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SECTION EC
CONTENTS
PRECAUTIONS .................................................. EC-3 BATTERY AND GROUND SYSTEM ................ EC-56
General Precautions for Service Operations ... EC-3 ECM Input/Output Signal Specifications ...... EC-56
On Board Diagnostic (OBD) Circuit Diagram ............................................. EC-56
System of Engine ........................................... EC-4 CRANKSHAFT POSITION SENSOR 1°
Precaution ...................................................... EC-4 (POS) ................................................................ EC-57
ENGINE CONTROL SYSTEM ............................ EC-8 ECM Input/Output Signal Specifications ...... EC-57
Description ..................................................... EC-8 Circuit Diagram ............................................. EC-57
System Diagram ............................................. EC-9 Component Parts Inspection ........................ EC-57
Sensors and Actuators Control Items ........... EC-10 CRANKSHAFT POSITION SENSOR 120°
TROUBLE DIAGNOSIS .................................... EC-11 (REF) ................................................................. EC-58
How to Proceed with Trouble Diagnosis ...... EC-11 ECM Input/Output Signal Specifications ...... EC-58
Diagnosis Chart by Symptom ....................... EC-16 Circuit Diagram ............................................. EC-58
Component Parts Location ........................... EC-25 Component Parts Inspection ........................ EC-58
Circuit Diagram ............................................. EC-29 MASS AIR FLOW SENSOR SYSTEM ............. EC-59
ECM Terminal Layout ................................... EC-30 SST Data Monitor Display ............................ EC-59
ECM Input/Output Signal Specifications ...... EC-33 ECM Input/Output Signal Specifications ...... EC-59
Description ................................................... EC-39 Circuit Diagram ............................................. EC-59
Fail-safe Function ......................................... EC-39 Component Parts Inspection ........................ EC-59
Table of DTC ................................................ EC-40 ENGINE COOLANT TEMPERATURE
Service Tool ................................................. EC-48 SENSOR SYSTEM ........................................... EC-60
Self-Diagnosis Function (Without Service SST Data Monitor Display ............................ EC-60
Tool) .............................................................. EC-49 ECM Input/Output Signal Specifications ...... EC-60
ECM Input/Output Monitor............................. EC-50 Circuit Diagram ............................................. EC-60
ECM Active Test ........................................... EC-51 Component Parts Inspection ........................ EC-60
BASIC INSPECTION ........................................ EC-52 HEATED OXYGEN SENSOR SYSTEM ........... EC-61
Inspection of Idle Speed and SST Data Monitor Display ............................ EC-61
Ignition Timing .............................................. EC-52 ECM Input/Output Signal Specifications ...... EC-61
Throttle Valve Closed Position Learning and Circuit Diagram ............................................. EC-61
Idle Air Volume Learning .............................. EC-53 THROTTLE POSITION SENSOR SYSTEM ..... EC-62
Accelerator Pedal Released Position SST Data Monitor Display ............................ EC-62
Learning ....................................................... EC-54 ECM Input/Output Signal Specifications ...... EC-62
Fuel Pressure Inspection .............................. EC-54 Circuit Diagram ............................................. EC-62
Accelerator Pedal Released Position Component Parts Inspection ........................ EC-62
Learning ....................................................... EC-55
ACCELERATOR PEDAL POSITION LPG INJECTOR SYSTEM ................................ EC-74
SENSOR SYSTEM ........................................... EC-63 ECM Input/Output Signal Specifications ...... EC-74
SST Data Monitor Display ............................ EC-63 Inspection ..................................................... EC-74
ECM Input/Output Signal Specifications ...... EC-63 LPG ASSISTANCE INJECTOR SYSTEM ........ EC-75
Circuit Diagram ............................................ EC-63 ECM Input/Output Signal Specifications ...... EC-75
Component Parts Inspection ........................ EC-64 Circuit Diagram ............................................ EC-75
NEUTRAL SWITCH SYSTEM .......................... EC-65 Component Parts Inspection ........................ EC-75
SST Data Monitor Display ............................ EC-65 LPG FUEL PRESSURE SENSOR SYSTEM .... EC-76
ECM Input/Output Signal Specifications ...... EC-65 ECM Input/Output Signal Specifications ...... EC-76
Circuit Diagram ............................................ EC-65 Circuit Diagram ............................................ EC-76
INTAKE AIR TEMPERATURE SENSOR LPG INTERCEPTION VALVE SYSTEM .......... EC-77
SYSTEM ............................................................ EC-66 SST Data Monitor Display ............................ EC-77
SST Data Monitor Display ............................ EC-66 ECM Input/Output Signal Specifications ...... EC-77
ECM Input/Output Signal Specifications ...... EC-66 Circuit Diagram ............................................ EC-77
Circuit Diagram ............................................ EC-66 FUEL CONTROL CHANGING SWITCH
Component Parts Inspection ........................ EC-66 SYSTEM ........................................................... EC-78
STOP LAMP SWITCH SYSTEM ...................... EC-67 SST Data Monitor Display ............................ EC-78
SST Data Monitor Display ............................ EC-67 ECM Input/Output Signal Specifications ...... EC-78
ECM Input/Output Signal Specifications ...... EC-67 Circuit Diagram ............................................ EC-78
Circuit Diagram ............................................ EC-67 PCV GAS RESTORATION DEVICE ................ EC-79
Component Parts Inspection ........................ EC-67 System Diagram .......................................... EC-79
ELECTRICAL LOAD SWITCH SYSTEM ......... EC-68 Removal and Installation of PCV Valve ....... EC-79
SST Data Monitor Display ............................ EC-68 PCV Valve Inspection .................................. EC-79
ECM Input/Output Signal Specifications ...... EC-68 FUEL CUT FUNCTION ..................................... EC-80
Circuit Diagram ............................................ EC-68 Inspection Procedure ................................... EC-80
IGNITION SYSTEM ........................................... EC-69 ECM COMPONENTS ....................................... EC-81
SST Data Monitor Display ............................ EC-69 ECM ............................................................. EC-81
ECM Input/Output Signal Specifications ...... EC-69 Crankshaft Position Sensor
Circuit Diagram ............................................ EC-69 (Integrated Into the Distributor) .................... EC-81
Component Parts Inspection ........................ EC-69 Mass Air Flow Sensor .................................. EC-81
FUEL INJECTOR SYSTEM (GASOLINE) ........ EC-70 Engine Coolant Temperature Sensor ........... EC-81
SST Data Monitor Display ............................ EC-70 Heated Oxygen Sensor (With Heated
ECM Input/Output Signal Specifications ...... EC-70 Oxygen Sensor Heater) ............................... EC-82
Circuit Diagram ............................................ EC-70 Throttle Position Sensor (Electric Throttle
Component Parts Inspection ........................ EC-70 Control Actuator Assembly) ......................... EC-82
FUEL PUMP SYSTEM ...................................... EC-71 LPG Injector Holder ..................................... EC-83
SST Data Monitor Display ............................ EC-71 SERVICE DATA AND SPECIFICATIONS
ECM Input/Output Signal Specifications ...... EC-71 (SDS) ................................................................ EC-84
Circuit Diagram ............................................ EC-71 Standard, Repair Limit ................................. EC-84
Component Parts Inspection ........................ EC-71
THROTTLE CONTROL MOTOR SYSTEM ...... EC-72
ECM Input/Output Signal Specifications ...... EC-72
Circuit Diagram ............................................ EC-72
Component Parts Inspection ........................ EC-72
HEATED OXYGEN SENSOR HEATER
SYSTEM ............................................................ EC-73
SST Data Monitor Display ............................ EC-73
ECM Input/Output Signal Specifications ...... EC-73
Circuit Diagram ............................................ EC-73
Component Parts Inspection ........................ EC-73
PRECAUTIONS
PRECAUTIONS
General Precautions for Service Operations
• Even when ignition switch is OFF, battery voltage may damage
the control unit. Turn ignition switch OFF and disconnect battery
ground cable before removing and installing control unit
harness.
ECM0215
• Be careful not to damage connector terminals when connecting
and disconnecting. Check the terminals for bend or breakage
before connecting.
• Check the input/output signal of terminal before replacing
control unit. Confirm that it operates normally.
Refer to EC section, “ECM Input/Output Signal Specifications”.
ECM0216
• Ensure the appropriate distance between test probes when
using a circuit tester. A longer distance is recommended,
because if the distance is too short, it may cause contact of test
probes, resulting in a short circuit. A short circuit allows battery
voltage to be applied directly to the control unit, resulting in
damage to its internal power transistors.
EGM0063
EC-3
PRECAUTIONS
On Board Diagnostic (OBD) System of
Engine
The ECM has an on board diagnostic system. It will light up the
malfunction indicator lamp (MIL) to warn the driver of a malfunction
causing emission deterioration.
CAUTION:
• Be sure to turn the ignition switch OFF and disconnect the
negative battery cable before any repair or inspection
work. The open/short circuit of related switches, sensors,
solenoid valves, etc. will cause the MIL to light up.
• Be sure to connect and lock the connectors securely after
work. A loose (unlocked) connector will cause the MIL to
light up due to the open circuit. (Be sure the connector is
free from water, grease, dirt, bent terminals, etc.)
• Certain systems and components, especially those related
to OBD, may use a new style slide-locking type harness
connector.
• Be sure to route and secure the harnesses properly after
work. The interference of the harness with a bracket, etc.
may cause the MIL to light up due to the short circuit.
• Be sure to connect rubber tubes properly after work. A
misconnected or disconnected rubber tube may cause the
MIL to light up due to the malfunction of fuel injection
system, etc.
• Be sure to erase the unnecessary malfunction information
(repairs completed) from the ECM before returning the
vehicle to the customer.
Precaution
• Always use a 12 volt battery as power source.
• Do not attempt to disconnect battery cables while engine is
running.
• Before connecting or disconnecting the ECM harness
connector, turn ignition switch OFF and disconnect battery
ground cable. Failure to do so may damage the ECM
because battery voltage is applied to ECM even if ignition
switch is turned OFF.
• Before removing parts, turn ignition switch OFF and then
disconnect battery ground cable.
SEF0289H
• Do not disassemble ECM.
• If a battery cable is disconnected, the memory will return to
the ECM value. The ECM will now start to self-control at its
initial value. Engine operation can vary slightly when the
terminal is disconnected. However, this is not an indication
of a malfunction. Do not replace parts because of a slight
variation.
• If the battery is disconnected, the following emission-
related diagnostic information will be lost within 24 hours.
– Diagnostic trouble codes
– 1st trip diagnostic trouble codes
EC-4
PRECAUTIONS
Precaution (Cont’d)
• When connecting ECM harness connector, fasten it
securely with levers as far as they will go as shown in the
figure.
• When connecting or disconnecting pin connectors into or
from ECM, take care not to damage pin terminals (bend or
break).
Make sure that there are not any bends or breaks on ECM
pin terminal, when connecting pin connectors.
• Securely connect ECM harness connectors. A poor
connection can cause an extremely high (surge) voltage to
develop in coil and condenser, thus resulting in damage to
ICs.
• Keep engine control system harness at least 10 cm (4 in)
away from adjacent harness, to prevent engine control
system malfunctions due to receiving external noise,
degraded operation of ICs, etc.
• Keep engine control system parts and harness dry.
• Before replacing ECM, perform ECM Terminals and
Reference Value inspection and make sure ECM functions
properly.
• Handle mass air flow sensor carefully to avoid damage.
• Do not disassemble mass air flow sensor.
• Do not clean mass air flow sensor with any type of
detergent.
• Do not disassemble electric throttle control actuator.
• Even a slight leak in the air intake system can cause
serious incidents.
MEF040D • Do not shock or jar the crankshaft position sensor (POS),
(REF).
• After performing each TROUBLE DIAGNOSIS, perform DTC
Confirmation Procedure or Overall Function Check.
The DTC should not be displayed in the DTC Confirmation
Procedure if the repair is completed. The Overall Function
Check should be a good result if the repair is completed.
EC-5
PRECAUTIONS
Precaution (Cont’d)
• When measuring ECM signals with a circuit tester, never
allow the two tester probes to contact. Accidental contact
of probes will cause a short circuit and damage the ECM
power transistor.
• Do not use ECM ground terminals when measuring input/
output voltage. Doing so may result in damage to the
ECM's transistor. Use a ground other than ECM terminals,
such as the ground.
SEF348N
• Do not operate fuel pump when there is no fuel in lines.
• Tighten fuel hose clamps to the specified torque.
EC-6
PRECAUTIONS
Precaution (Cont’d)
• Do not depress accelerator pedal when starting.
• Immediately after starting, do not rev up engine
unnecessarily.
• Do not rev up engine just prior to shutdown.
SEF709Y
EC-7
ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM
Description
• Adopts Electronic Concentrated Engine Control System (ECM).
Fuel injection control, ignition timing control, idle speed control,
and electronically controlled governor control etc. are all
performed by a single control unit.
• Adopts electric throttle control actuator system to control
electronically controlled governor.
