Insert the injector assembly into the cylinder block At this time, do not touch the nozzle tip. 3. Spread oil on the injector tip and the cylinder head.FL417 “Tightening Torques High Pressure Pipe installation nut 25 ~ 29 Nem (18.44 ~ 21.39 lb-ft) 7. Connect the return hose (A) by inserting the fixing clip (6). & caution Afixing clip that was removed must be replaced with a newone, 8. Connect the injector electric connector (A). FUEL SYSTEM 8. Connect the battery (-) cable. 10. Start the engine and check for leakage on high pressure fuel line. & caution Check the fuel-system visualy for any leakage. Ifa leakage is detected even have been used the correct to- ‘que, the component(s) must be exchanged.FUEL DELIVERY SYSTEM-DIESEL INSPECTION ecerasso USING HI-SCAN(PRO) + COMPRESSION TEST + IDLE SPEED COMPARISON + INJECT QUANTITY COMPARISON ‘TEST PROCEDURE 4. Connect Hi-Scan(Pro) and select "Vehicle" and "En- gine Test Function". 1. HYUNDAI VEHICLE DIAGNOSIS MODEL : TUCSON SYSTEM : ENGINE(DIESEL) war 01. DIAGNOSISTIC TROUBLE CODE (02, CURRENT DATA (03, FLIGHT RECORD (04, ACTUATION TEST (05, SIMU-SCAN (06, IDENTIFICATION CHECK (08. DATA SETUP(UNIT CONV} FL418 Information for ECM version is displayed as below. 1.7. COMPRESSION TEST ‘SYSTEM IMFORMATION Pin: 99100-27820, ‘Siw : e8s2MDve you ready press [ENTER - 17. COMPRESSIONTEST SYSTEM IMFORMATION PIN : 39100-27820 ‘SW: B6S2MDVB es See After pressing "|ENTER]" select "COMPRESSION TEST" mode and press "[ENTERY’ 17. COMPRESSIONTEST (02, IDLE SPEED COMPARISON (03, INJECT. QUANTITY COMPARISON eraceeoeFL419 4, Set the test condition described as below screen and then, crank engine. When engine stop message being appeared, stop cranking. 7.1. COMPRESSION TEST ‘This tests used for detecting cylinder specic engine speed without injection, "Test condition ~Shitlover — : Por “Engine: Stop (GN. ON) ~ Eloctical Load :OFF Ht you ready, now cranking, and stop cranking when stop message appear on ‘tho soroen, Press {ENTER}, 5. Press "ANAL" and the test result is appeared, FUEL SYSTEM 17.4 COMPRESSION TEST Cylinder engine speed(RPM) “ e « “4 356 355 355 355 356 356 387 358 356 386 388 355 356 386 386 356 387 356 355 356 356 355 355 355 355 356 355 355 [| >) [ac HEL Data Scanning buon 6. Press "AVG" and the data average of each cylinder is appeared. 7.4 COMPRESSION TEST Press "HELP" and description ofthe data is appeare- ‘Oylinder engine speed(PM) 4. "1 #2 #3 4 = 8 = = a inder engine apecd(AP 356, 386 357 356 = = = 358 358 2350 255 Spaed(RPM) 200 250 300 950 AVG 2358 358 258 250 | baal ba pea oa J bed a pal posi bead 19 CY. SET = 355 SE 8 38 556. oo Cr ET 355 anal] S => ‘When the stop message appear, stop cranking. eeeeee teed ( nore During cranking engine does not start. ¥ 7.4 COMPRESSION TEST “Tha higher cylinder engine speed: >The low compression pressure “ttean help to dently the mechanical deocts, PREVFUEL DELIVERY SYSTEM-DIESEL FL420 7. After pressing "ESC", select IDLE SPEED COMPA- 9, The rpm data of each cylinder is appeared RISON’ and press “[ENTER|" 7.2 IDLE SPEED COMPARISON 7.4 COMPRESSION TEST Cylinder engine speed(RPM) 03. COMPRESSIONTEST " 2 #2 “ (03. INJECT. QUANTITY COMPARISON 730 00 752 770 796 798 756 2 788 800 752 770 708 802 754 re 798 802 754 770 708 ‘02 7 | m4 m2 02 we _| 7 ‘Analyze the test result. ‘ANALY 8, Set the test condition described as below screen and press "[ENTERT. ¥ 7.2.IDLE SPEED COMPARISON 7.2 IDLE SPEED COMPARISON This testis used for detecting cylinder epectic engine speed with Injector energizing Cylinder engine speeciFPM) (Gytnder balancing functions a 2 4“ a activated) 764 778 788 764 * Test condition 7288 