5l-e Engine Eletrical

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FOREWORD TOYOTA MOTOR CORPORATION

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TO MODEL INDEX

This supplement has been prepared to provide information covering general service repairs 5L-E for the 2000 TOYOTA MOTOR CORPORATION Engineequipped on the TOYOTA HILUX. A ll rights reserved. T hisCD may not be e r pr o-

ducedor copied, in whole or in part, withoutthe Applicable models:LN147, 152, 157, 167, 172, 192 series written permissionof Toyota Motor Corporation. FirstPrinting: J ul. 21, 2000 01--000721--00

Pleasenote thatthepublicationsbelowhave alsobeenpreparedas relevantservicemanualsforthecomponents and system in this engine. Manual Name

Pub.No.

S 2L, 3L EngineRepair Manual

RM520E

S 2L, 2L--T, 3L,5L Engine Repair Manual Supplement (Aug.,1997)

RM582E

All informationin this manual is based on thelatestproduct informationatthe time of publication. However, specifications and procedures are subjectto change without notice.

CAUTION This manual does notinclude all the necessaryitems aboutrepair and service. This manualismade for the purpose of the use for the persons who have special techniques and certifications. In the casesthatnon--specializedoruncertifiedtechnicians performrepairorserviceonlyusingthismanual or withoutproper equipment or tool, that maycause severe injury to you or other people around and also cause damage to your customer’s vehicle. In order to prevent dangerous operationand damages to your customer’s vehicle, besure to follow the instruction shown below. S

Mustreadthis manual thoroughly. Itis especiallyimportantto havegoodunderstandingallthe contents written in the PRECAUTION of ”IN”section.

S

Theservicemethod writteninthis manual is veryeffective to performrepairand service.When performingtheoperations followingtheproceduresusingthismanual,besureto usetoolsspecifiedand recommended. If using non--specifiedor recommended tools and service method, be sure to confirm safety of the technicians and any possibility of causing personal injury or damage to the customer’s vehiclebefore starting the operation.

S

par If treplacementisnecessary, mustreplacethepartwiththesame partnumberorequivalent part. Do not replace it with inferior quality.

S

Itis important to note that this manual contains various ”Cautions”and ”Notices”that mustbe carefully observedin order to reduce the risk of personal injuryduring serviceorrepair, orthe possibility thatimproperservice orrepairmaydamage thevehicleorrenderitunsafe. Itis also important to understand that these ”Cautions”and ”Notices”are not exhaustive, because itis important to warn ofallthepossible hazardous consequences that mightresult fromfailureto follow theseinstructions.

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MAIN INDEX: HILUX.

SUPPLEMENT: 5L-E ENGINES October 2000

INTRODUCTION PREPARATION SERVICE SPEC IFICATIONS DIAGNOSTICS ENGINE MECHANICAL EMISSION CONTROL ELECTRONIC CONTROL DIESEL ENGINE FUEL ALPHABETICAL INDEX

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INTRODUCTION HOW TO USE THIS MANUAL .............

IN--1

GENERAL INFORMATION . . . . . . . . . . . . . . . . . .

IN--1

IDENTIFICATION INFORMATION..........

IN--3

ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . .

IN--3

REPAIR INSTRUCTIONS .................

IN--4

FOR ALL OF VEHICLES ..................

IN--7

GENERAL INFORMATION . . . . . . . . . . . . . . . . . .

IN--4

PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IN--7

HO WTOT RO UB LE S HO O TE CUCO NT RO LLE D SYSTEMS ............................

IN--8

GENERAL INFORMATION . . . . . . . . . . . . . . . . . .

IN--8

HOW TO PROCEED WITH TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . .

IN--9

HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE . . . . . . . . . . . . . . .

TERMS ................................. ABBREVIATIONS USED IN THIS MANUAL . . . .

IN--19

IN--24 IN--24

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IN--1 INTRODUCTION --

HOW TO USE THIS MANUAL

HOWTOUSETHISMANUAL IN01F--07

G E N E RALI NFORMATI ON 1 . I NDE  X An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the Section Title and major heading are given at the top of every page. 2 . G E NE  RALDE S CRI P T I O N At the beginning of each section, a General Description is given that pertains to all repair operations contained in that section. Read these precautions before starting any repair task. 3. TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the cause. The fundamentals of how to proceed with troubles hooting are descri bed on page IN--8. Be sure to read this before performing troubleshooting. 4. PREPARATION Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Special Service Materials) which should be prepared before beginning the operation and explains the purpose of each one. 5 . RE PAI RP RO CE  DURE S Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: Drive Rotor z

Oil Pump Oil Seal

Oil Pump Pulley

Driven Rotor

47 (475, 34)

Oil Pump Body

Relief Valve z

Crankshaft Front Oil Seal Spring

z

N∙m (kgf∙cm, ft∙lbf) : Specified torque Non--reusable part

z

Gasket Plug P08000

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IN--2 INTRODUCTION -- HOW TO USE THIS MANUAL

The procedures are presented in a step--by--step format: S The illustration shows what to do and where to do it. S The task heading tells what to do. S The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example: Task heading : what to do

21. CHECK PISTON STROKEOF OVERDRIVE BRAKE (a) Place and a dial indicator onto theover drive brake PistonSST as shown in theillu stration. SST 09350--30020 (09350--06120) Illustration: what to do and where

Set part No. Detai led text :

Com ponent part No. how to do task

(b) Measurethe stroke applying and releasing the compressed air (392 — 785 kPa, 4 — 8 kgf/cm2 or 57 — 114 psi) as shown in the illustration. Piston stroke: 1.40 — 1.70 mm (0.0551 — 0.0669 in.) Specification

This format provides the experienced technician with a FAST TRACK to the information needed. The upper case task heading can be read at a glance when necessary, and the text below it provides detailed information. Important specifications and warnings always stand out in bold type. 6 . RE FE RE  NCE S References have been kept to a minimum. However, when they are required you are given the page to refer to. 7. SPECIFICATIO NS Specifications are presented in bold type throughout the text where needed. You never have to leave the procedure to look up your specifications. They are also found in Service Specifications section for quick reference. 8 . CAUTI O NS ,NO TI CE S ,HI NTS : S CAUTIONS are presented in bold type , and indicate there is a possi bility of injury to you or ot her people. S NOTICES are also pre sented in bold type, and indi cate the possibility of damage to the comp onents being repaired. S HINTS are separated fro m the text but do not appear in bol d. They provide additional information to help you perform the repair efficiently. 9 . S IUNI T The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the English System. Example:

Torque: 30 N m (310 kgf cm, 22 ft lbf) ∙

5L--E ENGINE SUP (RM817E)

∙

∙

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IN--3 INTRODUCTION -- IDENTIFICATION INFORMATION

IDENTIFICATIONINFORMAT ION IN01G--07

E NGI NES E RI ALNUM BE R The engine serial number is stamped on the engine block as shown.

B05491

5L--E ENGINE SUP (RM817E)

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IN--4 INTRODUCTION -- REPAIR INSTRUCTIONS

REPAIRINSTRUCTIONS IN01H--02

GE NE RALI NF O RM AT I O N

P23717

BAS I CRE PAI RHI NT (a) Use fend er, seat and fl oor co vers to kee p the veh icle clean and prevent damage. (b) During disassembly, keep parts in the appropriate order to facilitate reassembly. (c) Observe the following: (1) Before performing electrical work, disconnect the negative (--) terminal cable from the battery. (2) If it is ne cessary to dis connect the bat tery for i nspection or repair, always disconnect the negative (--) terminal cable which is grounded to the vehicle body. (3) To prevent damage to the battery terminal, loosen the cable nut and raise the cable straight up without twisting or prying it. (4) Clean the battery terminals and cable ends with a clean shop rag. Do not scrape themwi th a file oroth er abrasive objects. (5) Install the cable ends to the battery terminals with the nut loose, and tighten the nut after installation. Do not use a hammer to tap the cable ends onto the terminals. (6) Be sure the cover for the po sitive (+) terminal is properly in place. (d) Check hose and wiring connectorsto make sure that they are secure and correct. (e) Non--reusable parts (1) Always replace cotter pins, gaskets, O--rings and oil seals etc. with new ones. (2) Non--reusable parts are indicated in the component illustrations by the ” z ” symbol. (f) Precoated parts Precoated parts are bolts and nuts, etc. that are coated with a seal lock adhesive at the factory. (1) If a pre coated pa rt is r etighte ned, loo sened or caused to move in any way, it must be recoated with the specified adhesive. (2) When reusing precoated parts, cl ean off the old adhesive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads. (3) Precoated parts are indicated in the component illustrations by the ” L ” symbol. (g) When nec essary, use a sealer on gas kets to prev ent leaks. CONTINUED

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IN--5 INTRODUCTION -- REPAIR INSTRUCTIONS

(h) (i)

Medium Current Fuse and High Current Fuse Equal AmperageRating

(j)

Carefully observe all specifications for bol t tightening torques. Always use a torque wrench. Use of special service tools (SST) andspec ial service materials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure. A list of SST and SSM can be found in the preparation part at the front of each section in this manual.

When replacing fuses, be sure the new fuse has the correct amperage rating. DO NOT exceed the rating or use one with a lower rating.

BE1367

Illustration

Symbol

Part Name

Abbreviation

FUSE

FUSE

MEDIUM CURRENT FUSE

M--FUSE

HIGH CURRENT FUSE

H--FUSE

FUSIBLE LINK

FL

CIRCUIT BREAKER

CB

V00076

(k)

Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations. (1) If the vehicle is to be jacked up only at the front or rear end, be sure to block the wheels at theoppo site end in order to ensure safety. (2) After the vehicle is jacked up, be sure to support it on stands. It is extremely dangerous to do any work on a vehicle raised on a jack alone, even for a small job that can be finished quickly.

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IN--6 INTRODUCTION -- REPAIR INSTRUCTIONS

(l)

WRONG

Observe the following precautionsto avoid damage to the following parts: (1) Do not open the co ver or case of th e ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.)

(2)

CORRECT

(3) (4)

(5) IN0253

WRONG

(6)

CORRECT

(7)

(8)

IN0252

(m)

Example

(n)

To disconnect vacuum hoses, pull on the end, not the middle of the hose. To pull apart electrical connectors, pull on the connector itself, not the wires. Be careful not to drop electrical components, such as sensors or relays. If they are dropped on a hard floor, they should be replaced and not reused. When steam cleaning an engine, protect the electronic components, air filter and emissions--related components from water. Never use an im pact wrench to rem ove or ins tall temperature switches or temperature sensors. When checking continuity at the wire connector, insert the tester probe carefully to prevent terminals from bending. When using a vacuum gauge, never force the hose onto a connector that is too large. Use a step--down ada pte r in ste ad. Onc e the hos e has been stretched, it may leak.

Tag hoses before disconnecting them: (1) When disconnecting vacuum hoses, use tags to identify how they should be reconnected. (2) After completing a job, double check that the vacuum hoses are properly connected. A labelunderthe hood shows the proper layout. Unless otherwise stated, all resistance is measured at an ambient temperature of 20 C (68 F). Because the resistance may be outside specifications if measured at high temperatures immediately after the vehicle has been running, measurements should be made when the engine has cooled down. ˚

IN0002

5L--E ENGINE SUP (RM817E)

˚

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IN--7 INTRODUCTION -- FOR ALL OF VEHICLES

FORALLOFVEHICLES IN01I--01

PRECAUTION 1. FORVEHICLESEQUIP PEDWITHACATALYTICCONVERTER CAUTION: If large amounts of unburned gasoline flow into the converter, it may overheat and create a fire hazard. To preve nt this, obser ve the following precautions and explain them to your customer. (a) Use only unleaded gasoline (b) Avoid prolonged idling Avoid running the engine at idle speed for more than 20 minutes. (c) Avoid spark jump test (1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible. (2) While testing, never race the engine. (d) Avoid prolonged engine compression measurement Engine compression tests must be done as rapidly as possible. (e) Do not run engine when fuel tank is nearly empty This may cause the engine to misfire and create an extra load on the converter. (f) Avoid coasting with ignition turned off and prolonged braking (g) Do not dispose of used catalyst along with parts contaminated with gasoline or oil 2. IFVEHICLEISEQUIPPEDWITHMOBILECOMMUNICATIONSYSTEM For vehicles with mobile communication systems such as two--way radios and cellular telephones, observe the following precautions. (1) Install the antenna as far as possible away from the ECU and sensors of the vehicle’s electronic system. (2) Install the antenna feeder at least 20 cm (7 .87 in.) a way from the ECU an d sensors of the vehicle’s electronics systems. For details about ECU and sensors locations, refer to the section on the applicable component. (3) Do not wind the antenna feeder together with the other wiring. As much as possible, also avoid running the antenna feeder parallel with other wire harnesses. (4) Confirm that the antenna and feeder are correctly adjusted. (5) Do not install powerful mobile communications system. 3 . FO RUS I NGHAND -- HE LDTE S T E R CAUTION: Obser ve the following for saf ety reasons: Before using the hand--h eld tester, the hand--h eld tester ’s operator manual should be rea d S throughly. Be sure to route all ca bles securely when driving with the hand--he ld tester connec ted to the S vehicle. (i.e. Keep cables aw ay from fee t, pedals , stee ring whee l and shift leve r.) S Two persons are required when test driving with the hand--he ld tester, one person to drive the vehicle and one person to operate the hand--he ld tester.