Item Description
Electric throttle control • Adopts electronic throttle control actuator with integrated throttle control motor to adjust throttle valve opening
optimally according to driving conditions or to improve safety and operability by electronically controlled governor.
Fuel injection control • With SOFIS control, amounts of injected fuel are optimized to improve exhaust performance and response.
• Using feedback control through learning of air-fuel ratio compensation, the system corrects the ratio during
transitional conditions, such as sudden sharp changes in the ratio, in order to improve drive ability.
Ignition timing control • Controls ignition timing depending on driving conditions on basis of the ignition timing map stored in the ECM.
• Performs knock control, in which ignition timing is retarded or advanced according to the presence of knocking, so
that optimum ignition timing is selected according to operating conditions and fuel in use.
Idle speed control • Adopts electronic throttle control actuator that continuously regulates intake air amount required for idling.
Governor speed control • Performs maximum regulation of engine speed for oil pressure pump protection by engine speed signal.
Maximum speed • Performs maximum speed regulation by vehicle speed sensor signal. Also, performs variable control of maximum
regulation control speed by changeover switch as an option.
Idling area torque up • Performs torque up control in idling area by engine speed signal in order to also enable cargo work at idling.
control
Overheat prevention • Reduces engine heat generation by reducing maximum engine speed and regulating maximum throttle opening
control when engine coolant temperature reaches approximately 110°C (230°F).
• Prevents resulting in engine breakage by overheat by performing fuel cut at 1,000 rpm or more when engine
coolant temperature reaches approximately 135°C (275°F).
Start acceleration speed • Changes throttle opening characteristic of throttle position by Start acceleration speed selector switch, and then
selector mode control minute operation of engine speed is enabled.
Fuel pump control • Turns fuel pump relay ON/OFF depending on engine speed signal.
(gasoline)
LPG interception valve • Turns interception valve relay ON/OFF depending on engine speed signal and fuel pressure sensor signal.
control
Fail-safe function • Ensures vehicle's safe operation and enables vehicle to be driven in an emergency when any of the major system
components (mass air flow sensor, engine coolant temperature sensor, etc.) have malfunctioned.
Diagnostic system • Adopts self-diagnosis system for easier trouble diagnosis.
EC-8
ENGINE CONTROL SYSTEM
System Diagram
EC-9
ENGINE CONTROL SYSTEM
Sensors and Actuators Control Items
Main sensors and actuators related to the ECM are listed below.
Gasoline std std std std std std std std Combine std std
Fuel
LPG std std std – std std std std Combine std std
Fail-safe
Fuel pump control
Maximum engine speed control
Ignition timing control
Maximum vehicle speed control
Self-diagnosis
Idle speed control
Fuel changing (Gasoline and LPG)
Control Item Fuel injection control
Fuel cut-off control
Fuel injection control
A/F feedback control
: Significant impact to control
: Impact to control
Crankshaft position sensor (POS, REF)
Mass air flow sensor
Intake air temperature sensor
Engine coolant temperature sensor
Heated oxygen sensor
Vehicle speed sensor
Throttle position sensor
Sensors
Accelerator pedal position sensor
Ignition switch IGN
PNP switch
Stop lamp switch
Headlamp (electrical load) switch
Battery voltage
LPG fuel pressure sensor
Fuel changing switch
Gasoline injector
Ignition system Power transistor
Ignition coil
Throttle control motor relay
Throttle control motor
Gasoline fuel pump relay
Actuators
Gasoline fuel pump
Ignition relay
EGI relay
LPG injector
LPG assistance injector
LPG interception valve relay
LPG interception valve
EC-10
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS
How to Proceed with Trouble Diagnosis
1. The most important point in performing trouble diagnosis of
malfunctions is to thoroughly understand the vehicle systems
(both control and mechanical).
An ECM-based engine controls actuators such as injectors and
the ignition coil according to information from sensors. Then
through actuator operation, the engine (mechanical system)
runs. Sensors transmit information on the running condition,
which changes constantly, to ECM. It is important to understand
these cycles.
ECM0233
2. It is also important to clarify customer concerns before starting
the inspection. First of all, reproduce the symptom, and
understand it fully. Ask the customer about his/her complaints
carefully. In some cases, it will be necessary to check the
symptoms by driving the vehicle with the customer.
CAUTION:
Customers are not professionals. Do not assume “maybe the
customer means ...” or “maybe the customer mentioned this
symptom”.
ECM0234
3. It is essential to confirm symptoms right from the beginning in
order to ensure all malfunctions are completely repaired.
For an intermittent malfunction, it is important to reproduce the
symptom based on an interview with the customer and past
examples. Do not perform an inspection on an ad hoc basis.
Most intermittent malfunctions are caused by poor contacts. In
this case, it will be effective to shake the suspected harness or
connector by hand. When repairs are performed without any
symptom check, no one can judge if the malfunction has
actually been eliminated.
ECM0235
4. The next important thing is to find which system among the
following is causing the malfunction: ECM control signal
system, or a mechanical system (such as the engine main body
and auxiliary component). It is important to inspect the system
using SST or by checking the ECM input/output signals.
5. Use the reference value of input/output data (guideline) in this
manual in order to judge the ECM input/output signals. Measure
the data of another vehicle of the same model under the same
conditions when it is difficult to judge, and compare the data. It
is advisable to collect sufficient data of a normally operating
vehicle.
ECM0236
EC-11
TROUBLE DIAGNOSIS
How to Proceed with Trouble Diagnosis (Cont’d)
TROUBLE DIAGNOSIS FLOW CHART
There are many different malfunction symptoms. So there is no
perfect trouble diagnosis technique applicable to all malfunctions.
Experience is also important to achieving an accurate trouble
diagnosis.
Nonetheless, an accurate trouble diagnosis can be performed by
applying similar procedures, regardless of the malfunction symptom.
Perform trouble diagnosis following the flow chart shown below.
ECM0237
EC-12
TROUBLE DIAGNOSIS
How to Proceed with Trouble Diagnosis (Cont’d)
DIAGNOSTIC WORK SHEET
DESCRIPTION
• In order to clarify the malfunction symptom, it is important to ask
the customer and collect information about their concerns.
• Ask the customer about what symptoms are present under what
conditions. Use the information to clarify the symptom.
• Use the diagnostic work sheet to be certain not to miss any vital
information.
ECM0238
EC-13
TROUBLE DIAGNOSIS
How to Proceed with Trouble Diagnosis (Cont’d)
TROUBLE DIAGNOSIS INFORMATION MEMO
EC-14
TROUBLE DIAGNOSIS
How to Proceed with Trouble Diagnosis (Cont’d)
CAUSE INVESTIGATION INFORMATION DECISION
FLOWCHART
ECM0393
EC-15
TROUBLE DIAGNOSIS
Diagnosis Chart by Symptom
TB45 ENGINE RELATIONSHIP BETWEEN MALFUNCTIONING
SYMPTOMS AND THE SENSOR CIRCUIT
The table below shows the possible symptoms caused by the
malfunction of each sensor circuit.
Check that symptoms are detected with self-diagnosis.
Check that symptoms are in fail-safe condition.
Im- Im-
possi- possi-
Symptoms Poor idle Poor driving control Engine stall Other
ble to ble to
start start
Inconsistent idle when engine is cold.
Inconsistent idle when warming up
After-burn
High idle rpm
Low idle rpm
Poor acceleration
During surge and acceleration
During surge and constant speed drive
No initial combustion
Initial combustion
Fast idle is not effective
Poor power output
Engine rpm does not increase smoothly.
Knocking
Backfire
At Idle
Driving
During deceleration
Overheat
When engine is cold
During a heavy load
Poor fuel
When engine is warming up
Description/notable characteristics of
the symptom
Actuator malfunction
: Highly possible
: Possible
Crankshaft position sensor OPEN • An open circuit in either POS or REF
(POS, REF) signal makes it impossible for the
vehicle to start.
• Control signals for fuel system and
ignition system are not output.
Momentarily • The symptom depends on the
open duration of momentarily open circuit
and the operating conditions. Slight
shocks and surges may be sensed
during driving, while engine stall may
be caused during idle.
Mass air flow Signal OPEN • It will be fail-safe condition, and
sensor vehicle runs at an engine speed of
800 rpm or less.
High output • The air-fuel ratio becomes rich. Black
smoke may accompany. Poor
connection of grounding may be a
possible cause.
Low output • The air-fuel ratio becomes lean.
Contaminated hot wire or suction of
air may be suspected.
Ground OPEN • It will be over-rich.
Power OPEN • It will be fail-safe condition, and
supply vehicle runs at an engine speed of
800 rpm or less.
Intake air temperature sensor OPEN/
SHORT
Engine coolant temperature OPEN/ • It will be fail-safe condition, and then
sensor SHORT MIL turns ON and perform STEP #1
overheat control. This malfunction
tends to occur when engine is cold or
when the engine coolant temperature
is high.
Resistance • The engine coolant temperature is
is large. judged as low. This malfunction
tends to occur after warming up.
Resistance is • The engine coolant temperature is
small. judged as high. This malfunction
tends to occur when engine is cold.
Heated oxygen sensor OPEN/
• It will be base air-fuel ratio.
SHORT
Vehicle speed sensor OPEN/ • Duration of fuel cut becomes shorter
SHORT or fuel may not be cut.
EC-16
TROUBLE DIAGNOSIS
Diagnosis Chart by Symptom (Cont’d)
Check that symptoms are detected with self-diagnosis.
Check that symptoms are in fail-safe condition.
Im- Im-
possi- possi-
Symptoms Poor idle Poor driving control Engine stall Other
ble to ble to
start start
Inconsistent idle when engine is cold.
Fast idle is not effective
Inconsistent idle when warming up
After-burn
Poor fuel
High idle rpm
Low idle rpm
Poor power output
Poor acceleration
No initial combustion
Initial combustion
During surge and acceleration
Knocking
Backfire
At Idle
Driving
Overheat
Engine rpm does not increase smoothly.
During surge and constant speed drive
During deceleration
During a heavy load
When engine is cold
When engine is warming up
Description/notable characteristics of
the symptom
Actuator malfunction
: Highly possible
: Possible
Throttle position sensor OPEN/ • Idle will be base rpm. No addition for
SHORT acceleration.
Output • Possible interruption by unnecessary
fluctuation fuel injection. Poor ground or control
unit connection may be the cause.
Poor • Idling is judged as OFF during idle.
adjustment Turning ignition switch repeatedly to
ON and OFF will set the system to
normal.
Accelerator pedal position OPEN/
sensor SHORT
Output
fluctuation
Ignition switch (IGN) OPEN • Impossible to start without outputs for
fuel and ignition systems.
PNP switch OPEN • PNP switch is judged as OFF, and
the target cold engine speed in N/P
position is lowered.
SHORT • PNP switch is judged as ON, and fast
idle is effective for cold engine in
positions other than N/P position,
making the creep larger.
Stop lamp switch OPEN/
SHORT
Headlamp (electrical load) OPEN/
switch SHORT
Power supply for ECM OPEN • Impossible to start without outputs for
fuel and ignition systems.
Sensor ground (coolant OPEN/
• The same as the open circuit in the
temperature sensor, throttle SHORT
applicable sensor.
position sensor)
Control unit and connector Poor • A slightly raised connector often
connection, results in poor connection. Entry of
water entry water causes engine stall and
afterwards it is momentarily
impossible to restart engine. In some
cases, restarting is possible after a
short wait.
LPG fuel pressure sensor SHORT • Impossible to start with LPG
interception valve off when the
sensor is shorted.
Fuel changing switch OPEN • Fuel changing cannot be done.
LPG fuel pressure sensor OPEN • LPG interception valve is OFF.
EC-17
TROUBLE DIAGNOSIS
Diagnosis Chart by Symptom (Cont’d)
TB45 ENGINE RELATIONSHIPS BETWEEN MALFUNCTIONING
SYMPTOMS AND ACTUATOR CIRCUITS
The table below shows the possible symptoms caused by the
malfunction of each actuator circuit.
Check that symptoms are detected with self-diagnosis.
Check that symptoms are in fail-safe condition.
Im- Im-
possi- possi-
Symptoms Poor idle Poor driving control Engine stall Other
ble to ble to
start start
Inconsistent idle when engine is cold.
Inconsistent idle when warming up
After-burn
High idle rpm
Low idle rpm
Poor acceleration
During surge and acceleration
During surge and constant speed drive
No initial combustion
Initial combustion
Fast idle is not effective
Poor power output
Engine rpm does not increase smoothly.
Knocking
Backfire
At Idle
Driving
During deceleration
Overheat
When engine is cold
During a heavy load
Poor fuel
When engine is warming up
Description/notable characteristics of
the symptom
Actuator malfunction
: Highly possible
: Possible
Gasoline injector Power OPEN • No fuel injection to cylinder with open
supply circuit, resulting in LEAN output of
circuit Momentarily
heated oxygen sensors.
open
• Starting engine is impossible when
Coil OPEN the circuits for all the cylinders are
open.