7 738 786 “ Compression test: Normal 786 776 758 786 “Shitlover — :Por 788 780 720 738 sEngine idle 7e4 776 726 74 + Electrical Load : OFF 708 70 72 a you ready, Pross [ENTER 708 7s | __ 708 766 < [| > |Cac HELP|FL421 10. Press "AVG" and teh data average of each cylinder is appeared. Press "HELP" and description of the data is appeare- 4d Cynder engine speed(APM) ‘SpeeaiRPM 650 700 750 600 ANG. 1 738 2 as 800 so 753, «ce 7m prev|({ wets v FUEL SYSTEM. TA ND 11. After pressing "ESC’, select "INJECT QUANTITY 12, COMPARISON’ and press "[ENTERY. 7.2 IDLE SPEED COMPARISON 01. COMPRESSION TEST 02, IDLE SPEED COMPARISON press "[ENTERT’ Set the test condition described as below screen and 7.8 INJECT. QUANTITY COMPARISON 712 IDLE SPEED COMPARISON “Tho tower engine spaod: ->Tho injector injocs less quantity than oer injectors. “The higher engine speed: Tha injector injects more quently than other injectors prev ‘This test is used for detecting cylinder specie quantiy with + Individual energizing of injector. (Cylinder balancing function is cectivated) “Test condition ~ Compression test :Normal *Shitlover— :PorN “Engine idle + Electrical Load : OFF lt you ready, Pross [ENTER],FUEL DELIVERY SYSTEM-DIESEL 43. The data of each cylinder about RPM and compens- ating injection quantity is appeared. FL422 14, Press "HELP" and description of the data is displayed as below. 7.3 INJECT. QUANTITY COMPARISON 7.3 INJECT. QUANTITY COMPARISON Eng. Speed(APM) Injection quanttymm3) wv [we [ea foe [or [oe |e 7e2 | 200 | 758 | 774 | a0 | 20 | 20 7es | 708 | 760 | 774 | 40 | 29 | 27 70s | ave | 752 | 776 | «0 | 29 | 27 ez | 708 | 752 | 774 | 40 | 20 | 27 zea | 708 | 758 | 772 | 40 |-26 | 26 70s | aoz | 750 | 772 | 40 |-28 | 28 700 _| 708 | 754 | 770 | 40 | -20 | 26 ‘Analyze the test result, ANAL ¥ Cynder engine speed(RPM) SpeeciFPM)650 700 750 800 AVG | —— | 731 ct TT 799 ot ad TT 73 Quantinm)-4 20 2G #1 OY, i «0 eon = 28 co 27 mow Rs 23 Prev |(reur) - “The postive cortecton value: +The fue Injection ofthe oylinder is loss than that of oer oyinder. “The negative corecion value: >The ful injection ofthe cylinder is more than that of other evinces. “Extreme corecton value identifies 8 problematic injector. After replacinga injector with new one, reset & confirm the engine conton 18. Replace the default injector, and then repeat previous test modes to check if the injector is normal WIRING HARNESS INSPECTION Refer to P0261 ~ P0272 DTC inspection procedures.FL-423 FUEL SYSTEM ACCUMULATOR DESCRIPTION | ceizecso The common rail stores the fuel at high pressure. At the same time, the pressure oscillations which are generated due to the high-pressure pump delivery and the injection of fuel are damped by the rail volume. This common rail common to all cylinders, hence its name "common rail" Even when large quantities of fuel are extracted, the common rail maintains its inner pressure practically constant from the moment the injector opens. In order to comply with the wide variety of engine installation conditions, the common rail with its flow limiters and the provistions for attaching rail pressure sensor, fuel pre~ ssure control valve, and pressure limiter vaive is available in a number of different designs. ‘The available common rail volume is permanently filled with pressurized fuel. The compressibility of the fuel resu- Iting from the high pressure is utilized to achieve the accumulator effect. When fuel leaves the rail for injection, the pressure variations resulting from the pulsating fuel supply from the high-pressure pump are compensated for. REMOVAL & caution + Common Rail Fuel Injection System is subject to extremely high pressure (Approximately 1,350 bar) + Never perform any work on injection system with engine running or within 30 seconds after the engine stops. + Always pay attention to-asfety precaution, + Ensure the absolute cleanliness + [tis not recommended to remove the injectors without any notice. 