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HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

HOWTOT ROUBLESHOOTECUCONTROLLEDSYSTEMS IN01J--06

GE N E RALI NFORMATI ON A large number of ECU controlled systems are used in the HILUX. In general, the ECU controlled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of these systems is not complex. If you have adequate understanding of the system and a basic knowledge of electricity, accurate diagn osis and necessary repair can be performed to locate and fix the problem. This manual is designed through emphasis of the above standpoint to help service technicians perform accurate and effective troubleshooting, and is compiled for the following major ECU controlled systems: System Engine

Page I -- 1

D

The troubleshooting procedure and how to make use of it are described on the following pages. FO  RUS I NGHAND -- HE LDTE S T E R S Before using the hand--held tester, the hand--held tester’s operator manual should be read throughly. S If the hand--held tester cannot communicate with ECU controlled systems when you have connected the cable of the hand--held tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. (1) If communication is normal when the tool is connected to another vehicle, inspect the diagnosis data link line (Bus  line) or ECU power circuit of the vehicle. (2) If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so perform the Self Test procedures outlined in the Tester Operator’s Manual.

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IN--9

HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

IN01K--07

HOWTOP ROCE E DWI T HT ROUBL E S HOOT I NG Carry out troubleshooting in acc ordance with the procedure on the following page. Here, only the basic procedure is shown. Detail s are provided in each section, showi ng the most effective methods for each circuit. Confirm the troub leshooting proc edures first for the relevant circuit before begin ning troubleshooting of that circuit. Vehicle Brought Workshop

1

2

1 Ask the customer about the conditions and the environment when the problem occurred.

Customer Problem Analysis

Symptom Confirmation and Diagnostic Trouble Code Check

3 Symptom Simulation 2, 3 Confirm the symptoms and the problem conditions, and check the diagnostic trouble codes. (When the problem symptoms do not appear during confirmation, use the symptom simulation method described later on.)

4

Diagnostic Trouble Code Chart

5

Matrix Chart of Problem Symptoms

6

Circuit Inspection or Parts Inspection

7

Repair

8

Confirmation Test

End

4, 5, 6 Check the results obtain in Step 2, then confirm the inspection procedure for the system or the part which should be checked using the diagnostic trouble code chart or the matrix chart of problem symptoms. 7 Check and repair the affected system or part in accordance with the instructions in Step 6. 8 After completing repairs, confirm that the problem has been eliminated. (If the problem is not reproduced, perform the confirmation test under the same conditions and in the same environment as when it occurred for the first time.)

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IN--10

INTRODUCTION --

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HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

1 . CUS TO ME RP RO  BLE MANALY S I S In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time it occurred. Important Point in the Problem Analysis : The following 5 items are important points in the problem analysis. Past problems which are thought to be unrelated andthe repair history, etc. may also help in some cases, so as much information as possible should be gathered and its relationship with the problem symptoms should be correctly ascertained for reference in troubleshooting. A customer problem analysis table is provided in the troubleshooting section for each system for your use. Important Points in the Customer Problem Analysis D What

---------- Vehicle model, system name

D When ---------- Date, time, occurrence frequency D Where

---------- Road conditions

D Under what conditions? ---------- Running conditions, driving conditions, weather conditions D How did it happen? ---------- Problem symptoms

(Sample) Engine control system check sheet.

CUSTOMER PROBLEM ANALYSIS CHECK ENGINE CONTROL SYSTEM Check Sheet

Inspector’s Name

Customer’s Name

Model and Model Year

Driver’s Name

Frame No.

Data Vehicle Brought in

Engine Model

License No.

Odometer Reading

s m o t p m y S m e l b o r P

Engine does not Start

E n gi n ed oesn o tc ran k

Difficult to Start

Engine cranks slowly Other

Poor Idling

I n c o r r e ct f i r st i d l e I dli n g r pm i s ab n o rm al Ro u ghi dli n g O t h er

Poor Drive ability

He s i t at i o n Kn ockin g

Engine Stall

S oo n af t er st ar t in g A f t er acceler at o r pedal depr essed A f t e r ac ce l e r at o r p e d al r el eas e d D u r in g A/ C oper at i on S hi f t in gf r omNt oD O t h er

B ackf i re O t h er

Noi n i t ialc o mb u st io n

Hi g h (

Mu f f lere xp lo si on( af t er -- f ir e)

Others

Datas Problem C o n st an t

S o m et i mes(

t im esp er

d ay/ m o n t h )

CONTINUED 5L--E ENGINE SUP (RM817E)

km miles Noc om p let ec om bu st i on

r pm )

Low (

S u r gi n g

rp m )

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IN--11

HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

2 . S Y MP TO MCO NFI RMATI O NANDDI AG  NO S T I CTRO UBLECO DECHE CK The diagnostic system in the HILUX fulfills various functions. The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during troubleshooting. Another function is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly. By using these ch eck functions, the problem areas can be narrowed down quickly and troubleshooting can be performed effectively. Diagnostic functions are incorporated in the following systems in the HILUX. System

Diagnostic Trouble

Input Signal Check

Other Diagnosis

Code Check

(Sensor Check)

Function

f

Engine

f

Diagnostic Test Mode

(with Check Mode)

In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diagnostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition, it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic trouble code is directly related to t he problem symptom or not. For this reason, the diagnostic trouble codes should be checked before and after the symptom confirmation to determine the current conditions, as shown in the table below. If this is not done, it may, depending on the case, result in unnecessary troubleshooting for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble code check. DI AG NO S T I CT RO UBL ECO DECHE CKP RO CE DURE Diagnostic Trouble C o d e C h e c k ( M ak e a

Confirmation of Symptoms

Diagnostic Trouble Code Check

note of and then clear) Problem symptoms Same diagnostic Diagnostic Trouble exist troub le code is Code Display displayed Normal code is displayed

No problem symptoms exist Normal Code Display

Problem is still occurring in the diagnostic circuit The problem is still occurring in a place other than in the diagnostic circuit. (The diagnostic trouble code displayed first is either for a past problem or it is a secondary problem.) The problem occurred in the diagnostic circuit in the past.

Problem symptoms Normal code is exist displayed No problem symptoms exist

Problem Condition

Normal code is displayed

The problem is still occurring in a place other than in the diagnostic circuit. The problem occurred in a place other than in the diagnostic circuit in the past.

CONTINUED

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HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

Taking into account the above points, a flow chart showing how to proceed with troubleshooting using the diagnostic trouble code check is shown below. This flow chart shows how to utilize the diagnostic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms.

Diagnostic trouble code check

Making a note of and clear ing of the diagnostic trouble codes displayed

Symptom confirmation Problem symptoms exist

No problem symptoms exist

Simulation test using the symptom simulation methods

Diagnostic trouble code check

D Diagnostic trouble code displayed D Problem symptoms exist

D Normal code displayed D Problem symptoms exist

Troubleshooting of problem indicated by diagnostic trouble code

Troubleshooting of each problem symptom

D Normal code displayed D No problem symptoms exist

System Normal If a diagnostic trouble code was displayed in the initial diagnostic trouble code check, it indicates that the trouble may have occurred in a wire harness or connector in that circuit in the past. Therefore, check the wire harness and connec t or s( S eepageI N -- 19) .

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HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

IN--13

3. SYMPTOMSIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer’s vehicle. No matter how much experience a technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem symptoms he will tend to overlook something important in the repair operation and make a wrong guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the engine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the problem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill. Since vibratio n, heat or water penetrati on (moisture) are likely causes for problems which are difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the external causes are applied to the vehicle in a stopped condition. Important Points in the Symptom Simulation Test: In the symptom simulation test, the problem symptoms should of course be confirmed, but the pro blem area or parts must also be found out. To do this, narrow down the possible problem circuits according to the symptoms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation test, judging whether the circuit being tested is defective or normal and also confirming the problem symptoms at the same time. Refer to the matrix chart of problem symptoms for each system to narrow down the possible causes of the symptom.

1

V I BRAT I O NM E T HO D:W h envi b rat i o nseemst ob et h emaj o rcau se.

CONNECTORS Slightly shake the connector vertically and horizontally.

Shake Slightly WIRE HARNESS Slightly shake the wire harness vertically and horizontally. The connector joint, fulcrum of the vibration, and body through portion are the major areas to be checked thoroughly.

Swing Slightly PARTS AND SENSOR

Vibrate Slightly

Apply slight vibration with a finger to the part of the sensor considered to be the problem cause and check if the malfunction occurs. HINT: Applying strong vibration to relays may result in open relays.

V07268

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5L-E

IN--14

2

INTRODUCTION --

HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

HE ATM E T HO D:W h ent h ep ro b l emseemst oo ccu rw h ent h esu sp ectareai sh eat ed .

Heat the component that is the likely cause of the malfunction with a hair dryer or similar object. Check to see if themalfu nction occurs. NOTICE: (1) Do not heat to more than 60 C (140 F). (Temperature limit that no damage is done to the component.) (2) Do not apply heat directly to parts in the ECU. ˚

3

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Malfunction

˚

h ent h emal f u n ct i o nseemst oo ccu ro narai n yd ayo ri na WAT ERSPRI NKL I NGMET HO D: W high -- humiditycondition.

Sprinkle water onto the vehicle and check to see if the malfunction occurs. NOTICE: (1) Never sprinkle water directly into the engine compartment, but indirectly change the temperature and humidity by applying water spray onto the radiator front surface. (2) Never apply water directly onto the electronic components. (Service hint) If a vehicle is subject to water leakage, the leaked water may contaminate the ECU. When testing a vehicle with a water leakage problem, special caution must be used. 4

O T HE R:W h enamal f u n ct i o nseemst oo ccu rw h enel ect ri call o adi sexcessi ve.

Tur nonallelec t r ic alloadsinc ludingt heheat erblower,head lights, rear window defogger, etc. and check to see if the malfunction occurs.

ON

V07469

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IN--15

4 . DI AG NO S T I CTRO UBLECO DECHART The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshooting using the diagnostic trouble codes displayed in the diagnostic trouble code check. Proceed with troubleshooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown below as an example. D DTC No.

Indicates the diagnostic trouble code. D Page or Instructions

D Trouble

Area Indicates the suspect area of the problem.

Indicates the page where the inspection procedure for each circuit is to be found, or gives instructions for checking and repairs. D Detection Item

Indicates the system of the problem or contents of the problem.