Momentarily
open
Drive OPEN
circuit
(C/U Momentarily
side) open
SHORT • Continuous fuel injection to cylinder
with short circuit, resulting in OVER-
RICH and misfiring.
• Starting engine is impossible when
the circuits for all the cylinders are
open.
Nozzle Foreign • The cylinder with foreign material will
hole material keep injecting.
intrusion
Clogging • The symptom depends on clogging
status. The correction factor of air-
fuel ratio becomes larger.
Ground OPEN
circuit
(C/U) Momentarily
open
Ignition signal circuit OPEN • Open
• Immediately engine stalls during
Momentarily
engine running, and then does not
open
restart.
Ignition coil Power OPEN • Injects fuel toward spark plug during
supply cranking.
circuit Momentarily • Momentarily open
open • Slight shocks and surges may be
sensed depending on the duration of
Coil OPEN momentarily open circuit and the
Momentarily operating conditions. Engine stall
may occur if duration of momentarily
open
open circuit is too long.
Ground OPEN
circuit
Momentarily
open
EGI relay circuit OPEN
Throttle control motor circuit OPEN/
SHORT
Throttle control motor relay OPEN • The same malfunction may occur as
circuit power supply open of throttle control
motor and throttle position sensor.
Heated oxygen sensor heater OPEN
circuit
EC-18
TROUBLE DIAGNOSIS
Diagnosis Chart by Symptom (Cont’d)
Check that symptoms are detected with self-diagnosis.
Check that symptoms are in fail-safe condition.
Im- Im-
possi- possi-
Symptoms Poor idle Poor driving control Engine stall Other
ble to ble to
start start
Inconsistent idle when engine is cold.
Fast idle is not effective
Inconsistent idle when warming up
After-burn
Poor fuel
High idle rpm
Low idle rpm
Poor power output
Poor acceleration
No initial combustion
Initial combustion
During surge and acceleration
Knocking
Backfire
At Idle
Driving
Overheat
Engine rpm does not increase smoothly.
During surge and constant speed drive
During deceleration
During a heavy load
When engine is cold
When engine is warming up
Description/notable characteristics of
the symptom
Actuator malfunction
: Highly possible
: Possible
Fuel pump relay circuit OPEN • Impossible to start
Fuel pump circuit
Ignition relay circuit Momentarily • Surge may occur.
open
Fuel pump pressure regulator Stuck
LPG injector HI side OPEN
circuit
SHORT
• LPG interception valve off when self-
Coil OPEN
diagnosis is NG.
LO side OPEN
circuit
SHORT
LPG assistance injector OPEN
Control unit
side short
LPG interception valve relay OPEN
Control unit
side short
LPG interception valve OPEN
MIL OPEN
Improper TAS learning
EC-19
TROUBLE DIAGNOSIS
Diagnosis Chart by Symptom (Cont’d)
TB45 ENGINE RELATIONSHIP BETWEEN MALFUNCTIONING
SYMPTOM AND THE ENGINE MAIN BODY/AUXILIARY
COMPONENT
When the three elements of combustion, compression pressure, fuel
mixture, and sparking are all normal, no malfunctions are caused in
the gasoline-type engine.
The ECM controls the fuel mixture and sparking (ignition timing). But
with malfunctions on the part of engine main body, malfunctioning
symptoms result.
The table below shows the possible symptoms caused by the
malfunction of engine main body system. It will be helpful in
malfunction trouble diagnosis. (The table lists general symptoms
and some may not be applicable.)
Im- Im-
possi- possi-
Symptoms Poor idle Poor driving control Engine stall Other
ble to ble to
start start
Inconsistent idle when engine is cold.
During surge and constant speed drive
Fast idle is not effective
Inconsistent idle when warming up
No initial combustion
Poor acceleration
Knocking
Backfire
After-burn
Initial combustion
Poor power output
Engine rpm does not increase smoothly.
At Idle
Driving
During deceleration
Overheat
When engine is cold
When engine is warming up
High idle rpm
Low idle rpm
During surge and acceleration
During a heavy load
Poor fuel
Description/notable characteristics of
the symptom
Main unit symptom
: Highly possible
: Possible
: Not very possible
Fuel Air sucked from oil level gauge • Air-fuel ratio becomes LEAN.
mixture • High air-fuel correction factor.
Air sucked from oil filler cap • Low suction power (vacuum pressure) of
intake manifold.
Use a pressure gauge to check the suction.
Air sucked from PCV hose
Generally applicable to air suction in air
(downstream of PCV) intake system
Air sucked from intake manifold and
gasket
PCV kept open • Noise (high hissing tone)
Clogged fuel strainer • Symptom depends on clogging status.
This tends to happen during high-speed or
Clogged air cleaner element high load operation.
Malfunctioning gasoline pressure • Symptom varies depending on combustion
regulator pressure.
Poor quality gasoline • Symptom varies depending on oil quality.
Improper LPG fuel (cold area and • Starting ability at cold area is changed
propane ratio) depending on propane ratio.
• Use LPG with proper propane ratio.
Malfunctioning LPG vaporizer • If the pressure is low, it is caused by poor
pressure adjusting valve output during high-speed or high load
operation.
• If the pressure is excessively high, relief
valve operates and engine stalls at rich.
Clogged LPG vaporizer hot water • Symptom depends on fuel temperature.
circuit This tends to happen during engine stall
and is impossible to restart during engine
warming up.
Clogged LPG interception valve filter • Symptom depends on clogging status.
This tends to happen during high-speed or
high load operation.
Valve deposit • The malfunction tends to happen during
high-speed or high load operation (low
vacuum).
EC-20
TROUBLE DIAGNOSIS
Diagnosis Chart by Symptom (Cont’d)
Im- Im-
possi- possi-
Symptoms Poor idle Poor driving control Engine stall Other
ble to ble to
start start
Inconsistent idle when engine is cold.
Fast idle is not effective
Inconsistent idle when warming up
After-burn
Poor fuel
High idle rpm
Low idle rpm
Poor power output
Poor acceleration
No initial combustion
Initial combustion
During surge and acceleration
Knocking
Backfire
At Idle
Driving
Overheat
Engine rpm does not increase smoothly.
During surge and constant speed drive
During deceleration
During a heavy load
When engine is cold
When engine is warming up
Description/notable characteristics of
the symptom
Main unit symptom
: Highly possible
: Possible
: Not very possible
Spark- Improper high-tension cord • Check the igniting sequence.
ing connection
Improper ignition timing adjustment –
Malfunctioning spark plug • Check that the gap is proper. Check plug
for soil (smoking).
Leakage from high-tension cord • Symptom varies depending on the level of
leakage.
Leakage from distributor cap. –
Loose or open of primary wire –
connection
Com- Improper bulb contact • Symptom varies depending on contact
pres- condition and the number of cylinders.
sion
pres- Worn piston ring • Symptom varies depending on degree of
sure
wear and the number of cylinders.
Other Clogged three-way catalytic • In some cases, after engine stall,
converter /exhaust system restarting is possible.
Low idle base speed • Engine stall may occur by power steering
load and cargo load during deceleration or
at idling.
Dragging of brakes • Tires/wheels are hot.
Belt tension too high (excessive –
tension)
High A/T load • Insufficient ATF amount, improper oil
specification (This symptom may
especially occur in the cold.)
High HYD PUMP load (PS, Cargo) • Malfunctioning oil pressure relief valve,
improper oil specification (This symptom
may especially occur in the cold.)
Foreign substance in fuel tank (such • With low fuel, this may easily occur.
as dust)
Damaged fan, malfunctioning water • Noise
pump
Clogged/restricted radiator/ –
condenser
Also check the following items other than the above:
• Check harness tension. • Check each connector connection. • Check ground wire for looseness. • Check battery connection for looseness or corrosion.
• Check water and oil condition. • Check fan belts for looseness.
EC-21
TROUBLE DIAGNOSIS
Diagnosis Chart by Symptom (Cont’d)
TB45 ENGINE RELATIONSHIP BETWEEN MALFUNCTIONING
SYMPTOM AND THE ENGINE MAIN BODY/AUXILIARY
COMPONENT
When the three elements of combustion, compression pressure, fuel
mixture, and sparking are all normal, no malfunctions are caused in
the engine.
The ECM controls the fuel mixture and sparking (ignition timing). But
with malfunctions on the part of engine main body, malfunctioning
symptoms result.
The table below shows the possible symptoms caused by the
malfunction of engine main body system. It will be helpful in
malfunction trouble diagnosis. The table lists general symptoms and
some may not be applicable.
Im- Im-
possi- possi-
Symptoms Poor idle Poor driving control Engine stall Other
ble to ble to
start start
Inconsistent idle when engine is cold.
During surge and constant speed drive
Fast idle is not effective
Inconsistent idle when warming up
No initial combustion
Poor acceleration
Knocking
High oil consume
Oil pressure warning lamp ON
Initial combustion
Poor power output
Engine rpm does not increase smoothly.
Backfire
After-burn
At Idle
Driving
During deceleration
Overheat
When engine is cold
When engine is warming up
High idle rpm
Low idle rpm
Overcool
Mechanical noise
During surge and acceleration
During a heavy load
Poor fuel
Description/notable characteristics of
the symptom
Main unit symptom
: Highly possible
: Possible
: Not very possible
Fuel Air sucked from oil level gauge • Air-fuel ratio becomes LEAN.
mixture • High air-fuel correction factor.
Air sucked from oil filler cap • Low suction power (vacuum pressure) of
intake manifold.
Air sucked from PCV hose
Check the suction using a pressure gauge.
(downstream of PCV)
Generally applicable to air suction in air
Air sucked from intake manifold intake system
and gasket
PCV kept open • Noise (high hissing tone)
Clogged fuel strainer • Symptom depends on clogging status. This
tends to happen during high-speed or high
Clogged air cleaner element load operation.
Malfunctioning gasoline pressure • Symptom varies depending on oil quality.
regulator
Poor quality gasoline • Symptom varies depending on oil quality.
Improper LPG fuel (cold area and • Starting ability in cold area is changed
propane ratio) depending on propane ratio.
• Use LPG with proper propane ratio.
Malfunctioning LPG vaporizer • If the pressure is low, it is caused by poor
pressure adjusting valve output during high-speed or high load
operation.
• If the pressure is excessively high, relief
valve operates and engine stalls at rich.
Clogged LPG vaporizer hot water • Symptom depends on fuel temperature.
circuit This tends to happen during engine stall
and is impossible to restart during engine
warming up.
Clogged LPG interception valve • Symptom depends on clogging status. This
filter tends to happen during high-speed or high
load operation.
Valve deposit • The malfunction tends to happen during
high-speed or high load operation (low
vacuum).
Spark- Improper high-tension cord • Check the igniting sequence.
ing connection
Improper ignition timing
–
adjustment
Malfunctioning spark plug • Check that the gap is proper. Check plug
for soil (smoking).
EC-22
TROUBLE DIAGNOSIS
Diagnosis Chart by Symptom (Cont’d)
Im- Im-
possi- possi-
Symptoms Poor idle Poor driving control Engine stall Other
ble to ble to
start start
Inconsistent idle when engine is cold.
Fast idle is not effective
Overcool
Oil pressure warning lamp ON
Inconsistent idle when warming up
After-burn
Poor fuel
High idle rpm
Low idle rpm
Poor power output
Poor acceleration
No initial combustion
Initial combustion
During surge and acceleration
Knocking
Backfire
At Idle
Driving
Overheat
Mechanical noise
Engine rpm does not increase smoothly.
During surge and constant speed drive
During deceleration
During a heavy load
High oil consume
When engine is cold
When engine is warming up
Description/notable characteristics of
the symptom
Main unit symptom
: Highly possible
: Possible
: Not very possible
Spark- Leakage from high-tension cord • Symptom varies depending on the level of
ing leakage.
Leakage from distributor cap. –
Loose or open of primary wire
–
connection
Com- Improper bulb contact • The symptom occurs depending on
pres- malfunctioning grade and the number of
sion Worn, stuck, broken piston ring malfunctioning cylinders.
pres-
sure Blow out from head gasket • The symptom occurs depending on
malfunctioning grade and the number of
malfunctioning cylinders. Precautions for
head bolt tightening torque.
Broken or deterioration valve • The symptom occurs depending on
spring malfunctioning grade and the number of
malfunctioning cylinders.
Stuck and upthrust valve stem • The symptom occurs depending on
malfunctioning grade and the number of
malfunctioning cylinders.
Pressure leakage from spark plug • Check gasket and tightening condition.
Others Low idle base speed • Engine stall may occur by power steering
load and cargo load during deceleration or
at idling.
Crack and water leakage on
cylinder block
Excessive crankshaft end
play
Main motor system
Crankshaft and connecting • Oil leakage around front or rear crankshaft.
rod bearing clearance task
Broken crankshaft front/rear • Oil leakage around front or rear crankshaft.
oil seal
Excessive clearance • Whitish exhaust gas. Worn piston or
between piston and cylinder cylinder.