4. Tum ignition switch to OFF position 2. Disconnect the negative battery (-) terminal and wait for about 30 seconds 3. Remove the high pressure pipe (A) connecting injectors and common rail 4, Remove the high pressure pipe (B) connecting high pressure pump and common rai 5. Disconnect the fuel pressure regulator connector (C) and rail pressure sensor connector (D) Disconnect the return lines (E) Remove the common rail (A) by unscrewing the three ‘mounting bolts (B).FL424 FUEL DELIVERY SYSTEM-DIESEL INSTALLATION Tightening Torques ‘common rail mounting bolt 8 ~ 10 Nem (5.9 ~ 7.37 Ibtt) Installation is in the reverse order of removal. Tightening Torques ‘Common rail mounting bolt: 8 ~ 10 Nem (5.9 ~7.37 Ib) High pressure installation nut: _25 ~29 Nim (18.44 ~ 21.39 Ib)FL-425 FUEL SYSTEM HIGH PRESSURE FUEL PUMP DESCRIPTION geocacra ‘The high-pressure pump is the interface between the low- pressure and the high-pressure stages. Under all operating conditions, itis responsible for providing adequate high-p- ressure fuel through out the vehicle's complete service life. This also includes the provision of extra as needed for rapid starting and for rapid build-up of pressure in the rail ‘The high pressure pump continually generates the system pressure as needed in the high-pressure accumulator (common rail). This means therefore, that in contrast to conventional systems, the fuel does not have to be specially compressed for each individual injection process.FUEL DELIVERY SYSTEM-DIESEL Nomaep FL.426 3 Driveshaft Eccentric cam Pumping element with pump plunger Pumping-element chamber Suction valve Outlet valve Seal 2 10. "1 High-pressure connection to the rail Ball valve Fuel return |. Fuel inlet from the fuel pump . Safety valve with throttle bore 18. Low-pressure passage to the pumping elementFL.427 FUEL SYSTEM ‘The high-pressure pump is installed preferably at the same point on the diesel engine as a conventional distributor pump. Itis driven by the engine (at half engine speed, but max. 3000 rpm) through a coupling, gear wheel, chain, cr toothed belt, and lubricated by the diesel fuel pressure control valve is installed directly on the high pressure pump or remote from it. Inside the high pressure pump, the fuel is compressed with theree radially arranged pump pistons which are at an angle of 120° to each other. Since three delivery stokes take place for every revolution, only low peak drive torques are generated so that the stress on the pump drive remains uniform. With 16 N-m, the torque is only about 1/9 of that required to drive a comparable distributor pump. This means that Common Rail places lessl- ‘oading on the pump drive than is the case with conventio- ral injection system. The power required to drive the pump climbs in proportion to the pressure set in the rail and to the pump's speed (delivery quantity). For a 2ulter engine turning at rated speed, and with a set pressure of 1,350 bar in the common rail, the high pressure pump requires 3.8kW presuming a mechanical efficiency of approx. 