DTC CHART (SAE Controlled) HINT: Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument or other factors. If a malfunction code is displayed during the DTC check in check mode, check the circuit for that code listed in the table below. For details of each code, turn to the page referred to under the ”See page” for the respective ”DTC No.” in the DTC chart. *1 Check Engine

DTC No. ( S eepage)

Detection Item

 oubleA r ea

Tr

Warming Light Nomal Mode/ Test Node

D Open

12*3 ( D I--12)

or short in NE, G circuit

D IIA

G, NE Signal Circuit

D Open or short

in STA circuit

ON / N.A

D Engine ECU D Open

12*4 ( D I--28)

NE Signal Circuit

or short in NE circuit

D IIA D Open or short

in STA circuit

ON / N.A

D Engine ECU D Open

13 ( D I--31)

NE Signal Circuit

14 ( D I--32)

Ignition Signal Circuit

or short in NE circuit

D IIA

ON / N.A

D Engine ECU DOpen orshortin

IGFor IGTcircu it from IIA toengineECU

D Igniter

ON / N.A

D Engine ECU D Oxygen

sensor circuit

D Oxygen sensor

CONTINUED

5L--E ENGINE SUP (RM817E)

*Memory

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IN--16

INTRODUCTION --

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HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

5. PROBLEMSYMPTOMSTABLE The suspect circuits or parts for each problem symptom are shown in the table below. Use this table to troubleshooting the problem when a ”Normal” code is displayed in the diagnostic trouble code check but the problem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should be checked. HINT: When the problem is not detected by the diagnostic system even though the problem symptom is present, it is considered that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a system other than the diagnostic system. D Page

Indicates the page where the flow chart for each circuit is located. D Circuit Inspection, Inspection Order

Indicates the circuit which needs to be checked for each problem symptom. Check in the order indicated by the numbers.

D Circuit or D Problem

Symptom

Part Name Indicates the circuit or part which needs to be checked.

PROBLEM SYMPTOMS TABLE Symptom

See page

Suspect Area

Engine does not crank (Does not start)

1. Starter and starter relay

No initial combustion (Does not start)

1. EngineECU power sourcecircuit 2. Fuel pump control circuit

ST--12, 13

3. Engine ECU

DI--124 DI--127 IN--30

No complete combustion (Does not start)

1. Fuel pump control circuit

DI--127

Engine cranks normally (Difficult to start)

1. Starter signal circuit 2. Fuel pump control circuit 3. Compression

DI--121 DI--127 EM--3

Cold engine (Difficult to start)

1. Starter signal circuit 2. Fuel pump control circuit

DI--121 DI--127

Hot engine

1. Starter signal circuit 2. Fuel pump control circuit

DI--121 DI--127

High engine idle speed (Poor idling)

1. A/C signal circuit (Compressor circuit) 2. Engine ECU power source circuit

AC--54 DI--124

idling)

1. A/C signal circuit 2. Fuel pump control circuit 1. Compression 2. Fuel pump control circuit

CONTINUED

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IN--17

6 . CI RCUI TI NSPECTION How to read and use each page is shown below.

D Diagnostic

Trouble Code No. and Detection Item D Circuit

Description The major role and operation, etc. of the circuit and its component parts are explained.

DTC

Knock Sensor Circuit

52

CIRCUIT DESCRIPTION Knocksensor is fittedto thecylinder blockto detect engine knocking. Thissensor contains a piezoelectric elementwhich generates a voltage whenit becomes deformed,which occurswhen thecylinderblock vibratesdue toknocking.If engine knocking occurs, ignition timing is retarded to suppress it. DTCNo.

52

DetectionItem

TroubleArea

No knock sensor signal to ECM with engine speed, 1,200 rpm or more.

D Open

or short in knock sensor1 circuit

D Knock

sensor 1 (looseness)

D ECM

If theECM detects the above diagnosiscondition s, it operates thefall safe function in which thecorrectiv e retardangle value is set to the maximum value.

D Indicates the diagnostic trouble code, diagnostic

trouble code set parameter and suspect area of the problem.

WIRING DIAGRAM

D Wiring

ECM Knock Sensor GR

12 KNK E6 E1

Diagram This shows a wiring diagram of the circuit. Use this diagram together with ELECTRICAL WIRING DIAGRAM to thoroughly understand the circuit. Wire colors are indicated by an alphabetical code. B = Black, L = Blue, R = Red, BR = Brown, LG = Light Green, V = Violet, G = Green, O = Orange, W = White, GR = Gray, P = Pink, Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe.

CONTINUED

V08423

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INTRODUCTION --

HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

D Indicates the position of the ignition switch during the check.

D Inspection

Procedure Use the inspection procedure to determine if the circuit is normal or abnormal, and , if it is abnormal, use it to determine whether the problem is located in the sensors, actuators, wire harness or ECU.

ON

LOCK

Ignition Switch ON

Ignition Switch LOCK (OFF) START

ACC

Ignition Switch ACC

Ignition Switch START

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INSPECTION PROCEDURE 1

Check cont in uity between termin al KNK of EC M conn ector and body grou nd. PREPARATION:

LOCK

(a) Remove the glove compartment (See page FI--37). (b) Disconnect the E6 connector of ECM.

KNK

CHECK: Measure resistance between terminal KNK of ECU connector and body ground. E6 Connector

OK: Resistance: 1 MΩ or higher

AB0117 A00265

A00255

OK

Go to step 3.

NG 2

Check knock sensor (See page FI--34) . OK

Replace knock sensor.

D Indicates the place to check the voltage or resistance. D Indicates the connector position to checked, from the front or back side.

Wire Harness Check from the connector back side. (with harness)

Check from the connector front side. (without harness) In this case, care must be taken not to bend the terminals.

D Indicates the condition of the connector of ECU during the check.

KNK

KNK

E6 Connector

Connector being checked is connected.

E6 Connector

Connector being checked is disconnected. V08425

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IN--19 IN01L--06

HOWTOUS ETHEDI AGNOS TI C CHARTANDI NS P E CT I ON PROCEDURE 1 .

FI0046

FI0047

FI0048

CO NNE CTO RCO NNE CTI O NANDTE RMI NAL INSPECTION S For troubleshooting, diagnostic trouble code charts or problem symptom charts are provided for each circuit with detailed inspection procedures on the following pages. S When all the component parts, wire harnesses and connectors of each circuit except the ECU are found to be normal in troubleshooting, then it is determined that the problem is in the ECU. Accordingly, if diagnosis is performed without the problem symptoms occurring, the instruction will be to check and replace the ECU, even if the problem is not in the ECU. So always confirm that the problem symptoms are occurring, or proceed with inspection while using the symptom simulation method. S The instructions ”Check wire harness and connector” and ”Check and replace ECU” which appear in the inspection procedure, are common and applicable to all diagnostic trouble codes. Follow the procedure outlined below whenever these instructions appear. O P E NCI RCUI T: This could be due to a disconnected wire harness, faulty contact in the connector, a connector terminal pulled out, etc. HINT: S It is rarely the case that a wire is broken in the middle of it. Most cases occur at the connector. In particular, carefully check the connectors of sensors and actuators. S Faulty contact could be due to rusting of the connector terminals, to foreign materials entering terminals or a drop in the contact pressure between the male and female terminals of the connector. Simply disconnecting and reconnecting the connectors once changes the condition of the connection and may result in a return to normal operation. Therefore, in troubleshooting, if no abnormality is found in the wire harness and connector check, but the problem disappears after the check, then the cause is considered to be in the wire harness or connectors. S HO RTCI RCUI T: This could be due to a short circuit between the wire harness and the body ground or to a short inside the switch etc. HINT: When there is a short between the wire harness and body ground, check thoroughly whether the wire harness is caught in the body or is clamped properly.

CONTINUED 5L--E ENGINE SUP (RM817E)

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IN--20

INTRODUCTION --

Sensor Side

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2 . (a)

ECU Side

IN0379

ECU Side Sensor Side

CO NTI NUI TYCHE CK(O P E NCI RCUI TCHE CK) Disconnect the co nnectors at bot h ECU a nd se nsor sides. (b) Measure the resistance between the applicable terminals of the connectors. Resistance: 1 Ω or less HINT: S Measure the resistance while lightly shaking the wire harness vertically and horizontally. S When tester probes are inserted into a connector, insert the probes from the back. For waterproof connectors in which the probes cannot be inserted from the back, be careful not to bend the terminals when inserting the tester probes.

IN0378

3 . (a) (b)

ECU Side Sensor Side

IN0380

RE S I S TANCECHE CK(S HO  RTCI RCUI TCHE CK) Disconnect the connectors at both ends. Measure the resistance between the applicable terminals of the connectors and body ground. Be sure to carry out this check on the connectors on both ends. Resistance : 1 MΩ or higher HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 4 . (a) (b)

Pull Lightly Looseness of Crimping

IN0381

V I S UALCHE CKANDCO NTACTP RE S S URECHE CK Disconnect the connectors at both ends. Check for rust or foreign material, etc. in the terminals of the connectors. (c) Check crimped portions fo r looseness or damage and check if the terminals are secured in lock portion. HINT: The terminals should not come out when pulled lightly. (d) Prepare a test male terminal and insert it in the female terminal, then pull it out. NOTICE: When testing a gold--pl ated female terminal, always use a gold--plated male terminal. HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section.

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IN--21

5 . CO NNE CTO RHANDLI NG When inserting tester probes into a connector, insert them from the rea r of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good care not to deform the connector termina ls.

FI7187

Fig. 1 Sensor

6 . CHE CKO P E NCI RCUI T For the open circuit in the wire harness in Fig.1, perform ”(a) Continuity Check” or ”(b) Voltage Check” to locate the section.

ECU C OPEN B 1 1 1 2

2

A 1

2

2

Z17004

(a) Fig. 2 ECU Sensor

C

A

B

21

1 2

12

Z17005

Fig. 3

Sensor

C 1 2

B2 1 2

B1 1 2

A 1 2

ECU

Z17807

Check the continuity. (1) Disconnect connectors ”A” and ”C” and measure the resistance between them. In the case of Fig.2, Between terminal 1 of connector ”A” and terminal 1 of connector ”C” → No continuity (open) Between terminal 2 of connector ”A” and terminal 2 of connector ”C” → Continuity Therefore, it is found out that there is an open circuit between terminal 1 of connector ”A” and terminal 1 of connector ”C”. (2) Disconnect connector ”B” and measure the resistance between them. In the case of Fig.3, Between terminal 1 of connector ”A” and terminal 1 of connector ”B1” → Continuity Between terminal 1 of connector ”B2” and terminal 1 of connector ”C” → No continuity (open) Therefore, it is found out that there is an open circuit between terminal 1 of connector ”B2” and terminal 1 of connector ”C”.

CONTINUED

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HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

(b)

Fig. 4

0V 5V

Sensor C

1 2

B

5V

ECU

A

5V

1 1 2

2

Z17007

7 . CHE CKS HO  RTCI RCUI T If the wire harness is ground shorted as in Fig.5, locate the section by conducting a ”continuity check with ground”.

Fig. 5 C B SHORT 1 1 2 2

Check the voltage. In a circuit in which voltage is applied (to the ECU connector terminal), an open circuit can be checked for by conducting a voltage check. As shown in Fig.4, with each connector still connected, measure the voltage between body ground and terminal 1 of connector ”A” at the ECU 5V output terminal, terminal 1 of connector ”B”, and terminal 1 of connector ”C”, in that order. If the results are: 5V: Between Terminal 1 of connector ”A” and Body Ground 5V: Between Terminal 1 of connector ”B” and Body Ground 0V: Between Terminal 1 of connector ”C” and Body Ground Then it is found out that there is an open circuit in the wire harness between terminal 1 of ”B” and terminal 1 of ”C”.

A 1 2

Z17008

Fig. 6

ECU Sensor

C 1 2

B 1 2

A 1 2

Z17009

Check the continuity with ground. (1) Disconnect connectors ”A” and ”C” and measure the resistance between terminal 1 and 2 of connector ”A” and body ground. In the case of Fig.6 Between terminal 1 of connector ”A” and body ground → Continuity (short) Between terminal 2 of connector ”A” and body ground → No continuity Therefore, it is found out that there is a short circuit between terminal 1 of connector ”A” and terminal 1 of connector ”C”.

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IN--23

(2)

Fig. 7

Sensor

C 1 2

B2 1 2

B1 1 2

A 1 2

ECU

Z17808

Disconnect connector ”B” and measure the resistance between terminal 1 of connector ”A” and body ground, and terminal 1 of connector ”B2” and body ground. Between terminal 1 of connector ”A” and body ground → No continuity Between terminal 1 of connector ”B2” and body ground → Continuity (short) therefore, it is found out that there is a short circuit between terminal 1 of connector ”B2” and terminal 1 of connector ”C”. 8 . CHE CKANDRE P L ACEE CU First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty, so replace the ECU with a known good one and check if the symptoms appear.