Excessive piston pin
clearance
Main motor system
Improper piston ring • Whitish exhaust gas. Improper location of
installation connecting end and assemble it upside
down.
Excessive piston ring • Whitish exhaust gas. Worn piston ring
clearance glove or piston ring.
Worn torque converter pilot
bushing
Crack and water leakage on
cylinder block
Carbon deposit in
Heads
combustion chamber
Worn valve stem or guide • Whitish exhaust gas
Deterioration of valve oil seal
lip
Excessive or clogged valve • Excessive clearance:
clearance Chattering noise at idling
• Clogged clearance:
Valves
Engine leakage at idling
Rocker cover gasket oil • Loose or broken gasket
leakage
EC-23
TROUBLE DIAGNOSIS
Diagnosis Chart by Symptom (Cont’d)
Im- Im-
possi- possi-
Symptoms Poor idle Poor driving control Engine stall Other
ble to ble to
start start
Inconsistent idle when engine is cold.
Fast idle is not effective
Overcool
Oil pressure warning lamp ON
Inconsistent idle when warming up
After-burn
Poor fuel
High idle rpm
Low idle rpm
Poor power output
Poor acceleration
No initial combustion
Initial combustion
During surge and acceleration
Knocking
Backfire
At Idle
Driving
Overheat
Mechanical noise
Engine rpm does not increase smoothly.
During surge and constant speed drive
During deceleration
During a heavy load
High oil consume
When engine is cold
When engine is warming up
Description/notable characteristics of
the symptom
Main unit symptom
: Highly possible
: Possible
: Not very possible
Others Slack of timing chain • Worn chain tensioner shoe
• Dropped chain guide
Chains
Improper valve timing • Check timing mark related to timing chain
for dislocation.
Front cover oil leakage • Loose or broken gasket
Improper engine oil • Insufficient oil amount, improper grade,
deterioration
• Refill full recommended oil.
Malfunctioning oil pump • Worn or broken rotor
• Operation malfunction or oil leakage of
regulator
Lubrications
Oil leakage around oil pan • Loose or broken oil pan gasket
• Loose oil pan drain plug
Clogged/restricted oil • Dirt or entry of foreign material in engine oil
strainer
Oil leakage of oil filter • Loose or broken gasket
• Apply oil to gasket when replacing oil filter.
Clogged/restricted oil filter • Dirt or entry of foreign material in engine oil
Loose or malfunctioning oil
pressure switch
Foreign material in fuel tank • With low fuel, this may easily occur.
Fuels
(such dust)
Oil leakage from fuel system • Check LPG leakage by applying snoop.
Rotation malfunction of fan • Slip or worn belt caused by belt looseness
or water pump
Malfunctioning water pump • Worn or broken bearing. Coolant leakage
from axle seal.
Malfunctioning thermostat
Malfunctioning engine
coolant temperature gauge
Coolants
Coolant leakage from engine
coolant temperature sensor
Radiator related malfunction • Deterioration of radiator cap pressure, and
water leakage
• Clogged/restricted radiator and condenser,
and water leakage
Contamination and
insufficient amount of coolant
Water leakage from coolant
piping
Engine drive belt tension too high
(excessive tension)
Clogged three-way catalytic • In some cases, after engine stall, restarting
converter /exhaust system is possible.
Dragging of brakes • Tires/wheels are hot.
High A/T load • Insufficient ATF amount, improper oil
specification (This symptom may
especially occur in the cold.)
High HYD PUMP load (PS, Cargo) • Malfunctioning oil pressure relief valve,
improper oil specification (This symptom
may especially occur in the cold.)
Also check the following items other than the above:
• Check harness tension. • Check ground for looseness. • Check each connector connection. • Check battery connection for looseness or corrosion.
• Check engine drive belt for looseness. • Check water and oil condition.
EC-24
TROUBLE DIAGNOSIS
Component Parts Location
Specifications
Main component part Type Location
LPG Gasoline Combine
Gasoline injector High resistance Intake manifold
LPG injector Gas injection Integrated in injector holder
(on intake manifold)
Fuel pump Electric motor/turbine Integrated in fuel tank
Actuators
Fuel pressure regulator Diaphragm
Throttle control motor Electric DC motor (DC motor) Integrated in electronic
throttle control actuator
Ignition coil Molded Integrated in distributor
Power transistor 1-channel
Crankshaft position sensor Photoelectric Integrated in distributor
Mass air flow sensor Hot wire Air horn
Accelerator pedal position sensors Variable resistance Integrated in accelerator
1 and 2 work unit (accelerator pedal
assembly)
Sensors
Throttle position sensors 1 and 2 Integrated in electronic
throttle control actuator
Engine coolant temperature Thermistor Thermostat housing
sensor
Intake air temperature sensor With air flow meter
Heated oxygen sensor Zirconia (with heater) Exhaust manifold
Vehicle speed sensor (Vehicle side)
ECM 121-pin digital control
EGI relay Compact general relay (2M)
EC-25
TROUBLE DIAGNOSIS
Component Parts Location (Cont’d)
ECM COMPONENT PARTS LOCATION: TB45 ENGINE
Specifications Reference
Component Location
LPG Gasoline Combine Actuator Sensor Other
Gasoline injector Intake manifold
LPG injector Integrated in injector holder
(on intake manifold)
Throttle control motor Integrated in electronic throttle
control actuator
Throttle position sensors 1 and 2 Integrated in electronic throttle
control actuator
Ignition coil Integrated in distributor
Crankshaft position sensor
Power transistor
Mass air flow sensor Air horn
Intake air temperature sensor With air flow meter
Engine coolant temperature sensor Thermostat housing
Accelerator pedal position sensors Integrated in accelerator work unit
1 and 2 (accelerator pedal assembly)
Fuel pump Integrated in fuel tank
Fuel pressure regulator
Heated oxygen sensor Exhaust manifold
Vehicle speed sensor (Vehicle side)
ECM (Vehicle side)
EGI & IGN coil relay (Vehicle side)
Stop lamp switch (Vehicle side)
Throttle control motor relay (Vehicle side)
Fuel pump relay (Vehicle side)
Vaporizer (Vehicle side)
LPG interception valve (Vehicle side)
EC-26
TROUBLE DIAGNOSIS
Component Parts Location (Cont’d)
EC-27
TROUBLE DIAGNOSIS
Component Parts Location (Cont’d)
EC-28
TROUBLE DIAGNOSIS
Circuit Diagram
EC-29
TROUBLE DIAGNOSIS
ECM Terminal Layout
ECM0246
The symbol in ( ) next to terminal numbers indicates the data link
connector.
Terminal Description
1 ECM ground
2 ECM ground
3 Throttle control motor relay power supply
4 Throttle control motor (Close)
5 Throttle control motor (Open)
6 –
7 –
8 –
9 –
10 –
11 LPG assistance injector
12 Slow operate mode (Start acceleration speed selector switch)
13 Crankshaft position sensor 1° (POS)
14 Crankshaft position sensor 120° (REF)
15 –
16 –
17 –
18 –
19 –
20 –
21 Injector No. 5
22 Injector No. 3
23 Injector No. 1
24 Heated oxygen sensor heater
25 –
26 –
27 –
28 –
29 –
30 –
31 LPG fuel pressure sensor
32 Fuel changing switch 2 (Gasoline)
33 –
34 Intake air temperature sensor
EC-30
TROUBLE DIAGNOSIS
ECM Terminal Layout (Cont’d)
Terminal Description
35 Heated oxygen sensor
36 –
37 –
38 –
39 –
40 Injector No. 6
41 Injector No. 4
42 Injector No. 2
43 –
44 –
45 –
46 –
47 Sensor power supply (Throttle position sensor)
48 Sensor power supply
49 Fuel changing switch power supply
50 Throttle position sensor 1
51 Mass air flow sensor
52 –
53 –
54 –
55 –
56 –
57 –
58 –
59 –
60 –
61 –
62 Ignition signal (power transmission drive signal)
63 –
64 –
65 –
66 Sensor ground (Throttle position sensor)
67 Sensor ground (Mass air flow sensor)
68 –
69 Throttle position sensor 2
70 Fuel changing switch 1 (LPG)
71 –
72 –
73 Engine coolant temperature sensor
74 –
75 –
76 –
77 –
78 Sensor ground (Heated oxygen sensor)
79 –
80 –
81 –
82 Sensor ground (Accelerator pedal position sensor 1)
EC-31
TROUBLE DIAGNOSIS
ECM Terminal Layout (Cont’d)
Terminal Description
83 Sensor ground (Accelerator pedal position sensor 2)
84 Headlamp switch
85 (K LINE) K-line (ECM data transmit/receive)
86 CAN communication (CAN L1)
87 –
88 –
89 –
90 Accelerator pedal position sensor 1 power supply
91 Accelerator pedal position sensor 2 power supply
92 –
93 –
94 CAN communication (CAN H1)
95 –
96 –
97 –
98 Accelerator pedal position sensor 2
99 –
100 –
101 Stop lamp brake switch
102 PNP switch
103 –
104 Throttle control motor relay
105 –
106 Accelerator pedal position sensor 1
107 –
108 –
109 (IGN) Ignition switch
110 BATT
111 Self shut off
112 LPG interception valve relay
113 Fuel pump relay
114 No 2 LPG INJ
115 (–) ECM ground
116 (–) ECM ground
117 Power supply for No 2 LPG INJ
118 Power supply for ECM
119 Power supply for No 1 LPG INJ
120 No 1 LPG INJ
121 Power supply for ECM
EC-32
TROUBLE DIAGNOSIS
ECM Input/Output Signal Specifications
REFERENCE VALUE LIST
Voltages is measured with a circuit tester, and the sample
waveforms obtained with an oscilloscope are shown below for each
ECM terminal. Measurement data varies depending on variation in
parts as well as many other factors. Such factors include vehicle
history, driving conditions, environmental conditions, maintenance
status, measuring instrument/method, etc. Data shown below are
reference values.
ECM0248
Terminal Signal name Condition Data (DC value)
24 Heated oxygen sensor heater At idle after warming up Approx. 0.3V
113 Fuel pump relay For approximately 1 second after Approx. 1V
ignition switch ON
After that Battery voltage
At cranking, engine running Approx. 1V
111 Self shut off For approximately 10 seconds when Approx. 1V
ignition switch ON and after ignition
switch OFF
Ignition switch OFF Battery voltage
EC-33
TROUBLE DIAGNOSIS
ECM Input/Output Signal Specifications (Cont’d)
Terminal Signal name Condition Data (DC value)
62 Ignition signal (power transmission At cranking At cranking: Approx. 0.5V
drive signal)
ECM0249
At idle after warming up At idling: Approx. 0.5V
ECM0250
At approx. 2,000 rpm Approx. 0.9V
ECM0251
101 Stop lamp brake switch Brake pedal released Approx. 0V
Brake pedal depressed Battery voltage
109 (IGN) Ignition switch Ignition switch OFF Approx. 0V
Ignition switch ON Battery voltage
102 PNP switch N position Approx. 0V
Other than above Battery voltage (A/T models)
85 (K LINE) K-line (ECM data transmit/receive) When connected to SST Approx. 6.6 - Battery voltage
When not connected to SST Approx. 6V
86 CAN communication line L Always Approx. 2.2V (Varies depending on
communication status.)
ECM0051
94 CAN communication line H Always Approx. 2.4V (Varies depending on
communication status.)