90%. The higher power demand (higher than theoretically necessary) results from the leak-fuel and control quantities at the injector, and from the fuel return thr- ‘ough the fuel pressure control valve. .FUEL DELIVERY SYSTEM-DIESEL 1. Driveshaft 2. Eocentric cam 3. Pumping element with pump piston 4, Inlet valve 5. Outlet valve 6. InletFL.429 FUEL SYSTEM weet METHOD OF OPERATION Via a fiter with water separator, the fuel pump pumps fuel from the tank to the high-pressure pump through the fuel inlet and the safety valve. It forces the fuel through the sa- {ety valve's throttle bore and into the high pressure pump's lubrication and cooling circuit. The driveshaft with its ecce- nitric cams moves the three pump plungers up and down in ‘accordance with the shape of the cam. As soon as the delivery pressure exceeds the safety valve's opening pressure (0.8 ~ 1.5 bar), the fuel pump can force tuel through the high pressure pump's inlet vaive into the pumping-ele- ‘ment chamber whose pump piston is moving downwards {suction stroke). The inlet valve closes when the pump pi- ‘ston passes through BDC and, since it is impossible for the fuel in the pumping-element chamber to escape, it can now be compressed beyond the delivery pressure, The increasing pressure opens the outlet vaive as soon as the rail pressure is reached, and the compressed fuel centers the high pressure circuit. The pump piston continues to deliver fuel unti it reaches TDC (delivery stroke), after which the pressure collapses so that the outlet vaive clos- ‘es, The fuel remaining in the pumping-element chamber drops below the fuel pump pressure, the inlet valve opens and the pumping process starts again FUEL-DELIVERY RATE ‘Since the high-pressure pump is designed for large detiv- ery quantities, excess high pressure fuel is delivered during idle and part-load operation. This excess fuel is returned to the tank via the fuel pressure control valve. The compressed fuel relaxes in the tank, and the energy is lost which was used for compressing the fuel in the first place. In addition to the unnecessary heating up of the fuel, over all efficiency is also reduced. To a certain extent, this loss of efficiency can be compensatd for by switching off one of the pumping elements.FUEL DELIVERY SYSTEM-DIESEL FL.430 TRANSMISSION RATIO. ‘The high-pressure pump's delivery rate is proportional to its rotational speed. And this, in turn, is a function of the engine speed. During the injection-system application-en- gineering work on the engine, the transmission ratio is defined so that on the one hand the amount of excess fuel is not too high, and on the other, the fuel requirements can still be satisfied during WOT operation. Referred to the cr- ankshaff, transmission ratios of 1:2 and 2:3 are possible REMOVAL caoaacse & caurion + Common Rail Fuel Injection System is subject to extremely high pressure (Approximately 1,350 bar) + Never perform any work on injection system with engine running or within 30 seconds after the ‘engine stops, + Always pay attention to safety precaution. + Ensure the absolute cleanliness. + Itis not recommended to remove the injectors without any notice, 1, Tum ignition switch to OFF position. 2, Disconnect the negative battery (-) terminal and wait for about 30 seconds, 3. Remove the high pressure pipe (A) connecting high pressure pump and common rail Release the flange bolt (F) and disconnect the fuel feed line (B) from fuel fiter. Disconnect the fuel return tines (C). Unscrew the three high pressure mounting bolts (D) and remove the high pressure pump (E)FL-431 FUEL SYSTEM ACCELERATION PEDAL COMPONENTS evesscra Lo REMOVAL ccarzacs 1. Unfasten acceleration pedal module mounting nuts(- 2EA) and bolt(1EA) 2. Remove acceleration pedal module assembly. INSTALLATION. erapreoe Installation is in reverse order of removal.FL432 FUEL DELIVERY SYSTE! FUEL FILTER COMPONENTS | excoccas Fuel fiter head Thermo switch 24.5 ~ 29.4 (18.07 ~ 21.68) Fuel iter heater ‘Stud bolt 196-245 (14.48 - 18.07) Gasket (O-rign) Fuel fiter ‘mounting bracket Fuel filter cartridge Fuel fitter water sensor 1.96 ~ 2.45 (1.44 1.8) Tightening torque : N-m (Ibf-ft)FL433 REMOVAL | cescecta 4, Tum ignition switch to OFF position. 