(1)

Measure the resistance between the ECU ground terminal and the body ground. Resistance: 1 Ω or less

Example Ground

IN0383

(2)

ECU Side

Ground W/H Side Ground IN0384

5L--E ENGINE SUP (RM817E)

Disconnect the ECU connector, check the ground terminals on the ECU side and the wire harness side for bend and check the contact pressure.

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IN--24 INTRODUCTION --

TERMS

TERMS IN01M--06

ABBRE V I AT I O NSUS E DI NT HI SM ANUAL Abbreviations

Meaning

A/C

Air Conditioning

AC

Alternating Current

ACC

Accessory

ACIS

Acoustic Control Induction System

ACSD

Automatic Cold Start Device

ALT

Alternator

AMP

Amplifier

APPROX.

Approximately

A/T BACS BAT BTDC BVSV CB CCO

Automatic Transmission (Transaxle) BoostAltitudeCompensationSystem Battery BeforeTopDeadCenter BimetallicVacuumSwitchingValve Circuit Breaker CatalyticConverterforOxidation

DC

Direct Current

DLC

DataLinkConnector

DTC

DiagnosticTroubleCode

ECD

ElectronicControlDiesel

ECT

ElectronicControlTransmission

ECU

ElectronicControlUnit

EDU

ElectronicDrivingUnit

EFI E/G

ElectronicFuelInjection Engine

EGR

ExhaustGasRecirculation

EVAP

EvaporativeEmissionControl

E--VRV EX FIPG FL Fr GND HAC IG IIA IN

ElectronicVacuumRegulatingValve Exhaust FormedInPlaceGasket Fusible Link Front Ground HighAltitudeCompensator Ignition IntegratedIgnitionAssembly Intake

ISC

IdleSpeedControl

J/B

Junction Block

J/C

JunctionConnector

LCD

LiquidCrystalDisplay

LED

LightEmittingDiode

LH

Left--Hand

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IN--25 INTRODUCTION -LHD LO

Left--HandDrive Low

MAP MAX.

ManifoldAbsolutePressure Maximum

MIL MIN. MP

MalfunctionIndicatorLamp Minimum Multipurpose

M/T N

TERMS

ManualTransmission Neutral

O2S

Oxygen Sensor

O/D

Overdrive

O/S

Oversize

PKB

Parking Brake

PS

Power Steering

RAM

RandomAccessMemory

R/B

Relay Block

RH

Right--Hand

RHD

Right--HandDrive

ROM

Read OnlyMemory

Rr

Rear

SICS SPEC

StartingInjectionControlSystem Specification

SSM

SpecialServiceMaterials

SST

SpecialServiceTools

STD SW

Standard Switch

TACH

Tachometer

TDC

Top Dead Center

TEMP.

Temperature

TM

Transmission

TMC

TOYOTAMotorCorporation

TWC

Three--WayCatalyst

U/D

Underdrive

VCV

VacuumControlValve

VIN

VehicleIdentificationNumber

VSV

VacuumSwitchingValve

w/ W/H w/o

With Wire Harness Without

WU--TWC

WarmUpThree--WayCatalyticConverter

2WD

TwoWheelDriveVehicle(4x2)

4WD

ForWheelDriveVehicle(4x4)

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PREPARATION ENGINE MECHANICAL ................... P--1

P

EMISSION CONTROL .................... P--2

P

ELECTRONIC CONTROL DIESEL ......... P--3 P ENGINE FUEL ...........................P--6

P

REFER TO FOLLOWING REPAIR MANUALS: Manual Name 2L,3 LEngineR epair Manual 2L,2L--T, 3L, 5L Engine Repair Manual Supplement (Aug., 1997)

Pub. No. RM520E RM582E

NOTE: The above pages contain only the points which differ from the above listed manuals.

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PP--1 PREPARATION-- ENGINE MECHANICAL

ENGINE MECHANICAL PP12U--05

EQUIPMENT Micrometer Torque wrench

5L--E ENGINE SUP (RM817E)

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PP--2 PREPARATION--

EMISSION CONTROL

EMISSION C ONTROL PP130-02

EQUIPMENT Torque wrench Vacuumgauge

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PP--3 PREPARATION--

ELECTR ONIC CONTRO L D IESEL

ELECTRONIC CONTROL DIESEL PP3GI--01

S S T (Special S ervice Tools) 09843-18020 Diagnosis CheckWire

rbocharger PressureGauge 09992-00242 Tu

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PP--4 PREPARATION--

ELEC TRONIC C ONTR OL DIESEL PP131-02

RECOMME NDED TOOLS 09082-00040 TOYOTA Electrical Tester.

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PP--5 PREPARATION--

ELECTR ONIC CONTRO L D IESEL PP132-02

EQUIPMENT Hand-heldtester 19mm deepsocketwrench Thermometer Vacuumgauge Voltmeter Ohmmeter Torque wrench

5L--E ENGINE SUP (RM817E)

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PP--6 PREPARATION-- ENGINE FUEL

ENGINE FUEL PP3GJ - 01

S S T (Special S ervice Tools) jection Pump Stand Set 09241-76022 In

ction Pump Stand Arm 09245-54010 Inje

jection Pump Tool Set 09260-54012 In

Distributor HeadPlug Wrench (09262--54010)

Socket 14 mm (09269--54020)

ction Nozzle Wrench Set 09268-64010 Inje

Injection NozzleHolder (09268--64020) RetainingNutWrench

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PP--7 PREPARATION-- ENGINE FUEL PP3GK--01

RECOMME NDED TOOLS 09040-00011 Hexagon Wrench Set .

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PP--8 PREPARATION-- ENGINE FUEL PP135-02

EQUIPMENT 19 mm deep socket wrench Injectionnozzletester Torque wrench

5L--E ENGINE SUP (RM817E)

Fuel temp.s ensor

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SERVICE SPECIFICATIONS STANDARD BOLT........................

SS--1

ENGINE MECHANICAL ...................

SS--4

EMISSION CONTROL ....................

SS--6

ELECTRONIC CONTROL DIESEL .........

SS--7

ENGINE FUEL ...........................

SS--9

REFER TO FO LLO WING RE PAI R MANUALS : ManualName 2L,3LEngineRepairManual 2L, 2L--T, 3L, 5L Engine Repair Manual Supplement (Aug., 1997)

Pub.No. RM520E RM582E

NOTE: The above pages contain only the points which differ from the above listed manuals.

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SS--1 SERVICE SPECIFICAT IONS -- STANDARD BOLT

STANDARD BOLT SS0ZS--01

HOW TO DETERMINE BOLT STRE NGTH Bolt Type Hexagon Head Bolt Normal Recess Bolt

Deep Recess Bolt

StudBolt

4

WeldB olt

Class

4T No Mark

No Mark

No Mark

5

5T

6

6T w/ Washer

7

w/ Washer

7T

8

8T

9

9T

10

10T

11

11T

B06431

5L--E ENGINE SUP (RM817E)

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5L-E

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SS--2 SERVICE SPECIFICA TIONS -- STANDARD BOLT SS0ZT--01

S PE CIF IE D TO RQUE FOR S TANDARDBOLTS Specified torque Class

4T

5T

6T

7T

8T

9T

10T

11T

Diameter mm

Pitch mm

Hexagon head bolt N∙m

kgf ∙cm

6

1

5

55

Hexagon flange bolt ft ∙lbf

N ∙m

kgf ∙cm

ft ∙lbf

48 in.∙lbf

6

60

52 in.∙lbf

8

1.25

12.5

130

9

14

145

10

10

1.25

26

260

19

29

290

21

12

1.25

47

480

35

53

540

39

14

1.5

74

760

55

84

850

61

16

1.5

115

1,150

83

--

--

--

6

1

6.5

65

56 in.∙lbf

7.5

75

65 in.∙lbf

8

1.25

15.5

160

12

17.5

175

13

10

1.25

32

330

24

36

360

26

12

1.25

59

600

43

65

670

48

14

1.5

91

930

67

100

1,050

76

16

1.5

140

1,400

101

--

--

--

6

1

8

80

69 in.∙lbf

9

90

78 in.∙lbf

8

1.25

19

195

14

21

210

15

10

1.25

39

400

29

44

440

32

12

1.25

71

730

53

80

810

59

14

1.5

110

1,100

80

125

1,250

90

16

1.5

170

1,750

127

--

--

--

6

1

10.5

110

8

12

120

9

8

1.25

25

260

19

28

290

21

10

1.25

52

530

38

58

590

43

12

1.25

95

970

70

105

1,050

76

14

1.5

145

1,500

108

165

1,700

123

16

1.5

230

2,300

166

--

--

--

8

1.25

29

300

22

33

330

24

10

1.25

61

620

45

68

690

50

12

1.25

110

1,100

80

120

1,250

90

8

1.25

34

340

25

37

380

27

10

1.25

70

710

51

78

790

57

12

1.25

125

1,300

94

140

1,450

105 31

8

1.25

38

390

28

42

430

10

1.25

78

800

58

88

890

64

12

1.25

140

1,450

105

155

1,600

116 35

8

1.25

42

430

31

47

480

10

1.25

87

890

64

97

990

72

12

1.25

155

1,600

116

175

1,800

130

5L--E ENGINE SUP (RM817E)

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SS--3 SERVICE SPECIFICAT IONS -- STANDARD BOLT SS0ZU--01

HOW TO DETERMINE NUT TRENGTH S Nut Type Present Standard Hexagon Nut

Old Standard Hexagon Nut Cold ForgingNu t

Class

Cutting ProcessedNu t

4N No Mark

5N (4T) No Mark (w/ Washer)

No Mark (w/ Washer)

No Mark

6N 6N

7N (5T) *

8N 8N

10N (7T) 10N

No Mark

11N 11N

12N 12N

*: Nut with 1 or more marks on one side surface of the nut. B06432

HINT: Use the nut with the same number of the nut strength classification or the greater than the bolt strength classification number when tightening parts with a bolt and nut. Example: Bolt = 4T Nut = 4N or more 5L--E ENGINE SUP (RM817E)

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SS--4 SERVICE SPECIFICA TIONS -- ENGINE MECHANICAL

ENGINE MECHANICAL SS0JM--05

SERVICE DATA Idle speed

720 -- rpm 820

Maximumspeed

4,770--5,030rpm Camlobeheight

Camshaft

5L--E ENGINE SUP (RM817E)

STD Intake Exhaust

54.890 - 54.910 mm (2.1610 -- 2.1618 in.) 54.990 - 55.010 mm (2.1650 -- 2.1657 in.)

Minimum Intake

54.39 mm (2.1413 in.)

Exhaust

54.49 mm (2.1453 in.)