ECM0050
84 Headlamp switch Lighting switch OFF Approx. 0V
Lighting switch ON Battery voltage
EC-34
TROUBLE DIAGNOSIS
ECM Input/Output Signal Specifications (Cont’d)
Terminal Signal name Condition Data (DC value)
67 Mass air flow sensor ground Always Approx. 0V
115 ECM ground Always Approx. 0V
116
1
2
13 Crankshaft position sensor 1° (POS) At cranking At cranking: Approx. 2.6V
ECM0252
At idle after warming up At idling: Approx. 2.5V
ECM0253
At approx. 2,000 rpm Approx. 2.5V
ECM0254
91 Accelerator pedal position sensor 2 Ignition switch ON, engine running Approx. 5V
power supply
48 Sensor power supply Ignition switch ON, engine running Approx. 5V
110 BATT Always Battery voltage
47 Electric throttle control actuator sensor Ignition switch ON, engine running Approx. 5V
power supply
78 Heated oxygen sensor ground Always Approx. 0V
82 Accelerator pedal position sensor 1 Always Approx. 0V
ground
90 Accelerator pedal position sensor 1 Ignition switch ON, engine running Approx. 5V
power supply
EC-35
TROUBLE DIAGNOSIS
ECM Input/Output Signal Specifications (Cont’d)
Terminal Signal name Condition Data (DC value)
14 Crankshaft position sensor 120° (REF) At cranking At cranking: Approx. 0.5V
ECM0255
At idle after warming up At idling: Approx. 0.5V
ECM0256
At approx. 2,000 rpm Approx. 0.5V
ECM0257
51 Mass air flow sensor Ignition switch ON Approx. 0.5V
At cranking Approx. 2V
At idle after warming up Approx. 2V
At approx. 2,000 rpm Approx. 3V
50 Throttle position sensor 1 At idle after warming up Approx. 0.9V
Ignition switch ON with engine stopped Approx. 0.9V
Accelerator pedal is fully depressed
Ignition switch ON with engine stopped Approx. 4.1V
Accelerator pedal is released
At approx. 2,000 rpm Approx. 1.3V
69 Throttle position sensor 2 At idle after warming up Approx. 4.1V
Ignition switch ON with engine stopped Approx. 4.1V
Accelerator pedal is fully depressed
Ignition switch ON with engine stopped Approx. 0.9V
Accelerator pedal is released
At approx. 2,000 rpm Approx. 3.7V
106 Accelerator pedal position sensor 1 At Idle Approx. 0.67 - 0.87V
Ignition switch ON with engine stopped Approx. 0.67 - 0.87V
Accelerator pedal is fully depressed
Ignition switch ON with engine stopped Approx. 4.4 - 4.6V
Accelerator pedal is released
At approx. 2,000 rpm Approx. 2.8V
98 Accelerator pedal position sensor 2 At Idle Approx. 0.33 - 0.43V
Ignition switch ON with engine stopped Approx. 0.33 - 0.43V
Accelerator pedal is fully depressed
Ignition switch ON with engine stopped Approx. 2.2 - 2.3V
Accelerator pedal is released
At approx. 2,000 rpm Approx. 1.4V
EC-36
TROUBLE DIAGNOSIS
ECM Input/Output Signal Specifications (Cont’d)
Terminal Signal name Condition Data (DC value)
34 Intake air temperature sensor Intake air temperature is approx. 20°C Approx. 3.5V
(68°F).
Intake air temperature is approx. 80°C Approx. 1.2V
(176°F).
83 Accelerator pedal position sensor 2 Always Approx. 0V
ground
35 Heated oxygen sensor At idle after warming up Changes between approx. 0.1 - 0.4V
approx. 0.6 - 0.9V
ECM0258
At approx. 2,000 rpm Changes between approx. 0.1 - 0.4V
approx. 0.6 - 0.9V
ECM0259
73 Engine coolant temperature sensor Engine coolant temperature is approx. Approx. 5V
20°C (68°F).
Engine coolant temperature is approx. Approx. 1.2V
80°C (176°F).
21 Injector drive signal At cranking Approx. 10.5V
22
23
40
41
42
ECM0260
At idle after warming up Battery voltage
ECM0261
At approx. 2,000 rpm Relatively lower than battery voltage
ECM0262
EC-37
TROUBLE DIAGNOSIS
ECM Input/Output Signal Specifications (Cont’d)
Terminal Signal name Condition Data (DC value)
118 Power supply for ECM Ignition switch ON, engine running Battery voltage
121
104 Throttle control motor relay Ignition switch ON, engine running Approx. 1V
3 Throttle control motor relay power Always Battery voltage
supply
5 Throttle control motor (Open) At idle after warming up Approx. 0.1 to 0.15V
At approx. 2000 rpm
4 Throttle control motor (Close) At idle after warming up Approx. 2 - 2.5V
At approx. 2000 rpm
32 Fuel changing switch 2 (Gasoline) Changing switch ON (At gasoline side) Approx. 5V
Changing switch ON (At LPG side or Approx. 0V
neutral)
49 Fuel changing switch power supply Changing switch ON Approx. 5V
Changing switch OFF (At neutral) Approx. 0V
70 Fuel changing switch 1 (LPG) Changing switch ON (At LPG side) Approx. 5V
Changing switch OFF (At LPG side or Approx. 0V
neutral)
112 LPG interception valve relay When ignition switch is ON (Approx. 1 Battery voltage
second) and for approximately 10
seconds after ignition switch is OFF
Ignition switch OFF Approx. 0V
EC-38
TROUBLE DIAGNOSIS
Description
• “When” a malfunction occurs that is caused by the sensors of
engine or the air-fuel ratio control, engine warning lamp of the
meter panel illuminates. Then, Diagnostic Trouble Code (DTC)
is displayed on the meter. At this time, the possible cause is
displayed by operating the button.
• For DTC, refer to Table of DTC (EC-40).
• When a malfunction has occurred, check the symptom and
perform the trouble diagnosis using “Diagnosis history”, “ECM
input/output monitor” and “Active test” in the meter.
NOTE:
• For “Diagnosis history”, refer to EC-40.
• For “ECM Input/Output Monitor”, refer to EC-50.
• For “ECM Active Test”, refer to EC-51.
Fail-safe Function
When any of the critical sensors or systems sends a malfunction
message, the fail-safe function estimates the driving conditions with
other input signals and selects safer conditions for engine (vehicle)
control, based on data previously stored in ECM.
Engine
Related sensors Malfunction condition Fail-safe Warning
lamp
Mass air flow sensor Same as self-diagnosis • Selects fuel injection pulse width depending on engine speed and ON
malfunction detection throttle position so the vehicle can be driven. However, fuel injection
conditions. will be inhibited (fuel cut off) when engine speed exceeds
approximately 800 - 1,600 rpm.
• Idle speed is 800 rpm.
Engine coolant • Uses the estimated engine coolant temperature (varies with elapsed ON
temperature sensor time after start) to perform controls so the vehicle can be driven.
Accelerator pedal position • When 1 circuit is open, fuel injection will be inhibited (fuel cut off) ON
sensor when engine speed exceeds approximately 2,500 rpm. Release
valve mechanically until it can drive at low speed when disconnecting
connector.
Throttle position sensor • Fixes output to a preset value so the vehicle can be driven. However, ON
fuel injection will be inhibited (fuel cut off) when engine speed
exceeds approximately 2,500 rpm.
EC-39
TROUBLE DIAGNOSIS
Table of DTC
SELF-DIAGNOSIS RESULTS
When a malfunction occurs in ECM input/output signal circuit, the
malfunctioning circuit is recorded and displayed. Also, the
malfunction item that is occurred is displayed.
Display sample [Example: When there is a malfunction in mass air
flow sensor] Display DTC and the malfunction item in the alarm
monitor screen.
DTC Name Engine warning lamp
— NO DTC —
VCM communication signal circuit malfunction
E-03 ON
ECM communication signal circuit malfunction
E-04 ON
DCM communication signal circuit malfunction
E-05 ON
MP communication signal circuit malfunction
E-07 ON
TMS communication signal circuit malfunction
E-08 ON
Mass air flow sensor signal circuit malfunction
E-21 ON
Engine coolant temperature signal circuit malfunction
E-22 ON
EC-40
TROUBLE DIAGNOSIS
Table of DTC (Cont’d)
DTC for
Malfunction return condition Diagnosis outline Trip
GST
— — — —
U1001 • Malfunction occurs in CAN communication transmit/receive data or in — 1
VCM, and data transmission/reception cannot be confirmed.
• CAN communication data is transmitted/received for predetermined
period.
U1001 • Malfunction occurs in CAN communication transmit/receive data or in — 1
ECM, and data transmission/reception cannot be confirmed.
• CAN communication data is transmitted/received for predetermined
period.
U1001 • Malfunction occurs in CAN communication transmit/receive data or in — 1
DCM, and data transmission/reception cannot be confirmed.
• CAN communication data is transmitted/received for predetermined
period.
U1001 • Malfunction occurs in CAN communication transmit/receive data or in — 1
MP, and data transmission/reception cannot be confirmed.
• CAN communication data is transmitted/received for predetermined
period.
U1001 • Malfunction occurs in CAN communication transmit/receive data or in
TMS, and data transmission/reception cannot be confirmed.
• CAN communication data is transmitted/received for predetermined
period.
P0102 When the engine is running and the mass air flow sensor output voltage Detect disconnection and short circuit and 1
has been 0.5V or less (open or shorted) for a predetermined period. make MIL go on.
P0103 When the engine is stopped (ignition switch ON) and the mass air flow
sensor output voltage has been approx. 4.9V or more (open or shorted)
for a predetermined period.
P0117 Engine coolant temp. sensor output voltage has been less than 0.06V Detect disconnection and short circuit and 1
(open or shorted) for a predetermined period. make MIL go on.
P0118 Engine coolant temp. sensor output voltage has been approx. 4.8V or
more (open or shorted) for a predetermined period.
EC-41
TROUBLE DIAGNOSIS
Table of DTC (Cont’d)
DTC Name Engine warning lamp
Throttle position sensor signal circuit malfunction
E-23 ON*
Accelerator pedal position sensor signal circuit malfunction
E-24 ON
Heated oxygen sensor signal circuit malfunction
E-25 ON
Heated oxygen sensor heater signal malfunction
E-26 ON
EC-42
TROUBLE DIAGNOSIS
Table of DTC (Cont’d)
DTC for
Malfunction return condition Diagnosis outline Trip
GST
P0122 Throttle position sensor 2 output voltage has been approx. 0.3V or less Detect disconnection and short circuit and 1
(open) for a predetermined period. make MIL go on.
P0123 Throttle position sensor 2 output voltage has been approx. 4.8V or more
(shorted) for a predetermined period.
P0222 Throttle position sensor 1 output voltage has been approx. 0.3V or less
(open) for a predetermined period.
P0223 Throttle position sensor 1 output voltage has been approx. 4.8V or more
(shorted) for a predetermined period.
P1225 When the throttle valve closed position learning value is excessively low. Compare inconsistency between two separate 2
P1226 When the throttle valve closed position learning cannot be performed. circuits which are installed for redundancy and
judges abnormal condition and make MIL go
P2135 A malfunction occurs in the relation between throttle position sensors 1
and 2. on.
P2122 Accelerator pedal position sensor 1 output voltage has been approx. Detect disconnection and short circuit and 1
0.15V or less (open) for a predetermined period. make MIL go on.
P2123 Accelerator pedal position sensor 1 output voltage has been approx. 5V
or more (shorted) for a predetermined period.
P2127 Accelerator pedal position sensor 2 output voltage has been approx.
0.15V or less (open) for a predetermined period.
P2128 Accelerator pedal position sensor 2 output voltage has been approx. 5V
or more (shorted) for a predetermined period.
P2138 A malfunction occurs in the relation between accelerator pedal position Compare inconsistency between two separate
sensors 1 and 2. circuits which are installed for redundancy and
judges abnormal condition and make MIL go
on.
P0132 Heated oxygen sensor output voltage is higher than normal (1.4V or Detect disconnection and short circuit and 2
more). make MIL go on.
P0134 Heated oxygen sensor signal circuit is open.
P0031 Heated oxygen sensor heater control voltage has been approx. less than Detect disconnection and short circuit of an 2
0.12V (open or shorted) for a predetermined period. oxygen sensor heater circuit and make MIL go
P0032 Heated oxygen sensor heater control voltage has been approx. 4.7V or on.
more (shorted) for a predetermined period.
EC-43
TROUBLE DIAGNOSIS
Table of DTC (Cont’d)
DTC Name Engine warning lamp
Crankshaft position sensor (POS) or (REF) signal circuit malfunction
E-28 ON
Self shut off malfunction
E-29 ON
ECM circuit malfunction
E-30 ON*
Electric throttle control actuator control signal circuit malfunction
E-31 ON
Overheat signal (STEP1)
E-32 ON
Overheat signal (STEP2)
E-33 ON*
Ignition signal circuit malfunction
E-34 ON
EC-44
TROUBLE DIAGNOSIS
Table of DTC (Cont’d)
DTC for
Malfunction return condition Diagnosis outline Trip
GST
P0340 • At start-up, no crankshaft position sensor (POS) or (REF) signal has Detect abnormal crankshaft position sensor 2
been detected for more than a predetermined period. (POS) or (REF) signal and make MIL go on.
• The crankshaft position sensor (POS) or (REF) signal is not detected
for a predetermined time during engine running.
• A crankshaft position sensor (POS) or (REF) signal irregular
waveform is detected for a predetermined time during engine running.
P0605 Self shut off of ECM doesn’t operate normally. — 1
P0605 CPU system or circuits in ECM have a malfunction. Detect abnormal condition in CPU or an 1 or 2
engine control module circuit and make MIL (Note)
go on.
P1065 Power is not supplied to ECM for some time. Detect insufficient power supply for ECM and
make MIL go on.
P1229 Sensor power supply voltage has been 5.6V or more or less than 4.6V for Detect improper voltage output for sensors
a predetermined period. and make MIL go on.
P1124 Electric throttle control motor power supply circuit is shorted. Detect disconnection and short circuit of a 1
P1126 Electric throttle control motor power supply circuit is open. motor driving circuit and make MIL go on.
P1128 Electric throttle control motor signal circuit is shorted.
P0605 When an abnormal occurs for the target of throttle position. Compare the difference between target 1
P1121 Because of mechanical malfunction of the electric throttle control actuator, throttle position and actual throttle position,
the electric throttle control actuator does not operate normally. judge abnormal condition and make MIL go
on.