2. Disconnect the negative battery (-) terminal and wait for about 30 seconds. 3, Remove the air cleaner assembly. 4. Before disconnecting fuel hose, spread out service towel under the fuel filter not to contaminated by fue- i 5. Disconnect the heater connector, water sensor connector and thermo switch connector. 6. Unfasten fuel fiter bracket mounting nut(1EA) and bolts(2EA) and remove the fuel fiter assembly. 7. Unfasten mounting nut (2EA) and bolts(3EA) on fuel fiter head and bol(1EA) in fuel fitter bracket. FUEL SYSTEM INSPECTION — eoezei2a, 4. General inspection a. Hose and pipe for bent, damage, clogging or corrosion. b. Fuel fiter for cologging and damage. 2. The fuel fiter inspection must be complete in case of below. a. Draining fuel in fuel tank and then refilling fuel b. Replacing the fuel fiter. Removing the main fuel hose(pipe).FUEL DELIVERY SYSTEM-DIESEL FL-434 FUEL TANK COMPONENTS = eze7cr20 $< 1.96 ~ 2.94 (1.44 ~ 2.17) Fuel pump reste DS GS) ve gender Fusl pressure ose Tr 1. ~ 2.94 (1.44 ~ 2.17) e e Fue! fiter Suction fuel sender ‘Sub fuel: sender unit ¢ ee uel fiter Fuel filer hose Fue! tank strap 4a - 54 (28.8 - 40) Tightening torque : N-m (Ibf-ft)FUEL SYSTEM. 35 REMOVAL eacoascs & caurion When liting up or down vehicte, be sure to place blocks between vehicle and liter to prevent fuel tank from being damaged. 1. Remove front muffler and main muffler assemblys, 2. Remove profellershaft assembly. (4WD only) 3, Remove fuel tank under cover. 4, Remove clamps(3EA) for fuel filer hose(A), leveling hose(B) and ventilation(C), 5. Support fuel tank with jack and remove fuel tank str- aps(2EA). 6. Unfasten parking brake cable mounting bolts(2EA) in each right and left sides. 7. Lifing down fuel tank slowly, remove fuel pump wiring connector, and then main fuel hose and return fuel hose connected to fuel fank 8. Disconnect fuel sender wiring connector. 9. Remove fuel tankFUEL DELIVERY SYSTEM-DIESEL INSTALLATION — gosjecce Installation is in reverse order of remaval. DISASSEMBLY scezcact 1, Remove the suction hose between fuel pump module and sub fuel sender unit, 2. Unscrew fuel pump module mounting bolts and sub fuel sender unit mounting bolts. & caution When lifting up fuel pump module and sub fuel sender, be careful not to do damage to the sender. ASSEMBLY | croscoss Assembly is in reverse order of disassembly. FL436L437 FUEL SYSTEM FUEL PUMP 6. Unscrew fuel pump plate mounting bolts(D). DISASSEMBLY — exesacse 4, Turn ignition key off and disconnect battery (-) cable- 2, Remove the second seat. 3. Remove the capet covering service cover (A) for fuel pump and service cover (A). 7. Remove the fuel pump module. 4, Disconnect the fuel pump wiring connector(B). 5, Spread out service towel around fuel hoses(C) and disconnect fuel hoses(C).FUEL DELIVERY SYSTEM-DIESEL SUB FUEL SENDER Fl 38 6. Unscrew sub fuel sender plate mounting bolts(D). DISASSEMBLY ezceecoa 4, Tur ignition key off and disconnect battery (-) cable-. 3. Remove the capet covering service cover(A) for sub fuel sender unit and service cover. 7. Remove the suction fuel sender unit. 4. Disconnect the sub fuel sender wiring connector(B) 5. Spread out service towel around fuel hoses(C) and disconnect fuel hoses(C).

FL - Fuel System (D4EA)

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