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SS--5 SERVICE SPECIFICAT IONS -- ENGINE MECHANICAL SS0JN--05

TORQUE S PE CIFICAT ION Parttightened InjectionpumpxTimingbeltcase InjectionpumpxInjectionpumpstay Intake manifold xEGR valve EGRadapterxIntakemanifold EGR valve EGR x pipe CrankpositionsensorxCylinderblock

5L--E ENGINE SUP (RM817E)

N 20.5 26 13 19 108

∙m

kgf

ft 15

270

19

130

9

195 1100

5

∙cm

210

51

14 79 4

∙lbf

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SS--6 SERVICE SPECIFICATIONS -- EMISSIONCONTROL

EMISSION C ONTROL SS1IC--01

TORQUE S PE CIFICAT ION Parttightened IntakemanifoldxEGRvalve EGR adptor EGR x valve EGRadptorxIntakemanifold EGR pipe EGR x valve

5L--E ENGINE SUP (RM817E)

N 13 19 19 108

∙m

kgf

∙cm

ft

130 195

14 14

195 1,100

14 80

∙lbf

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-- ELECTRONIC CONTROL DIESEL

ELECTRONIC CONTROL DIESEL SS0JR--02

SERVICE DATA Continuity

Throttle full switch

Fullyclosed Fully open

Throttle control Resistance motor

at20

Timing control Resistance valve

at20

Spillcontrolvalve E--VRVforEGR

˚

˚

Resistance

at20

R esistance

at20

Resistance

˚

˚

at--20

˚

closed position sensor

˚

C (--4 F) ˚

4 -- 7 kΩ 2 -- 3 kΩ

˚

˚

at 40 C (104 F)

0.9 -- 1.3 kΩ

at 60 C (140 F)

0.4 -- 0.7 kΩ

at 80 C (176 F)

0.2 -- 0.4 kΩ

˚

˚

at--20

˚

˚

C (--4 F) ˚

Fully open

5L--E ENGINE SUP (RM817E)

10 -- 20 kΩ

at 0 C (32 F)

4 -- 7 kΩ

at 20 C (68 F)

2 -- 3 kΩ

˚

˚

˚

˚

˚

˚

at 40 C (104 F) at 60 C (140 F)

0.9 -- 1.3 kΩ 0.4 -- 0.7 kΩ

at 80 C (176 F)

0.2 -- 0.4 kΩ

˚

4.75-- 5.25V

at20

˚

C (68 F)

205 -- 255

atCold

19 -- 32Ω

˚

at Hot Continuity

10 -- 20 kΩ

at 20 C (68 F)

Powersourcevoltage

Accelerator pedal

˚

at 0 C (32 F)

˚

Resistance

Ω

0.2 -- 0.4 kΩ

˚

˚

position sensor

10 -- 20 kΩ

˚

Ω

0.4 -- 0.7 kΩ

˚

Crankshaft

C (--4 F)

˚

˚

˚

Engine speed senResistance sor

46 -- 50

˚

at 80 C (176 F)

˚

sensor

1 -- 2

C (68 F)

0.9 -- 1.4 kΩ

˚

Turbo pressure

C (68 F)

˚

˚

ature sensor

Ω

at 60 C (140 F)

˚

Intake air temper-

10 -- 14

˚

2 -- 3 kΩ

at--20

Resistance

C (68 F)

˚

˚

sensor

Ω

at 40 C (104 F) ˚

Fuel temperature

18 -- 22

˚

4 -- 7 kΩ

˚

Resistance

C (68 F)

at 0 C (32 F) ˚

sensor

Continuity

at 20 C (68 F)

˚

Water temperature

No continuity

Fullyclosed

Ω

24 -- 37Ω No continuity Continuity (0 -- 20 Ω)

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SS--8 SERVICE SPECIFICATIONS -- ELEC TR O N ICC O N TR O LD IESEL SS0JS--02

TORQUE S PE CIFICAT ION Parttightened ThrottlebodyxIntakemanifold

N

∙m

12

kgf

∙cm

120

ft

WatertemperaturesensorxCylinderblock

25

250

FueltemperaturesensorxInjectionpump

22.1

250

16

5.0

50

43in.

CrankshaftpositionsensorxCylinderblock Accelerator pedal assembly x Body

5L--E ENGINE SUP (RM817E)

5.0

∙lbf

9 18

50

∙lbf 43 in. ∙lbf

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SS--9 SERVICE SPECIFICAT IONS -- ENGINE FUEL

ENGINE FUEL SS0JT--02

SERVICE DATA Injection nozzles

Nozzle opening pressure

New nozzle

15,790 - 16,570 kPa (161 -- 169 kgf/cm2, 2,290 -- 2,404 psi)

Reused nozzle

15,200 - 16,180 kPa (155 -- 165kgf/cm2, 2,205 -- 2,347 psi)

Adjusting shim thickness

0.900 mm (0.0354 in.) 0.950 mm (0.0374 in.) 1.000 mm (0.0394 in.) 1.050 mm (0.0413 in.) 1.100 mm (0.0433 in.) 1.150 mm (0.0453 in.) 1.200 mm (0.0472 in.) 1.250 mm (0.0492 in.) 1.300 mm (0.0512 in.) 1.350 mm (0.0531 in.) 1.400 mm (0.0551 in.) 1.450 mm (0.0571 in.) 1.500 mm (0.0591 in.) 1.550 mm (0.0610 in.) 1.600 mm (0.0630 in.) 1.650 mm (0.0650 in.) 1.700 mm (0.0669 in.) 1.750 mm (0.0689 in.) 1.800 mm (0.0709 in.) 1.850 mm (0.0728 in.) 1.900 mm (0.0748 in.) 1.950 mm (0.0768 in.)

5L--E ENGINE SUP (RM817E)

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SS--10 SERVICE SPECIFICA TIONS -- ENGINE FUEL SS0JU--02

TORQUE S PE CIFICAT ION Parttightened

∙m

N

InjectionnozzlexCylinderhead

64

kgf

∙cm

650

ft

NozzleleakagepipexInjectionnozzle

27.0

275

20

InjectionpipexInjectionnozzle

29.5

300

22

InjectionpipexInjectionpump

24.5

250

18

FuelinlethollowscrewxInjectionpumpbody

36.8

375

27

DeliveryvalveholderxDistributivehead

58.85

600

43

DistributiveheadplugxDistributivehead

88

900

65

Fuelinletpipex injectionpump

Nut(A) Bolt (B)

26.55

271

24.5

250

20 18

FueloutletpipexInjectionpump

26.55

271

20

InjectionpumpxTimingbeltcase

20.5

210

15

Fueltemp.sensorxInjectionpump

21.6

PumpstayxInjectionpump

26

270

19.6

PumpstayxCylinderblock

26

270

19.6

5L--E ENGINE SUP (RM817E)

220

∙lbf

47

16.5

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DIAGNOSTICS ENGINE ................................

DI--1

HOW TO PROCEED WITH TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . .

DI--1

CUSTOMER PROBLEM ANALYSIS CHECK . . .

DI--3

PRE--CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DI--4

DIAGNOSTIC TROUBLE CODE CHART . . . . . .

DI--14

PARTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . .

DI--16

TERMINALS OF ECU . . . . . . . . . . . . . . . . . . . . . .

DI--17

PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . .

DI--25

CIRCUIT INSPECTION . . . . . . . . . . . . . . . . . . . . .

DI--27

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DI--1 DIAGNOSTICS--

ENGINE

ENGINE DI0Z7--04

HOWTO PROCE E D WIT H TROUBL E S H OOT ING

When using hand--held tester, troubleshoot in accordance with the procedure on the following pages. Titles inside are titles of pages in this manual, with the page number indicated in the bottom portio n. See the indicated pagesfordetailedexplanations.

Vehicle Brought to Workshop 1

CustomerProblemAnalysisP.DI -- 1

2

Connectthehand -- heldtestertoDLC3.P.DI -- 4 Ifthedisplayindicatesacommunicationfaultinthetool,inspectDLC3.P.DI -- 4

3

Check Diagnostic Trouble Code and Freezed Frame Data (Pre--check) RecordorPrintDTCandFreezedFrameDataP.DI -- 4

4

ClearDTCandFreezedFrameDataP.DI -- 4

5

Visual Inspection

6

SettingCheck(Test)ModeDiagnosisP.DI -- 4

7

Problem Symptom Confirmation If the engine does not start, perform steps 10 and 12 first Malfunction occurs.

9

8

Malfunction does not occur. Symp tomSimulatio nP.IN -- 9

DTCcheckP.DI -- 1 Normal

10

12 14

Malfunctioncode. 11

BasicInspectionP.DI -- 1

ProblemSymp tomTableP.DI -- 25 

Parts Inspection 15

DTCChartP.DI -- 14 

13

Circu itI n sp e c tio nP.DI -- 2 7

CheckforIntermittentProblemsP.DI -- 4

Identification of Problem 16

Adjustment, Repair

17

Confirmation Test CONTINUED

End

5L--E ENGINE SUP (RM817E)

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DI--2 DIAGNOSTICS--

ENGINE

When not using hand--held tester, troubleshoot in accordance with the procedure on the following pages. Titles inside

Vehicle Brought to Workshop Customer Problem Analysis P.DI--3

Check and clear Diagnostic Trouble Code (Prec--heck) P.DI--4 Problem Symptom Confirmation Symptom Simulation P.IN--9

Diagnostic Trouble Code Check P.DI--4

5 Normal code

6

Malfunction code. 7

Basic Inspection P.DI--4

Diagnostic Trouble Code Chart P.DI--14

Problem Symptoms Table P. D I --52 Circuit Inspection P.DI--27 9

Parts Inspection

Identification of Problem 12

Adjustment, Repair

13

Confirmation Test

5L--E ENGINE SUP (RM817E)

11 Check for Intermittent Problem P.D I--4

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DI--3 DIAGNOSTICS --

ENGINE DI0Z9--03

CUS TO M E RP ROBL E MANALY S I SCHE CK Inspector’s Name

ENGINE CONTROL SYSTEM Check Sheet Customer’s Name

Model and Model Year

Driver’s Name

Frame No.

Date Vehicle Brought in

Engine Model

License No.

Odometer Reading

s m o t p m y S m e l b o r P

Engine does not Start

E n g i n e d o es n o t c r an k

Difficult to Start

Engine cranks slowly

km miles

N o i n i t i al c o m b u s t i o n

No c o m p l et e co m b u s t i o n

Other

Poor Idling

I n c o r r ec t f i r s t i d l e Id li n g rp m is ab n or m al R ou gh id li n g O t h er

Poor Driveability

Hesi t at ion K n o c ki n g

Engine Stall

So on af ter starti ng Af ter accelerator pedal depressed Aft er accelerator pedal released During A/C operation S h if t i n g f ro m N t o D O t h er

B ack f ir e O t h er

Hi gh(

r pm )

Low (

Mu f f ler exp losio n ( af t er--f ir e)

rp m)

S u r gi n g

Others

Dates Problem Occurred C on st an t Other

Problem Frequency

n rs e u hc Wc nO o m tii e d lb no or CP

S o m et i m e s (

t im es per

Weather

F in e

C lou dy

R ai n y

Outdoor Temperature

Hot

War m

C oo l

Place

Hig hw ay R o u g h r o ad

Engine Temp.

C ol d

Engine Operation

S t ar t i n g Ju st af t er st ar t in g ( D r ivin g C o n s t an t sp e ed A / C sw i t c h O N / O F F O t h er

C on dit i on of Mal f u n ct i on in dicat or L am p

Diagnostic Trouble Code Inspection

Normal mode (Precheck) Check Mode

5L--E ENGINE SUP (RM817E)

In n er Ci t y

A f t er War mi n g u p

R em ai n s o n N o r m al

N o r m al

Sn o w y C o l d ( ap p r o x .

S u bu r b s O t her War m in g u p

d ay/ m o n t h )

O n ce on ly

Var io u s/O t h er

˚

F/

Uphi ll

An y t emp .

m in .) Idl in g A c c e l e r at i o n

S o m e t i m es l i g h t u p

˚

C) Do w n hil l

O t her R ac i n g D e c e l e r at i o n

D oes n o t li gh t u p

Mal f u n ct i on code( s) ( cod e F r ee z e d f r am e d at a (

)

)

Malf u n ct i on code( s) ( cod e F r ee z e d f r am e d at a (

)

)

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DIAGNOSTICS: PRE CHECK: 1. DIAGNOSIS Pg DI-4 / 5 2. INSPECT DIAGNOSIS (Normal Mode) Pg DI-6 / 7 3. INSPECT DIAGNOSIS ((CHECK (Test) Mode) Pg DI-7 / 8 4. FAIL-SAFE CHART Pg DI-9 5. CHECK FOR INTERMITTENT PROBLEMS Pg DI-9 6. BASIC INSPECTION Pg DI-10 / DI-12 7. REFERENCE VALUE OF ENGINE ECU DATA Pg DI-12 / 13

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DI--4 DIAGNOSTICS--

ENGINE

P RE-- CHE CK 1. (a)

DIAGNOSISSYSTEM Description S When troubleshooting Multiplex OBD (M--OBD) vehicles, the only difference from the usual troubleshooting procedure is that you need to connect the vehicle to the hand--held tester, and read off various data output from the vehicle’s engine ECU. S The vehi cle’s on--board compu ter li ghts up the DI8NM--01

FI2547

check engine warning light on the instrument panel when the computer detects a malfunction in the computer itself or in drive system components. In addition to the check engine warning light lighting up when a malfunction is detected, the applicable diagnostic trouble codes are recorded in the engine ECUmemory.(SeepageDI -- 14) If the malfunction has been repaired, the check engine warning light goes off automatically but the diagnostic trouble codes remain recorded in the engine ECU memory. S