P1122 • When a malfunction occurred due to the correlation between the
target throttle position and the actual throttle position.
• Over current flows into throttle motor control circuit.
P1218 Engine coolant temp. sensor output voltage has been approx. 0.6V or less — 1
for a predetermined period (with the coolant temp. sensor normal)
P1217 Engine coolant temp. sensor output voltage has been approx. 0.35V or Detect overheat condition by water 1
less for a predetermined period (with the coolant temp. sensor normal) temperature sensor and make MIL go on.
P0350 • Ignition signal has not been continuously generated while the engine Detect electric current in an ignition coil 2
is running. circuit, judge abnormal ignition interval and
make MIL go on.
EC-45
TROUBLE DIAGNOSIS
Table of DTC (Cont’d)
DTC Name Engine warning lamp
LPG fuel injection open circuit malfunction
E-35 ON
LPG vaporizer malfunction
E-38 ON
Oil pressure sensor malfunction
E-40 —
Stop lamp switch malfunction
E-41 ON
LPG fuel pressure sensor malfunction
E-36 ON*
EC-46
TROUBLE DIAGNOSIS
Table of DTC (Cont’d)
DTC for
Malfunction return condition Diagnosis outline Trip
GST
P1240 Over current flows into LPG injector 1 (injection area). Detect abnormal electric current in an LPG 1
P1241 Over current flows into LPG injector 1 (no injection area). injector driving circuit and make MIL go on.
P1242 Over current flows into LPG injector 2 (injection area).
P1243 Over current flows into LPG injector 2 (no injection area).
P1249 • LPG fuel pressure sensor circuit is open. Detect abnormally higher fuel pressure by 1
• LPG fuel pressure in fuel piping from LPG Vapo to injector has been LPG fuel pressure sensor and make MIL go
excessively increased for a predetermined period. on.
— — — —
P1805 Brake switch signal circuit is open or shorted. — 1
P1245 LPG fuel pressure sensor circuit is shorted. Detect disconnection and short circuit and 1
make MIL go on.
EC-47
TROUBLE DIAGNOSIS
Service Tool
Trip 1: If a malfunction is detected by self-diagnosis between the
time ignition switch is turned ON (engine is running) and then turned
OFF (this is defined as “trip”), Engine Warning lamp is lit. The
corresponding DTC is recorded immediately after detection.
Trip 2: When a malfunction is detected by self-diagnosis for the first
time in the first trip, a tentative DTC is recorded. If the same
malfunction is detected again by self-diagnosis in the next trip
(second trip), Engine Warning lamp is lit and the corresponding final
DTC is recorded.
Self-diagnostic results timing
• For items of trip 1, timing “0” is displayed immediately after
detection of a malfunction.
• For items of trip 2, when a malfunction is detected for the first
time (trip 1), timing “1t” is displayed. When a malfunction is
detected again in the next trip (trip 2), it is displayed as “0”.
Accumulative counting is performed at the end of warming-up
operation,
Conditions to turn off Engine Warning lamp
• The Engine Warning lamp, marked with *, is turned off when
ignition switch is turned ON (engine starts) again after normal
state is resumed.
• For other self-diagnostic items, self-diagnostic results shall be
erased by turning ignition switch to OFF after normal operation
is resumed.
EC-48
TROUBLE DIAGNOSIS
Self-Diagnosis Function (Without Service
Tool)
DIAGNOSTIC TEST MODE II - SELF-DIAGNOSTIC
RESULTS
• In this mode, the MIL blinks (indicating the DTC) to identify the
system that returned a malfunction.
• If no DTC is detected, DTC “0000” is displayed.
EC-49
TROUBLE DIAGNOSIS
ECM Input/Output Monitor
In ECM input/output monitor, the items related to engine control
(engine status, sensors or switches) can be checked.
Name Remarks (Display, etc.)
Engine speed Idle speed: 675 rpm, maximum engine speed without load: 2,450 rpm
Closed throttle position switch Accelerator fully-closed: ON, accelerator open: OFF
Throttle opening angle At idle: 0%, accelerator fully-open: 100%
Battery voltage
Accelerator pedal position At idle: 0%, accelerator fully-open: 100%
Engine coolant temperature Approx. 80°C (176°F) or more after warming up engine
Injection pulse GAS At idle: 2-4 s
Injection pulse LPG At approx. 2,000 rpm: Approx. 2 - 4 s
Starter switch Ignition switch ON and START: ON, ignition switch OFF: OFF
Neutral switch FR lever in neutral: ON, any position other than neutral: OFF
Electricity load switch Headlamp switch ON: ON, OFF: OFF
Brake switch Depressing brake pedal: ON, Not depressing brake pedal: OFF
Learned Air-fuel ratio value clear DONE/NOT
Idle Air Volume Learning
Ignition timing adjustment
Air-fuel ratio adjustment
Power balance adjustment
Fuel pressure clear adjustment
Self-diagnosis result clear
Mass air flow sensor At idle: Approx. 1.3V, engine speed at 2,000 rpm: Approx. 1.6V
Charging efficiency GAS At idle: Approx. 30%, At approx. 2,000 rpm: Approx. 20%
Charging efficiency LPG At idle: Approx. 30%, At approx. 2,000 rpm: Approx. 20%
Air-fuel ratio (Gasoline) Proper value: 100%, range: 75 - 125%
Air-fuel ratio (LPG) Proper value: 100%, range: 75 - 125%
Change fuel switch 1 LPG: ON, GAS: OFF
Change fuel switch 2 GAS: ON, LPG: OFF
Fuel control GAS/LPG/NEU
O2 sensor RICH/LEAN judgement While the engine is running: Switches between LEAN/RICH
Fuel pump relay Ignition switch ON (when the fuel pump is operating), OFF (when the fuel pump is stopped)
LPG interception valve relay When the engine is stopped: OFF, while the engine is running: ON
Throttle relay Ignition switch ON: ON, OFF: OFF
Heated oxygen sensor heater At idle after warning up the engine: ON
Fully-closed learning update empirical flag
Idle Air Volume Learning completion flag
Ignition timing Proper value: 10BTDC (at idle)
Heated oxygen sensor output voltage At idle: Changes between approx. 0.1 - 0.4V0.6 - 0.9V
Maintain at approx. 2,000 rpm: Changes between approx. 0.1 - 0.4V0.6 - 0.9V
Intake air temperature sensor Values according to intake air temperature
LPG fuel pressure sensor Ignition switch ON: Approx. 29 kPa (0.29 bar, 0.3 kg/cm2, 4 psi)
EC-50
TROUBLE DIAGNOSIS
ECM Active Test
ECM active test has the following items.
Name
Idle Air Volume (Normal)
Air-fuel ratio adjustment
Air-fuel ratio clear
Ignition timing adjustment
Fuel pressure clear
Power balance
Self-diagnosis clear
(1) Idle Air Volume Learning
If the idle speed or the ignition timing is outside the standard (engine
status is malfunctioning) or if the electronic throttle control actuator
or ECM is replaced, perform Idle Air Volume Learning.
Standard
Idle speed: 67550 rpm
Ignition timing: 102/675 (°BTDC/rpm)
(2) Air-fuel ratio adjustment
If the values of “Air-fuel ratio” in ECM input/output monitor are
outside the standard, adjust the air-fuel ratio.
Proper value: 100%
Adjustment range: 75 - 125%
(3) Ignition timing adjustment
If the values of “Ignition timing” in ECM input/output monitor are
outside the standard, adjust the ignition timing.
Proper value: 10°BTDC
Adjustment range: 0 - 10°
(4) Fuel pressure clear
Relieve fuel pressure before removing fuel piping to secure safety.
For relieving procedure of fuel pressure, refer to “Fuel pressure
clear”.
(5) Power balance
When the engine does not run smoothly or the misfires occur in
some cylinders, forcibly stop each cylinder in “Power balance”, and
then check which cylinder has the malfunction.
EC-51
BASIC INSPECTION
BASIC INSPECTION
Inspection of Idle Speed and Ignition Timing
SERVICE DATA AND SPECIFICATIONS (SDS)
Fuel pressure [kPa (bar, kg/cm2, psi)] 0.35 (0.0035, 0.0036, 0.051)
Idle speed (rpm) A/T model (at N position) 675±50
Ignition timing (°BTDC/rpm) A/T model (at N position) 10±2/675
Firing order 1-5-3-6-2-4
Spark plug Manufacturer/type/gap mm (in) NGK/BPR4ES-D or BPR4ES-H/0.8 - 0.9 (0.0031 - 0.035)
Ignition advance device Electrically controlled ignition advance
Density of CO at idle speed (%)/Density of HC at idle speed (ppm) 0.1/50 or less
• Turn ignition switch ON, and then make sure that no
malfunction is detected by self-diagnosis.
• Make sure that engine is free of oil pressure pump loads and
any electrical loads. Perform the inspection with the shift lever in
the neutral or N position.
• Warm up engine and transmission to the normal operating
temperature.
IDLE SPEED
With ECM Input/Output monitor
NOTE:
The idle speed can be checked in ECM Input/Output Monitor.
CAUTION:
Perform “Idle Air Volume Learning” when idle speed is outside
the standard.
Without ECM Input/Output monitor
1. Connect an induction type (current detection type) tachometer
to the primary wire of the 1 cylinder to check idle speed.
• The primary wire for the 1 cylinder is looped and longer than the
wires for other cylinders. It is used for detecting idle speed and
ignition timing.
2. Make sure that idle speed is 67550 rpm.
CAUTION:
Perform “Idle Air Volume Learning” when idle speed is outside
the standard.
IGNITION TIMING INSPECTION
NOTE:
The ignition timing can be checked in ECM Input/Output monitor.
1. Install a timing light to the primary wire for 1 cylinder.
2. Make sure that ignition timing and idle speed are 102°BTDC/
675 rpm.
CAUTION:
Perform “Idle Air Volume Learning” when ignition timing is
outside the standard.
EC-52
BASIC INSPECTION
Throttle Valve Closed Position Learning and
Idle Air Volume Learning
DESCRIPTION
When electric throttle control actuator or ECM connector is removed,
it is necessary for ECM to learn throttle valve closed position (throttle
position sensor output with throttle valve fully closed) after
reinstallation. Thus, throttle valve closed position learning is
performed.
When electric throttle control actuator or ECM is replaced, the
minimum required idle air volume needs to be learned. Thus, throttle
valve closed position learning and idle air volume learning are
performed.
Idle air volume learning is necessary even when idle speed or
ignition timing is outside the standard. Note that idle air volume
learning is equivalent to the base idle speed adjustment by
conventional throttle adjusting screw of carburetor or LPG mixer.
OPERATION PROCEDURE FOR THROTTLE VALVE
CLOSED POSITION LEARNING
1. Turn ignition switch ONOFF. (And hold it for approximately 5
seconds after turning it OFF.)
2. Make sure that throttle valve operates. (Check for operating
sound.)
3. Upon completion of the above, learning is complete.
CAUTION:
Throttle valve closed position learning cannot be performed
with Service tool.
OPERATION PROCEDURE FOR IDLE AIR VOLUME
LEARNING
1. Perform throttle valve closed position learning.
2. Fully warm up engine, transmission, and lubricant. [Engine
coolant temperature: 70 to 90°C (158 to 194°F)]
3. Set the selector lever to neutral or N position. Make sure that
the engine is free of electrical loads, such as air conditioner, oil
pressure pump, and other electrical components.
4. Perform “Idle Air Volume Learning” of “ECM Active Test”.
CAUTION:
“IDLE AIR VOL LEARN (PLANT)” is the original setting on the
vehicle. Do not use it.
EC-53
BASIC INSPECTION
Throttle Valve Closed Position Learning and
Idle Air Volume Learning (Cont’d)
CAUTION:
It will take approximately 20 seconds to complete the idle air
volume learning. Do not turn OFF the ignition switch until
completion.
• Complete “Idle Air Volume Learning”, then make sure that idle
speed and ignition timing are within the standard.
• Perform “Idle Air Volume Learning” again if values are outside
the standard.
Accelerator Pedal Released Position
Learning
DESCRIPTION
When the accelerator pedal assembly has been replaced or the
accelerator pedal position sensor connector has been disconnected,
the accelerator pedal released position needs to be learned after
being repaired, so learn accelerator pedal in fully-released position.
OPERATION PROCEDURE
1. Turn ignition switch ON and wait at least 2 seconds.
2. Turn ignition switch OFF and wait at least 10 seconds.
3. Then turn ignition switch ON again and wait at least 2 seconds
(learning completed).
Fuel Pressure Inspection
QUICK INSPECTION
With Active Test
1. Perform “Fuel pressure clear” of ECM Active Test.
2. Pinch the fuel feed hose with the fingers. Hose should not feel
hard.
Without Active Test
• When the fuel feed hose is squeezed while fuel pump is
operating (for 1 second after the ignition switch is turned ON or
while cranking), the hose should be swelling with pressure or
pulsating.
FUEL PRESSURE INSPECTION
CAUTION:
• Safely and securely remove and install fuel hose.
• Use the fuel pressure gauge for fuel pressure inspection.
• Do not inspect fuel pressure while other systems are
operating. Malfunctions may occur in fuel pressure value.
1. Release the fuel pressure.
2. Install fuel pressure gauge using fuel hose for fuel pressure
inspection.
3. Remove fuel hose, and then install fuel hose for fuel pressure
inspection.
CAUTION:
Usable period of fuel hose for fuel pressure inspection is 30
times or less. (Fuel hoses that are damaged and allow fuel
leakage are not contained above.)
EC-54
BASIC INSPECTION
Fuel Pressure Inspection (Cont’d)
4. Turn ignition switch ON, and then make sure that there is no
fuel leakage.
5. Start engine, and check for fuel leakage.
6. Make sure that fuel pressure is within the standard.
At idle: 353 kPa (3.53 bar, 3.6 kg/cm2, 51 psi)
• If the vehicle shows poor starting, check fuel pressure with fuel
pump operating for approximately 1 second after ignition switch
is turned ON, and during cranking.
For 1 second after ignition switch is turned ON and
during cranking:
353 kPa (3.53 bar, 3.6 kg/cm2, 51 psi)
• Check the following items if a malfunction is detected.
CAUTION:
Also check fuel pressure at increased engine speed.
• Malfunctioning pressure regulator (integrated with fuel pump)
• Clogged fuel piping
• Clogged fuel filter (with fuel pump)
• Poor fuel pump discharge
FUEL PRESSURE RELEASE
CAUTION:
Relieve fuel pressure before removing fuel piping to secure
safety.
Accelerator Pedal Released Position
Learning
With Active Test
1. Perform “Fuel pressure clear” of ECM Active Test.
2. Crank engine 2 or 3 times to consume the fuel in the fuel line
after it stalls.
3. Turn ignition switch OFF.
Without Active Test
1. Disconnect fuel pump fuse.
2. Start engine.
3. Crank engine 2 or 3 times to consume the fuel in the fuel line
after it stalls.
4. Turn OFF the ignition switch, and install the fuel pump fuse.
EC-55
BATTERY AND GROUND SYSTEM
BATTERY AND GROUND SYSTEM
ECM Input/Output Signal Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal Signal name Measurement condition Measured value
111 Self shut off Ignition switch ON and engine running Approx. 1V
Ignition switch OFF Battery voltage
109 (IGN) Ignition switch Ignition switch ON and engine running
118 Power supply for ECM
121
110 BATT Always
1 Ground Approx. 0V
2
115
116
Circuit Diagram
EC-56
CRANKSHAFT POSITION SENSOR 1° (POS)
CRANKSHAFT POSITION SENSOR 1° (POS)
ECM Input/Output Signal Specifications
Check waveform between terminals shown below and ground using
an oscilloscope.
NOTE:
Numerical values (reference values) are obtained using an analog
circuit tester.
Terminal Signal name At cranking At idle after warming up At approx. 2,000 rpm
13 Crankshaft position At cranking: Approx. 2.6V At idling: Approx. 2.5V Approx. 2.5V
sensor 1° (POS)
ECM0287 ECM0288 ECM0289
Circuit Diagram
Component Parts Inspection
CRANKSHAFT POSITION SENSOR (POS)
• Remove distributor (with the harness connector connected)
from the engine.
• Turn ignition switch ON.
• Slowly turn the crankshaft position sensor shaft by hand and
check voltage between terminal 3 and ground.
3 - Ground (1° signal):
Approx. 0.2 or 5V
CAUTION:
Check voltage after disconnecting the injector fuse to inhibit
ECM0291
injector operation.
Malfunctions may or may not be accurately detected by self-
diagnosis depending on how the shaft is turned. Note that there
is no malfunction in this case.
EC-57
CRANKSHAFT POSITION SENSOR 120° (REF)
CRANKSHAFT POSITION SENSOR 120° (REF)
ECM Input/Output Signal Specifications
Check waveform between terminals shown below and ground using
an oscilloscope.
NOTE:
Numerical values (reference values) are obtained using an analog
circuit tester.
Terminal Signal name At cranking At idle after warming up At approx. 2,000 rpm
14 Crankshaft position At cranking: Approx. 0.5V At idling: Approx. 0.5V Approx. 0.5V
sensor 120° (REF)
ECM0292 ECM0293 ECM0294
Circuit Diagram
Component Parts Inspection
CRANKSHAFT POSITION SENSOR (REF)
• Remove distributor (with the harness connector connected)
from the engine.
• Turn ignition switch ON.
• Slowly turn the crankshaft position sensor shaft by hand and
check voltage between terminal 4 and ground.
4 - Ground (120° signal):
Approx. 0.2 or 5V
CAUTION:
Check voltage after disconnecting the injector fuse to inhibit
ECM0296
injector operation.
Malfunctions may or may not be accurately detected by self-
diagnosis depending on how the shaft is turned. Note that there
is no malfunction in this case.
EC-58
MASS AIR FLOW SENSOR SYSTEM
MASS AIR FLOW SENSOR SYSTEM
SST Data Monitor Display
Monitor item At idle after warming up At approx. 2,000 rpm
MAS A/F SE Approx. 2V Approx. 3V
ECM Input/Output Signal Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal Signal name At cranking At idle after warming up At approx. 2,000 rpm
51 Mass air flow sensor Approx. 1.5V Approx. 2V Approx. 3V
67 Mass air flow sensor
Approx. 0V
ground
Circuit Diagram
Component Parts Inspection
MASS AIR FLOW SENSOR
1. Remove mass air flow sensor.
2. Turn ignition switch to ON. While blowing air into the mass air
flow sensor from the air cleaner case side, check output voltage
between terminal 3 and ground.
No air blowing:
Approx. 1V
With air blowing:
Approx. 1.3V
(The more the air is blown, the higher the voltage is.)
NOTE:
If air is blown from the air duct side, the voltage becomes lower.
EC-59
ENGINE COOLANT TEMPERATURE SENSOR SYSTEM
ENGINE COOLANT TEMPERATURE SENSOR SYSTEM
SST Data Monitor Display
Monitor item At idle At approx. 2,000 rpm
Temperature sensor After warming up: Approx. 80°C (176°F) or more
ECM Input/Output Signal Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal Signal name At idle after warming up At approx. 2,000 rpm
73 Engine coolant
At coolant temperature 20°C (68°F): Approx. 5V
temperature
At coolant temperature 80°C (176°F): Approx. 1.2V
sensor
NOTE:
When failure engine coolant temperature sensor, change value of
engine coolant temperature signal and cranking time together, then
possible normal driving.
Circuit Diagram
Component Parts Inspection
ENGINE COOLANT TEMPERATURE SENSOR
1. Remove engine coolant temperature sensor.
2. Check resistance between engine coolant temperature sensor
terminals 1 and 2.
Resistance
Engine coolant temperature at approx. 20°C (68°F):
Approx. 2.5 k
Engine coolant temperature at approx. 80°C (176°F):
Approx. 0.3 k
EC-60
HEATED OXYGEN SENSOR SYSTEM
HEATED OXYGEN SENSOR SYSTEM
SST Data Monitor Display
Monitor item At idle after warming up At approx. 2,000 rpm
HO2S1 Changes between approx. 0.1 - 0.4Vapprox. 0.6 - 0.9V
H02S1 MNTR RICH and LEAN alternate slowly. RICH and LEAN alternate at least 5 times in
10 seconds.
ECM Input/Output Signal Specifications
Check waveform between terminals shown below and ground using
an oscilloscope.
NOTE:
Numerical values (reference values) are obtained using an analog
circuit tester.
Terminal Signal name At idle after warming up At approx. 2,000 rpm
35 Heated oxygen sensor Changes between approx. 0.1 - 0.4V Changes between approx. 0.1 - 0.4V
approx. 0.6 - 0.9V approx. 0.6 - 0.9V
Circuit Diagram
ECM0304
EC-61
THROTTLE POSITION SENSOR SYSTEM
THROTTLE POSITION SENSOR SYSTEM
SST Data Monitor Display
Monitor item At idle after warming up At approx. 2,000 rpm
ETC THRTL SEN 1 Approx. 0.6V Approx. 0.7V
ETC THRTL SEN 2 Approx. 4.5V Approx. 4.4V
ECM Input/Output Signal Specifications
Terminal Signal name At idle after warming up At approx. 2,000 rpm
47 Sensor power supply (Throttle position sensor) Approx. 5V
66 Sensor ground (Throttle position sensor) Approx. 0V
50 Throttle position sensor 1 Approx. 0.6V Approx. 0.7V
69 Throttle position sensor 2(*) Approx. 4.5V Approx. 4.4V
(*): Throttle position sensor 2 signal (terminal 69) voltage is different from DATA
MONITOR display of SST because it is converted in ECM.
Circuit Diagram
ECM0307
Component Parts Inspection
THROTTLE POSITION SENSOR 1, 2 (ELECTRIC
THROTTLE CONTROL ACTUATOR ASSEMBLY)
Check voltage between ECM terminal 50, 69 and ground.
Refer to EC section, “ECM Input/Output Signal Specifications” for
the voltage.
CAUTION:
• Make sure that there is no moisture around connector
when removing and installing throttle position sensor
connector. If there are any water drops, completely wipe
ECM0308
them off.
• Do not apply voltage to throttle position sensor terminal.
• Perform “Throttle Valve Closed Position Learning” if
disconnecting connector.
• Do not disassemble electric throttle control actuator.
EC-62
ACCELERATOR PEDAL POSITION SENSOR SYSTEM
ACCELERATOR PEDAL POSITION SENSOR SYSTEM
SST Data Monitor Display
Monitor item At Idle At approx. 2,000 rpm
ETC ACCEL SEN 1 0.67 - 0.87V Approx. 2.8V
ETC ACCEL SEN 2 0.33 - 0.43V Approx. 2.8V
ECM Input/Output Signal Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal Signal name At Idle At approx. 2,000 rpm
82 Sensor ground Approx. 0V
83 Accelerator pedal position sensor 2 ground Approx. 0V
90 Accelerator pedal position sensor 1 power supply Approx. 5V
91 Accelerator pedal position sensor 2 power supply Approx. 5V
98 Accelerator pedal position sensor 2 (*) 0.33 - 0.43V Approx. 1.4V
106 Accelerator pedal position sensor 1 0.67 - 0.87V Approx. 2.8V
When the accelerator pedal is depressed slowly from the fully-
closed position, the voltage must increase in proportion to the
opening of the throttle. [Ignition switch ON (engine stopped)]
Ignition switch ON with engine Ignition switch ON with engine
Terminal Signal name stopped Accelerator pedal is fully stopped Accelerator pedal is fully
depressed released
98 Accelerator pedal position sensor 2 (*) 0.33 - 0.43V 2.2 - 2.3V
106 Accelerator pedal position sensor 1 0.67 - 0.87V 4.4 - 4.6V
(*): Accelerator pedal position sensor 2 signal (terminal 98) voltage is different from
DATA MONITOR display of SST because it is converted in ECM.
Circuit Diagram
ECM0309
EC-63
ACCELERATOR PEDAL POSITION SENSOR SYSTEM
Component Parts Inspection
ACCELERATOR PEDAL POSITION SENSOR 1, 2
(ACCELERATOR WORK UNIT)
Check voltage between ECM terminal 98, 106 and ground.
Refer to EC section, “ECM Input/Output Signal Specifications” for
the voltage.
CAUTION:
• Do not apply voltage to accelerator pedal position sensor
terminal.
• Do not disassemble accelerator work unit.
• When replace accelerator pedal assembly or disconnect
connector of accelerator pedal position sensor, perform
“Throttle Valve Closed Position Learning” after reinstall it.
EC-64
NEUTRAL SWITCH SYSTEM
NEUTRAL SWITCH SYSTEM
SST Data Monitor Display
Monitor item At neutral position or “P” range At except neutral position or “P” range
Neutral switch ON OFF
ECM Input/Output Signal Specifications
Check voltage between terminals shown below and ground using a
circuit tester.
Terminal Signal name At neutral position or “P” range At except neutral position or “P” range
102 PNP switch Approx. 0V Battery voltage (A/T)
Approx. 4.8V (M/T)
Circuit Diagram
EC-65
INTAKE AIR TEMPERATURE SENSOR SYSTEM
INTAKE AIR TEMPERATURE SENSOR SYSTEM
SST Data Monitor Display
Monitor item At idle At approx. 2,000 rpm
Intake air temperature sensor Values according to intake air temperature
ECM Input/Output Signal Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal Signal name At idle At approx. 2,000 rpm
34 Intake air temperature sensor signal Intake air temperature at 20°C (68°F): approx. 3.5V
Intake air temperature at 80°C (176°F): approx. 1.2V
Circuit Diagram
Component Parts Inspection
INTAKE AIR TEMPERATURE SENSOR (JOINED
WITH MASS AIR FLOW SENSOR)
Check resistance between intake air temperature sensor (mass air
flow sensor connector) terminals 1 and 2.