Hand--Held Tester

D00730

S

To check the diagnostic trouble codes, connect the hand--held tester to the Data Link Connector 3 (DLC3) on the vehicle or read the number of blinks of the check engine warning light when TC and CG terminals on the DLC3 are connected. The hand-held tester also enables you to erase the diagnostic trouble codes and activate the several actuators and check freeze frame date and various forms of engine data. (For operating instructions, see the hand--held tester instruction book.) The diagnosis system operates in the normal mode during a normal vehicle use. It also has a check (test) mode for technicians to simulate malfunction symptoms and troubl eshoot. Some diagn ostic trouble codes use 2 trip detection logic * to prevent an erroneous detection and ensure thorough the malfunction detection. By switching the engine ECU to the check (test) mode using hand--held tester when troubleshooting, a technician can cause the check engine warning light to light up for a malfunction that is only detected once or momentarily. (hand -- heldtesteronly)(SeepageDI -- 14)

CONTINUED

5L--E ENGINE SUP (RM817E)

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DI--5 DIAGNOSTICS--

ENGINE

*2 trip detection logic: When a logic malfunction is first detected, the malfunction is temporarily stored in the engine ECU memory. If the same malfunction is detected again during the second drive test, this second detection causes the check engine warning light to light up. The 2 trip repeats the same mode twice time. (However, the ignition switch must be turned OFF between the 1st trip and 2nd trip). S Freeze frame data: Freeze frame data records the engine condition when a malfunction is detec ted, as freeze fra me data records the engine conditions (fuel system, calculator load, engine coolant temperature, fuel trim, engine speed, vehicle speed, etc.) when the malfunction is detected. When troubleshooting, it is useful for determining whether the vehicle was running or stopped, the engine was warme d up or not, the air--fuel ratio was lean or r ich, etc. at the time of the malfunction. (b) Check the DLC3. The vehicle’s engine ECU uses ISO 14230 for communication. The terminal arrangement of DLC3 complies with SAE J1962 and matches the ISO 14230 format. S

1 2 34 5 6 7 8 9 10 11121314 1516 DLC3 A04550

TerminalNo. 7

Connection/VoltageorResistance Bus

+ Line/Pulsegeneration

4

Chassis Ground -- Body Ground/1 orlessΩ

16

BatteryPositive-- BodyGround/9-- 14V

Condition During transmission Always Always

HINT: If your display shows UNABLE TO CONNECT TO VEHICLE when you have connected the cable of the hand--held tester to the DLC3, turned the ignition switch ON and operated the hand--held tester, there is a problem on the vehicle side or tool side. S If the communication is normal when thetool is connected to another vehicle, inspect the DLC3 on the srcinal vehicle. S If the communication is still impossible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool’s instruction manual. CONTINUED 5L--E ENGINE SUP (RM817E)

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DI--6 DIAGNOSTICS--

ENGINE

2. (a)

FI2547

INSPECT DIAGNOSIS(Normal Mode) Check the check engine warning light. (1) The check engine warning light comes on when the ignition switch is turned ON and the engine is not running. HINT: If the check engine warning light does not light up, troubleshoot the combination meter. (2) when the engine is started, the check engine warning light should go off. If the lamp remains on, the diagnosis system has detected a malfunction or abnormality in the system. (b) Check the DTC using hand--held tester. NOTICE: When thediagnosissystemis switched fromnormalmode to check test mode, it erases all DTCs and freezed frame data recorded innormalmode. So before switchingmodes, always check the DTCs and freezed frame data, and note themdown. (1) Prepare the hand--held tester. (2) Connect the hand--held tester to the DLC3. (3) Turn the ignition switch ON and switch the ha nd-held tester main switch ON. (4) Use the hand--held tester to check the DTCs and freezed frame data, note them down. (for operating instructions, see the hand --held tester’s instruction book.) (5) Confirm the details of the DTCs.

(c) CG 1 2 34 5 6 7 8 9 1011121314 1516 DLC3

Check the DTC not using hand--held tester. (1) Turn the ignition switch ON. (2) Using SST, connect between terminals 13 (TC) and 4 (CG) of DLC3. SST09843 -- 18020

TC A04550

(3)

Normal 0.25 sec. ON

Read the diagnostic trouble code from check engine warning light.

HINT: S If a diagnostic trouble code is n ot output, check the di agnosticconnector(DLC3)circuit(SeepageDI -- 113).

ON ON ON

OFF OFF OFF

0.25 sec. FI0294

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DI--7 DIAGNOSTICS--

0.5 sec.

ON OFF

4.5 sec. 2.5 sec. 0.5 sec.

Repeat

One Cycle Start

As an example, the blinking patterns for codes; normal, 12 and 31 are as shown on the illustration. (4) Check the details of the malfunction using the diagnostictroublecodechartonpageDI -- 14. (5) After completing the check, disconnect terminals 13 (TC) and 4 (CG) and turn off the display. HINT: In the event of 2 or more malfunction codes, indication willbegi n from the smaller numbered code and continue in order to the larger. NOTICE: When simulatingsymptoms without a hand--heldtester to check the DTCs, use normal mode. For code on the DTCs chart subject to ”2 trip detection logic”, turn the ignition switch OFF after the symptom is simulated the firsttime. Then repeatthesimulationprocessagain. When theproblem has been simulated twice, the check engine warning light lights up and the DTCs are recorded in the engine ECU. 3. INSPECT DIAGNOSIS (Check (Test) Mode) HINT: HAND--HELD TESTER only: Compared to the normal mode, the check mode has an increased sensitivity to detect malfunctions. Furthermore, the same diagnostic items which are detected in the normal mode can also be detected in the check (test) mode. (a) Check the DTC. (1) Initial conditions. S Battery positive voltage 11 V or more S Throttle valve fully closed. S Transmission in neutral position S Air conditioning switched OFF. (2) Turn the ignition switch OFF. (3) Prepare the hand--held tester. (4) Connect the hand--held tester to the DLC3. (5) Turn the ignition switch ON and push thehand--held tester main switch ON. S

1.5 sec.

4.5 sec.

BR3589

(6) Flashing ON

(7)

OFF

(8)

0.13 Sec. FI3605

5L--E ENGINE SUP (RM817E)

ENGINE

Switch the hand--held tester normal mode to check (test) mode. (Check that the check engine warning light flashes.). Start the engine. (The check engine warning light goes out after the engine start.). Simulate the con ditions of the malfu nction de scribed by the customer.

NOTICE: Leave the ignition switch ON until you have checked the DTCs, etc. CONTINUED

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DI--8 DIAGNOSTICS--

(9)

ENGINE

After simulating the malfunction conditions, use the hand--held tester diagnosi s selector to check the DTCs and freezed frame data, etc.

HINT: Take care not to turn the ignition switch OFF. Turning the ignition switch OFF switches the diagnosis system from check (test) mode to normal mode, so all diagnostic codes, etc. are erased. (10) After checking the DTCs, inspect the applicable circuit. (b) Clear the DTC. The following actions will erase the DTCs and freezed frame data. (1) Operating the hand--held tester to erase the codes. (See the hand--held tester’s instruction book for operating instructions.) (2) Disconnecting the battery terminals or ECD fuse. NOTICE: If the hand--held tester switches the engine ECU fromnormal mode to check (test) mode orvice-versa, orifthe ignition switch is turned fromON to ACC or OFF during check (test) mode, the DTCs and freezed frame data will be erased. CONTINUED

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DI--9 DIAGNOSTICS --

ENGINE

4 . FAI L -- S AFECHART If any of the following codes is recorded, the ECU enters fail--safe mode. DTCNo. 12

Fail--SafeOperation

Fail--SafeDeactivationConditions

TCV duty is fixed at 30 %

2 of more TDC signals are detected for 4 engine revolution

Fuel cut

S

13

TCV duty is fixed at 2 %

2 of more NE signals are detected for 0.5 sec.

S

Close diesel throttle valve

S

EGR off

S

15

IDL SW ON : Diesel throttle is fixed at idle position

S

IG switch OFF

IDL SW OFF : Diesel throttle valve is fully open Accelerator pedal position below 25 %

S

18

Fuel cut

S

IG switch OFF or starter ON from OFF

Close diesel throttle valve

S

Accelerator pedal closed position SW ON : 19(1)

Accelerator pedal position is fixed at 0 % Accelerator pedal closed position SW OFF :

IG switch OFF

Accelerator pedal position is fixed at 8 % Accelerator pedal closed position SW ON : Accelerator pedal position is fixed at 0 % 19(2)

Accelerator pedal closed position SW OFF :

IG switch OFF

Accelerator pedal position is fixed at 8 % Accelerator pedal position below 10 % 19(3)

Accelerator pedal position below 10 %

19(4)

Accelerator pedal position below 10 %

22

Engine coolant temp. is fixed at 9

24 35

IG switch OFF IG switch OFF IG switch OFF

C (48 F)

˚

˚

Intake air temp. is fixed at 130 C (266 F) Intake air pressure is fixed at 101.3 kPa (760 mmHg, 30 in.HG)

39

Fuel temp. is fixed at 20

42

Vehicle speed is fixed at 0 km/h (0 mile)

˚

C(68F)

Return to normal condition Return to normal condition Return to normal condition Returntonormalcondition Vehicle speed > 10 km/h (6 mile)

5 . CHE CKFO RI NT E  RMI TTE NTP RO  BLE MS HINT: HAND--HELD TESTER only: By putting the vehicle’s engine ECU in check (test) mode, 1 trip detection logic is possible instead of 2 trip detection logic and sensitivity to detect open circuits is increased. This makes it easier to detect intermittent problems. (a) CleartheDTC(Seestep2). (b) Setthecheck(test)mode(Seestep3). (c) Performasimulationtest(SeepageIN -- 9). (d) Checktheconnectorandterminal(SeepageIN -- 19). (e) Handletheconnector(SeepageIN -- 19).

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DI--10 DIAGNOSTICS--

ENGINE

6. BASIC INSPECTION When the malfuncti on code is not confirmed in the DTC check, troubleshooting should be carri ed out in the order for all possible circuits to be considered as the cases of the problems. In many cases, by carrying out the basic engine check shown in the following flow chart, the location causing the problem can be found quick ly and efficiently. Therefore, use of this check is essential in engine troubleshooting.

1

Is bat tery positivevoltage 11 V or more whenengineis stopped?

NO

Charge or replace battery.

NO

Proceed to problemsympt oms table onpage DI-- 25 .

YES

2

Is enginecranked?

YES

3

Check air ilter f (Refer to Pu b. No. RM520E o n EM section).

NG

Repair or replace.

OK

4

Check fuelquality.

CHE CK: S Check that use only diesel fuel. S Check that the fuel does not contain any impurity. NG

Replace fuel.

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DI--11 DIAGNOSTICS--

5

ENGINE

Check engine oil (Referto Pu b. No. RM582E o n L U section ).

NG

Addo r replace.

OK

6

Check coolant (Refer ot Pub. No. RM520E o n CO sectio n).

NG

Replace coolant.

OK

7

Check injection timin g (See page EM -- 1).

NG

Adjusting injection timing.

OK

8

Check idle sp eed an d maximu m speed(See p age EM -- 2).

NG

Repair or replace injection pump.

OK

9

Checkdiagnosticconnect or (DLC3) circui t (SeepageDI -- 113). NG

Repair or replace.

OK

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DI--12 DIAGNOSTICS--

10

ENGINE

Check vacu u m pump (See page EC -- 3).

NG

Repair or replace.

OK

Proceed to problem symptoms table n page o DI -- 25.

Hand--Held Tester

D00730

7. REFERENCE VALUE O F E NG NE I E CU DATA NO TI CE: Thevalues given belowfor ”Normal Condition” are representativevalues, so a vehiclemaystill benormalevenifits values fromthose listed here. So do not decidewhether a partis faulty ornot solely according to the”Normal Condition” here. HINT: Engine engine ECU data can be monitored by hand--held tester. (a) Connect the hand--held tester to the DLC3. (b) Monitor engine ECU data by following the prompts on the tester screen. Please refer to the hand--held tester operator’s manual for further detail. CONTINUED

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DI--13 DIAGNOSTICS --

(c)

ENGINE

Reference Value Item

InspectionCondition Engineatidling *1 Engineracingat2,000rpm*1

INJECTION VOLUME

Engineracingat3,000rpm*1 Engineatidling*1 Engineracingat2,000rpm*1

INJECTION TIMING

ENGINE SPD

ReferenceValue 3 or less

10mm

3 or less

10mm

3 or

5--15mm 17--19

˚

20.6--22.6

CA

˚

Engineracingat3,000rpm*1

24--26

RPM kept stable (Comparison with tachometer)

No great changes

Engine at idling *1 PIM

˚

98--101 kPa

Engineracingat2,000rpm*1

101--111kPa

Engineracingat3,000rpm*1

126--141kPa

Engineatnormaloperatingtemp.

INTAKE AIR

Engineatnormaloperatingtemp.

Ambient temp.

FUELTEMP

Engineatnormaloperatingtemp.

Ambienttemp.

75--95

˚

C (185--203 F) *2

Accelerator pedal fully closed Acceleratorpedalfullyopened

VEHICLE SPD

0 -- 34 % 58--100% Gradually increases No large differences

A/C switch ON

Acceleratorpedalfullclosed D uring cranking

A/C CUT SIG EGR SYSTEM

ON ReferenceValue ON ON

A/C switch OFF Idling

*1: All accessories and A/C are switched OFF. *2: If the water temp. sensor circuit is open or shorted, the engine ECU.

5L--E ENGINE SUP (RM817E)

˚

90 C

∼

From closed position to wide open accelerator pedal

InspectionCondition

IDLSIG STARTERSIG

˚

100 C

∼

During driving (Comparison with speed meter)

A/C SIG Item

CA

(735--758 mmHg, 28.9--29.8 in.Hg)

COOLANT TEMP

ACCELE POSITION

less

CA

ON OFF

˚

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DI--14 DIAGNOSTICS--

ENGINE DI0ZD--04

DIAGNOS T IC TROUBLE CODE CHART HINT: Parameters listed in the chart may not be exactly the same as you reading due to the type of instrument or other factors. If a malfunction code is displayed during the DTC check in check(test) mode, check the circuit for that code listed in the table below . For details of each code, turn to the page referred to under the ”See page” for the respective ”DTC No.” in the DTC chart. *1 Check Engine

DTC No. ( Se eP age)

etection D Item

TroubleArea

Warning Light Normal Mode/

*2 Memory

Test Node) 12 ( D I -- 27)

13 ( D I -- 29)

Crankshaft Position Sensor Circuit Malfunction

Engine Speed Sensor Circuit Malcunction

SOpen or short

SCrankshaft position sensor

14

Timing Control System Malfunction

ON/ON

f

ON/ON

f

ON/N.A.

f

ON/N.A.

f

SEngine ECU SOpen or short

in engine speed sensor circuit

SEngine speed sensor SEngine ECU SOpen or short

( D I -- 30)

in crankshaft position sensor circuit

SFuel filter

in timing control valve circuit

(Clogging)

SFuel (Freezing, Air in) SInjection pump (Internal pressure

and timing control valve)

SEngine ECU SOpen or short

15 (DI--35)

Throttle Control Motor Circuit Malfunction

in throttle control motor circuit

SThrottle control motor SThrottle valve SThrottle body SEngione ECU

17 18 ( D I -- 37)

19( 1) ( D I -- 40)

19( 2) ( D I -- 48)

19( 3) ( D I -- 53)

Interior IC Malfunction

ECU SEngine SOpen

Spill Control Circuit Malfunction

ON/N.A.

SSpill control valve

ON/N.A.

f

ON/ON

f

ON/N.A.

f

ON/N.A.

f

SEngine ECU

Accelerator Pedal Position Sen-

SOpen or short

sor Circuit Malfunction (Open/

SAccelerator pedal position sensor

Short)

SEngine ECU

Accelerator Pedal Position Sen-

SOpen or short

sor Circuit Malfunction

SAccelerator pedal position sensor

(IDL Switch / Range)

SEngine ECU

Accelerator Pedal Closed Posi-

SShort

tion Switch Circuit Malfunction

SAccelerator pedal closed position switch

(Short)

SEngine ECU

Accelerator Pedal Closed Posi-

SOpen in accelerator pedal closed position switch circuit

in accelerator pedal position sensor circuit

in accelerator pedal position sensor circuit

in accelerator pedal closed position switch circuit

S

( D I -- 53)

f

or short in spill control valve circuit

tion Switch Circuit Malfunction (Open)

Accelerator pedal closed position switch

SEngine ECU

f

ON/N.A.

*1: ”ON” displayed in the diagnosis mode column indicates that the check engine warning light is lighted up when a malfunction is detected. ”N.A.” indicates that the item is not included in malfunction diagnosis. *2: ”f ” in the memory column indicates that a diagnostic trouble code is recorded in the ECU memory when a malfunction occurs. Accordingly, output of diagnostic results in normal or test mode is done with the IG switch ON.

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DI--15 DIAGNOSTICS--

ENGINE *1 Check Engine

DTC No.

etection D Item

(See Page)

TroubleArea

Warning Light Normal Mode/

*2 Memory

Test Node 22 ( D I -- 55)

24 ( D I -- 60)

32 ( D I -- 66)

35 ( D I -- 68)

39 ( D I -- 75)

Water Temp. Sensor Circuit Malfunction

Intake Air Temp. Sensor Circuit Malfunction

Injection Pump System Malfunction

Intake air Pressure Sensor Circuit Malfunction

Fuel Temp. Sensor Circuit Malfunction

SOpen or short SWater

temp. sensor

( D I -- 80)

ON/ON

f

OFF/ON

f

OFF/N.A.

f

ON/ON

f

ON/ON

f

ON/ON

f

SEngine ECU SOpen or short

in intake air temp. sensor circuit

SIntake air temp. sensor SEngine ECU SInjection pump correction unit cuicuit SInjection pump correction unit SEngine ECU SOpen or short

in turbo pressure sensor circuit

SIntake air pressure sensor SEngine ECU SOpen or short

in fuel temp. sensor circuit

SFuel pressure sensor SEngine ECU SOpen or short

42

in water temp. sensor circuit

Vehicle Speed Sensor Signal

SVehicle

Circuit Malfunction

SCombination

in fuel temp. sensor circuit

speed sensor meter

SEngine ECU

*1: ”ON” displayed in the diagnosis mode column indicates that the check engine warning light is lighted up when a malfunction is detected. ”OFF” indicates that the ”CHECK ENGINE” does not light up during malfunction diagnosis, even if a malfunction is detected. ”N.A. ” indicates that the item is not included in malfunction diagnosis. *2: ”f ” in the memory column indicates that a diagnostic trouble code is recorded in the ECU memory when a malfunction occurs. Accordingly, output of diagnostic results in normal or test mode is done with the IG switch ON.

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DI--16 DIAGNOSTICS--

ENGINE DI062--16

PARTS LOCATION Accelerator Pedal Position Sensor

Diesel Slottle

Combination Meter

Accelerator Pedal Closed Position Sensor ECD Relay

DLC3

Starter Relay

Intake Air Pressure Sensor

EGR Valve

Engine ECU

Sub Glow Relay Neutral Start Switch (A/T) Glow Plug

Crank Shaft Position Sensor

Water Temp. Sensor

Fuel Temp.Sensor

Check Connector

Engine Speed SensorSpill Control Valve

Intake Air Temp. Sensor

E--VRV for EGR

PUMP ROM (Injection Pump Correction Unit) Timing Control Valve

A15260

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TERMINALS OF ECU: 1. 2. 3. 4.

AUSTRALIA (EXCEPT THAILAND MADE)DI-17 /18 AUSTRALIA (THAILAND MADE)DI-19/20 THAILAND DI-21/22 SOUTH AFRICA DI-23/24

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DI--17 DIAGNOSTICS --

ENGINE DI8NN--01

T E RM I NAL SO FE CU Austra lia(Exce ptTha ilandMa de  ) Engine ECU Terminals

E6

E9

13 12 11 10 9 8 7 6 5 4 3 2 1

E4

E5

5 4 3 2 1

6 5 4 3 2 1

26 25 24 23 22 21 20 19 18 17 16 15 14 16 15 14 13 12 11 10 9

8 7 6

12 11 10 9 8 7

11 10 9

8 7

6 5 4

3 2 1

22 21 20 19 18 17 16 15 14 13 12

A02958

Symbols(TerminalsNo.)

WiringColor

Condition

STDVoltage(V)

BATT(E6--1)--E1(E4--14)

R--B--BR

+B(E6--12)--E1(E4--14)

R--L--BR

IGswitchON

9--14

VC(E5--1)--E2(E5--9)

B--G--R

IGswitchON

4.5--5.5

V--LG

IGswitchON

4.5--5.5

VCC(E9--6)--E2C(E9--4) VA (E9--5) -- E2C (E9--4)

VAS (E9--12) -- E2C (E9--4)

Always

B--L -- LG

R -- LG

9--14

Accelerator pedal fully closed

0.3 -- 0.8

Accelerator pedal fully opened

2.9 -- 4.9

Accelerator pedal fully closed

0.3 -- 0.8

Acceleratot pedal fully opened

2.9 -- 4.9

Accelerator pedal fully closed

9 -- 14

Acceleratot pedal fully opened

0 -- 3

IDL (E9--9) -- E2C (E9--4)

B--R -- LG

PIM (E5--2) -- E2 (E5--9)

B--Y -- G--R

Apply vacuum 40 kPa (300 mmHg, 11.8 in.Hg) Apply vacuum 69 kPa (518 mmHg, 20.4 in.Hg)

THA (E5--3) -- E2 (E5--9)

P--L -- G--R

Idling, air intake temp. 0

THW(E5--4) -- E2 (E5--9)

P -- G--R

THF (E5--5)-- E2 (E5--9) DATA (E5--6) -- E1 (E4--14) CLK (E5--14) -- E2 (E5--9) STA(E6--11)--E1(E4--14)

˚

0.2 -- 0.8 3.2 -- 3.8

C (32 F) to 80 C (176 F)

Idling, engine coolant temp. 60

˚

˚

˚

0.5--3.4

˚

C (140 F) to 120 C (248 F) ˚

˚

0.2--1.0

˚

LG--B -- G--R

IG switch ON (at engine cold)

0.5 -- 3.4

V -- BR

For 0.5 sec. after IG switch ON

Pulse generation

P -- G--R

For 0.5 sec. after IG switch ON

Pulse generation

P--BR

Cranking

TDC+ (E4--17) -- TDC-- (E4--16)

R -- G

Idling

NE+ (E4--19) -- NE-- (E4--18)

W -- B

Idling

SP1(E6--9) -- E1(E4--14)

G--O -- BR

TCV (E4--11) -- E01 (E4--13)

G--B -- W--B

IG switch ON Rotate driving wheel slowly IG switch ON

SPV+ (E4--12) -- E1 (E4--14)

GR -- BR

SPV-- (E4--25) -- E1 (E4--14)

R--B -- BR

Idling

6.0ormore Pulse generation ( Se epageD I -- 27) Pulse generation ( Se epageD I -- 27) Pulse generation 14 --9 Pulse generation ( Se epageD I -- 30)

IG switch ON

14 --9

Idling

Pulsegeneration

Idling

Pulse generation ( Se epageD I -- 37)

LU+A (E4--10) -- E01 (E4--13)

R -- W--B

Racing (engine warmed up)

Pulse generation

LU-- A(E4--9) -- E01 (E4--13)

Y -- W--B

Racing (engine warmed up)

Pulse generation

LU+ B(E4--8) -- E01 (E4--13)

P -- W--B

Racing (engine warmed up)

Pulse generation

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DI--18 DIAGNOSTICS-LU-- B(E4--7) -- E01 (E4--13)

LG -- W--B

ENGINE

Racing (engine warmed up) IG switch ON

MREL (E6--3) -- E1 (E4--14)

SREL (E6--2) -- E01 (E4--13) IGSW(E6--14)--E1(E4--14)

L--O -- BR

B--R -- W--B B--W--BR Y -- BR

ACT (E9--8) -- E1 (E4--14)

LG--R -- BR

14 --9

IG switch OFF (after IG switch OFF for 2 sec.)

0 -- 1.5

Cranking

14 --9

Idling (engine start and after 600 sec.)