Resistance
Intake air temperature at approx. 20°C (68°F):
Approx. 2.5 k
Intake air temperature at approx. 80°C (176°F):
Approx. 0.3 k
ECM0312
EC-66
STOP LAMP SWITCH SYSTEM
STOP LAMP SWITCH SYSTEM
SST Data Monitor Display
Monitor item At not depress brake pedal At depress brake pedal
Stop lamp switch OFF ON
ECM Input/Output Signal Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal Signal name At not depress brake pedal At depress brake pedal
101 Stop lamp brake switch signal Approx. 0V Battery voltage
Circuit Diagram
Component Parts Inspection
STOP LAMP SWITCH
Check resistance between stop lamp switch connector terminals 1
and 2.
When not depress brake pedal: Continuity not exist.
When depress brake pedal: Continuity exist.
EC-67
ELECTRICAL LOAD SWITCH SYSTEM
ELECTRICAL LOAD SWITCH SYSTEM
SST Data Monitor Display
Monitor item At head lamp switch to OFF At head lamp switch to ON
Electrical load signal OFF ON
ECM Input/Output Signal Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal Signal name At head lamp switch to OFF At head lamp switch to ON
84 Head lamp switch signal Approx. 0V Battery voltage
Circuit Diagram
EC-68
IGNITION SYSTEM
IGNITION SYSTEM
SST Data Monitor Display
Monitor item At idle after warming up At approx. 2,000 rpm
IGN TIMING Approx. 10°BTDC 35 - 45°BTDC
ECM Input/Output Signal Specifications
Check waveform between terminals shown below and ground using
an oscilloscope.
NOTE:
Numerical values (reference values) are obtained using an analog
circuit tester.
Terminal Signal name At cranking At idle after warming up At approx. 2,000 rpm
62 Ignition signal (power Approx. 0.5V Approx. 0.5V Approx. 0.9V
transmission drive
signal)
ECM0317 ECM0318 ECM0319
Circuit Diagram
Component Parts Inspection
SPARK PLUG
• Check electrode for dirt, damage, and wear and insulator for
damage.
• Make sure that the spark plug gap is normal, using a feeler
gauge.
Spark plug gap:
0.8 - 0.9 mm (0.031 - 0.035 in)
• Replace spark plug if necessary.
CAUTION:
• Check terminals for looseness.
ECM0321
• Check insulator for cracks or damage.
• Check for contamination by oil, water, and dust.
EC-69
FUEL INJECTOR SYSTEM (GASOLINE)
FUEL INJECTOR SYSTEM (GASOLINE)
SST Data Monitor Display
Monitor item At idle after warming up At approx. 2,000 rpm
INJ PULSE 4 - 6 msec
ECM Input/Output Signal Specifications
Check waveform between terminals shown below and ground using
an oscilloscope.
NOTE:
Numerical values (reference values) are obtained using an analog
circuit tester.
Terminal Signal name At cranking At idle after warming up At approx. 2,000 rpm
21 Injector drive signal Approx. 10.5V Battery voltage Relatively lower than battery
22 voltage
23
40
41
42
ECM0324 ECM0325
ECM0326
Circuit Diagram
Component Parts Inspection
INJECTOR
Check resistance between each cylinder injector terminals 1 and 2.
Standard resistance (all cylinders):
Approx. 14.5; (at room temperature)
ECM0328
EC-70
FUEL PUMP SYSTEM
FUEL PUMP SYSTEM
SST Data Monitor Display
Monitor item At fuel pump stop At fuel pump operating
Fuel pump OFF ON
ECM Input/Output Signal Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal Signal name At approx. 1 second after IGN switch to ON At cranking and engine running
113 Fuel pump relay control signal Approx. 1V (after 1 second: battery voltage) Approx. 1V
Circuit Diagram
Component Parts Inspection
FUEL PUMP
Check resistance between terminals 3 and 6.
Resistance:
Approx. 1 (at room temperature)
EC-71
THROTTLE CONTROL MOTOR SYSTEM
THROTTLE CONTROL MOTOR SYSTEM
ECM Input/Output Signal Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal Signal name At idle after warming up At approx. 2,000 rpm
4 Throttle control motor 2 (Close) Approx. 2 - 2.5V
5 Throttle control motor 1 (Open) Approx. 0.1 - 0.15V
Circuit Diagram
ECM0331
Component Parts Inspection
ELECTRIC THROTTLE CONTROL MOTOR
(ELECTRIC THROTTLE CONTROL ACTUATOR
ASSEMBLY)
Check resistance between electric throttle control motor (throttle
position sensor connector) terminals 3 and 6.
Resistance: Approx. 1 - 15; [at 25°C (77°F)]
CAUTION:
• Make sure that there is no moisture around connector
when removing and installing throttle position sensor
ECM0332 connector. If there are any water drops, completely wipe
them off.
• Do not apply voltage to electric throttle control motor
terminal.
• Perform “Throttle Valve Closed Position Learning” if
disconnecting connector.
• Do not disassemble electric throttle control actuator.
EC-72
HEATED OXYGEN SENSOR HEATER SYSTEM
HEATED OXYGEN SENSOR HEATER SYSTEM
SST Data Monitor Display
Monitor item At idle after warming up
HO2S1 MTR ON
ECM Input/Output Signal Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal Signal name At idle after warming up
24 Heated oxygen sensor heater open signal Approx. 0.3V
Circuit Diagram
ECM0334
Component Parts Inspection
HEATED OXYGEN SENSOR HEATER
Check resistance between heated oxygen sensor terminals 2 and 3.
Resistance: Approx. 1 - 1.5
EC-73
LPG INJECTOR SYSTEM
LPG INJECTOR SYSTEM
ECM Input/Output Signal Specifications
Check waveform between terminals shown below and ground using
an oscilloscope.
Terminal signal Description Measurement condition Measured value
117 LPG injector No. 2 Battery voltage
(power supply) Time axis may change according to
setting data and driving condition.
119 LPG injector No. 1
(power supply)
114 LPG injector No. 2 (-) Battery voltage
Time axis may change according to
setting data and driving condition.
120 LPG injector No. 1 (-)
Inspection
LPG INJECTOR
• Check resistance between terminals 1 and 2.
Resistance:
Approx. 1(at room temperature)
• Remove fuse cover, and then check fuse for open.
CAUTION:
Do not apply voltage to LPG injector.
EC-74
LPG ASSISTANCE INJECTOR SYSTEM
LPG ASSISTANCE INJECTOR SYSTEM
ECM Input/Output Signal Specifications
Check voltage between terminals shown below and ground using a
circuit tester.
Terminal Signal name At Idle
11 LPG assistance injector Battery voltage
Circuit Diagram
Component Parts Inspection
• Check resistance between LPG assistance injector terminals 1
and 2.
Resistance:
Approx. 27(at room temperature)
• Apply battery voltage directly to terminals 1 and 2, and then
check solenoid operation.
Battery voltage applied:
Continuity should exist.
No voltage:
Continuity should not exist.
ECM0123
EC-75
LPG FUEL PRESSURE SENSOR SYSTEM
LPG FUEL PRESSURE SENSOR SYSTEM
ECM Input/Output Signal Specifications
Check voltage between terminals shown below and ground using a
circuit tester.
Terminal Signal name At Idle
31 LPG fuel pressure sensor 0.78V
Circuit Diagram
EC-76
LPG INTERCEPTION VALVE SYSTEM
LPG INTERCEPTION VALVE SYSTEM
SST Data Monitor Display
Monitor item At engine stop At engine running
MAIN CUT RELAY OFF ON
ECM Input/Output Signal Specifications
Check voltage between terminals shown below and ground using a
circuit tester.
Terminal Signal name At engine stop At engine running
112 Main cut relay Approx. 0V Battery voltage
Circuit Diagram
EC-77
FUEL CONTROL CHANGING SWITCH SYSTEM
FUEL CONTROL CHANGING SWITCH SYSTEM
SST Data Monitor Display
Monitor item At neutral At gasoline mode At LPG mode
FUEL SW 1 OFF OFF ON
FUEL SW 2 OFF ON OFF
ECM Input/Output Signal Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal Signal name At neutral At gasoline mode At LPG mode
70 FUEL SW 1 Approx. 0V Approx. 0V Approx. 5V
32 FUEL SW 2 Approx. 0V Approx. 5V Approx. 0V
Circuit Diagram
EC-78
PCV GAS RESTORATION DEVICE
PCV GAS RESTORATION DEVICE
System Diagram
Removal and Installation of PCV Valve
1. Remove and install PCV hose.
2. Remove and install PCV valve.
PCV Valve Inspection
• Hissing noises should be heard from the air passage of the
valve.
• Check continuity when blowing/sucking air to/from PCV valve
rocker cover side.
Blowing air: Air flow exists
Sucking air: No air flow
ECM0353
EC-79
FUEL CUT FUNCTION
FUEL CUT FUNCTION
Inspection Procedure
WITH SST
1. Check “INJ PULSE-B1” (gasoline) or “LPG INJ PULSE” (LPG)
in DATA MONITOR menu, and increase the engine speed to
approximately 2,400 rpm after warming up engine.
2. Make sure that when the acceleration pedal is released, “INJ
PULSE-B1” (gasoline) or “LPG INJ PULSE” (LPG)
instantaneously drops.
EC-80
ECM COMPONENTS
ECM COMPONENTS
ECM
REMOVAL AND INSTALLATION
1. Disconnect ECM connector.
2. Remove ECM.
3. Install in the reverse order of removal.
CAUTION:
• Perform “Throttle Valve Closed Position Learning and Idle
Air Volume Learning” after installation if replacing ECM.
• Check pin for bend and damage when installing ECM.
Crankshaft Position Sensor (Integrated Into
the Distributor)
REMOVAL AND INSTALLATION
Refer to EM section, “Removal and Installation”.
Mass Air Flow Sensor
REMOVAL AND INSTALLATION
1. Remove harness connector.
2. Remove mass air flow sensor assembly from air horn.
Engine Coolant Temperature Sensor
REMOVAL AND INSTALLATION
1. Disconnect radiator drain plug, and drain coolant.
CAUTION:
Make sure to drain when the coolant temperature is cold.
2. Remove harness connector.
3. Remove coolant temperature sensor using a socket specially
designed for removing and installing coolant temperature
sensors [commercially available: thermosensor socket
manufactured by KTC (part No.: B20T-19)] and similar parts.
ECM0392
EC-81
ECM COMPONENTS
Heated Oxygen Sensor (With Heated Oxygen
Sensor Heater)
REMOVAL AND INSTALLATION
1. Remove harness connector from heated oxygen sensor.
2. Remove heated oxygen sensor using a socket designed for
heated oxygen sensor removal and installation (SST).
CAUTION:
Handle it carefully and avoid impacts.
Throttle Position Sensor (Electric Throttle
Control Actuator Assembly)
REMOVAL
1. Remove air duct from air horn.
2. Remove harness connector.
CAUTION:
Also, remove harness connectors of mass air flow sensor, LPG
injector, and LPG fuel pressure sensor so that when removing
and installing air horn, LPG injection holder (LPG and
Combined) is performed at the same time.
3. Loosen bolts diagonally, remove air horn, LPG injection holder
(LPG or Combined) or air horn spacer (Gasoline), and then
remove electric throttle control actuator.
INSTALLATION
Caution for installation
Uniformly tighten bolts diagonally in several steps.
CAUTION:
• Make sure that there is no moisture around connector
when removing and installing throttle position sensor
connector. If there are any water drops, completely wipe
them off.
• Do not apply voltage to throttle position sensor terminal.
• Perform “Throttle Valve Closed Position Learning” if
disconnecting connector.
• Do not disassemble electric throttle control actuator.
EC-82
ECM COMPONENTS
LPG Injector Holder
REMOVAL
1. Remove air duct from air horn.
2. Remove harness connectors of mass air flow sensor, LPG
injector, and LPG fuel pressure sensor.
3. Loosen bolts in turn, remove air horn, and then remove injector
holder.
INSTALLATION
Caution for installation
• Uniformly tighten bolts diagonally in several steps.
CAUTION:
• Make sure that there is no moisture around connector
when removing and installing each connector. If there are
any water drops, completely wipe them off.
• Do not apply voltage to each terminal.
EC-83
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Standard, Repair Limit
Fuel pressure [kPa (bar, kg/cm2, psi)] 353 (3.53, 3.6, 51)
Idle speed (rpm) N position 675±50
Ignition timing (°BTDC/rpm) N position 10±2/675
Firing order 1-5-3-6-2-4
Spark plug Manufacturer/type/gap [mm (in)] NGK/BPR4ES-D or BPR4ES-H/[0.8 - 0.9 (0.31 - 0.35)]
Ignition advance device Electronically controlled ignition advance
Density of CO at idle speed (%) /Density of HC at idle speed (ppm) 0.1/50 or less
EC-84
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