IGswitchON

AC1 (E9--2) -- E1 (E4--14)

Pulse generation

0 -- 1.5 9--14

A/C switch ON (at magnet clutch ON)

0 -- 1.5

A/C switch OFF

7.5 -- 14

IG switch ON

14 --9

at A/C cut controlled

0− 3

(Driving below 30km/h, accelerator pedal fully opened for 5 sec.) Accelerator pedal fully closed PDL (E9--3) -- E1 (E4--14)

L -- BR

TAC(E9--7)--E1(E4--14)

R--W--BR

TC(E6--4)--E1(E4--14)

V--BR

Idling IGswitchON

THOP (E5--15) -- E1 (E4--14)

GIND (E9--1) -- E1 (E4--14)

5L--E ENGINE SUP (RM817E)

P -- BR

L--R -- BR

GR--L -- BR

0

−

Pulsegeneration

Check enginewarninglightlights up W (E6--5) -- E1 (E4--14)

9 -- 14

Accelerator pedal fully opened

except check engine warning light lights up

9--14 0 -- 3 9 -- 14

Idling(enginewarmedup)

9--14

IGswitchON(onecewithin5sec.)

0-- 3

Glowindicatorlightlightsup

0--3

except glow indicator light lights up

9 -- 14

3

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DI--19 DIAGNOSTICS --

ENGINE

Aus tra l i a(Tha i l a ndMa de ) Engine ECU Terminals

E10

E6

13 12 11 10 9 8 7 6 5 4 3 2 1

E4

E5

5 4 3 2 1

6 5 4 3 2 1

26 25 24 23 22 21 20 19 18 17 16 15 14 16 15 14 13 12 11 10 9

8 7 6

12 11 10 9 8 7

11 10 9

8 7

6 5 4

3 2 1

22 21 20 19 18 17 16 15 14 13 12

A02958

Symbols(TerminalsNo.)

WiringColor

Condition

STDVoltage(V)

BATT(E10--1)--E1(E4--14)

R--B--BR

+B(E10--12)--E1(E4--14)

R--L--BR

IGswitchON

VC(E5--1)--E2(E5--9)

B--G--R

IGswitchON

4.5--5.5

V--LG

IGswitchON

4.5--5.5

VCC(E6--6)--E2C(E6--4) VA (E6--5) -- E2C (E6--4)

VAS (E6--12) -- E2C (E6--4)

IDL (E6--9) -- E2C (E6--4)

Always

B--L -- LG

R -- LG

B--R -- LG

9--14 9--14

Accelerator pedal fully closed

0.3 -- 0.8

Accelerator pedal fully opened

2.9 -- 4.9

Accelerator pedal fully closed

0.3 -- 0.8

Acceleratot pedal fully opened

2.9 -- 4.9

Accelerator pedal fully closed

9 -- 14

Acceleratot pedal fully opened

0 -- 3

Apply vacuum 40 kPa (300 mmHg, 11.8 in.Hg) PIM (E5--2) -- E2 (E5--9)

B--Y -- G--R

THA (E5--3) -- E2 (E5--9)

P--L -- G--R

THW(E5--4) -- E2 (E5--9) THF (E5--5)-- E2 (E5--9) DATA (E5--6) -- E1 (E4--14) CLK (E5--14) -- E2 (E5--9) STA(E10--11)--E1(E4--14)

P -- G--R

0.2 -- 0.8

Apply vacuum 69 kPa (518 mmHg, 20.4 in.Hg) Idling, air intake temp. 0

˚

3.2 -- 3.8

C (32 F) to 80 C (176 F)

Idling, engine coolant temp. 60

˚

˚

˚

0.5--3.4

˚

C (140 F) to 120 C (248 F) ˚

˚

0.2--1.0

˚

LG--B -- G--R

IG switch ON (at engine cold)

0.5 -- 3.4

V -- BR

For 0.5 sec. after IG switch ON

Pulse generation

P -- G--R

For 0.5 sec. after IG switch ON

Pulse generation

P--BR

Cranking

TDC+ (E4--17) -- TDC-- (E4--16)

R -- G

Idling

NE+ (E4--19) -- NE-- (E4--18)

W -- B

Idling

SP1(E10--9) -- E1(E4--14)

G--O -- BR

TCV (E4--11) -- E01 (E4--13)

G--B -- W--B

IG switch ON Rotate driving wheel slowly IG switch ON

SPV+ (E4--12) -- E1 (E4--14)

GR -- BR

SPV-- (E4--25) -- E1 (E4--14)

R--B -- BR

Idling

6.0ormore Pulse generation ( Se epageD I -- 27) Pulse generation ( Se epageD I -- 27) Pulse generation 14 --9 Pulse generation

IG switch ON

( Se epageD I -- 30) 14 --9

Idling

Pulsegeneration

Idling

Pulse generation ( Se epageD I -- 37)

LU+A (E4--10) -- E01 (E4--13)

R -- W--B

Racing (engine warmed up)

Pulse generation

LU-- A(E4--9) -- E01 (E4--13)

Y -- W--B

Racing (engine warmed up)

Pulse generation

LU+ B(E4--8) -- E01 (E4--13)

P -- W--B

Racing (engine warmed up)

Pulse generation

LU-- B(E4--7) -- E01 (E4--13)

LG -- W--B

Racing (engine warmed up)

Pulse generation

5L--E ENGINE SUP (RM817E)

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DI--20 DIAGNOSTICS--

ENGINE

IG switch ON MREL (E10--3) -- E1 (E4--14)

SREL (E10--2) -- E01 (E4--13) IGSW(E10--14)--E1(E4--14)

L--O -- BR

B--R -- BR B--W--BR

14 --9

IG switch OFF (after IG switch OFF for 2 sec.)

0 -- 1.5

Cranking

14 --9

Idling (engine start and after 600 sec.) IGswitchON

0 -- 1.5 9--14

Accelerator pedal fully closed PDL (E6--3) -- E1 (E4--14) TAC(E6--7)--E1(E4--14) TC(E10--4)--E1(E4--14)

L -- BR R--W--BR V--BR

Idling IGswitchON

THOP (E5--15) -- E1 (E4--14)

GIND (E6--1) -- E1 (E4--14)

5L--E ENGINE SUP (RM817E)

P -- BR

L--R -- BR

GR--L -- BR

0

−

Pulsegeneration

Check enginewarninglightlights up W (E10--5) -- E1 (E4--14)

9 -- 14

Accelerator pedal fully opened

except check engine warning light lights up

9--14 0 -- 3 9 -- 14

Idling(enginewarmedup)

9--14

IGswitchON(onecewithin5sec.)

0-- 3

Glowindicatorlightlightsup

0--3

except glow indicator light lights up

9 -- 14

3

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DI--21 DIAGNOSTICS --

ENGINE

Tha  i l a nd Engine ECU Terminals

E7

E6

13 12 11 10 9 8 7 6 5 4 3 2 1

E4

E5

5 4 3 2 1

6 5 4 3 2 1

26 25 24 23 22 21 20 19 18 17 16 15 14 16 15 14 13 12 11 10 9

8 7 6

12 11 10 9 8 7

11 10 9

8 7

6 5 4

3 2 1

22 21 20 19 18 17 16 15 14 13 12

A02958

Symbols(TerminalsNo.)

WiringColor

Condition

STDVoltage(V)

BATT(E7--1)--E1(E4--14)

Y--BR

+B(E7--12)--E1(E4--14)

R--L--BR

IGswitchON

9--14

VC(E5--1)--E2(E5--9)

B--G--R

IGswitchON

4.5--5.5

V--LG

IGswitchON

4.5--5.5

VCC(E6--6)--E2C(E6--4) VA (E6--5) -- E2C (E6--4)

VAS (E6--12) -- E2C (E6--4)

IDL (E6--9) -- E2C (E6--4)

Always

B--L -- LG

P -- LG

B--R -- LG

9--14

Accelerator pedal fully closed

0.3 -- 0.8

Accelerator pedal fully opened

2.9 -- 4.9

Accelerator pedal fully closed

0.3 -- 0.8

Acceleratot pedal fully opened

2.9 -- 4.9

Accelerator pedal fully closed

9 -- 14

Acceleratot pedal fully opened

0 -- 3

Apply vacuum 40 kPa (300 mmHg, 11.8 in.Hg) PIM (E5--2) -- E2 (E5--9)

B--Y -- G--R

THA (E5--3) -- E2 (E5--9)

P--L -- G--R

THW(E5--4) -- E2 (E5--9) THF (E5--5)-- E2 (E5--9) DATA (E5--6) -- E1 (E4--14) CLK (E5--14) -- E2 (E5--9) STA(E7--11)--E1(E4--14)

0.2 -- 0.8

Apply vacuum 69 kPa (518 mmHg, 20.4 in.Hg) Idling, air intake temp. 0

P -- G--R

˚

3.2 -- 3.8

C (32 F) to 80 C (176 F)

Idling, engine coolant temp. 60

˚

˚

˚

0.5--3.4

˚

C (140 F) to 120 C (248 F) ˚

˚

0.2--1.0

˚

LG--B -- G--R

IG switch ON (at engine cold)

0.5 -- 3.4

V -- BR

For 0.5 sec. after IG switch ON

Pulse generation

P -- G--R

For 0.5 sec. after IG switch ON

Pulse generation

P--L--BR

Cranking

TDC+ (E4--17) -- TDC-- (E4--16)

R -- G

Idling

NE+ (E4--19) -- NE-- (E4--18)

W -- B

Idling

SP1(E7--9) -- E1(E4--14)

G--O -- BR

TCV (E4--11) -- E01 (E4--13)

G--B -- W--B

IG switch ON Rotate driving wheel slowly IG switch ON Idling

6.0ormore Pulse generation ( Se epageD I -- 27) Pulse generation ( Se epageD I -- 27) Pulse generation 14 --9 Pulse generation

IG switch ON

( Se epageD I -- 30) 14 --9

Idling

Pulsegeneration

SPV+ (E4--12) -- E1 (E4--14)

GR -- BR

SPV-- (E4--25) -- E1 (E4--14)

R--B -- BR

EGR (E4--24) -- E01 (E4--13)

G--W -- W--B

LU+A (E4--10) -- E01 (E4--13)

R -- W--B

Racing (engine warmed up)

Pulse generation

LU-- A(E4--9) -- E01 (E4--13)

Y -- W--B

Racing (engine warmed up)

Pulse generation

Idling IG switch ON

5L--E ENGINE SUP (RM817E)

EGR ON (maintain engine speed at 1500 rpm)

Pulse generation ( Se epageD I -- 37) 14 --9 Pulse generation

CONTINUED

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DI--22 DIAGNOSTICS--

ENGINE

LU+ B(E4--8) -- E01 (E4--13)

P -- W--B

Racing (engine warmed up)

Pulse generation

LU-- B(E4--7) -- E01 (E4--13)

LG -- W--B

Racing (engine warmed up)

Pulse generation

IG switch ON MREL (E7--3) -- E1 (E4--14)

SREL (E7--2) -- E01 (E4--13) IGSW(E7--14)--E1(E4--14)

L--O -- BR

B--R -- W--B B--W--BR

14 --9

IG switch OFF (after IG switch OFF for 2 sec.)

0 -- 1.5

Cranking

14 --9

Idling (engine start and after 600 sec.)

0 -- 1.5

IGswitchON

AC1 (E6--2) -- E1 (E4--14)

Y -- BR

ACT (E6--8) -- E1 (E4--14)

LG--B -- BR

9--14

A/C switch ON (at magnet clutch ON)

0 -- 1.5

A/C switch OFF

7.5 -- 14

IG switch ON

14 --9

at A/C cut controlled

0 -- 3

(Driving below 30km/h, accelerator pedal fully opened for 5 sec.) Accelerator pedal fully closed PDL (E6--3) -- E1 (E4--14) TAC(E6--7)--E1(E4--14) TC(E7--4)--E1(E4--14) W (E7--5) -- E1 (E4--14)

NSW (E7--22) -- E1 (E4--14)

L -- BR B--BR V--BR

Idling

P -- BR

P -- BR

L--R -- BR

GIND (E6--1) -- E1 (E4--14)

R--W -- BR

0 -- 3 Pulsegeneration

IGswitchON

THOP (E5--15) -- E1 (E4--14)

5L--E ENGINE SUP (RM817E)

9 -- 14

Accelerator pedal fully opened

9--14

Check enginewarninglightlights up

0 -- 3

except check engine warning light lights up

9 -- 14

At shift position in P and N position

0 -- 3

At other shift position in P and N position

9 -- 14

Idling(enginewarmedup)

9--14

IGswitchON(onecewithin5sec.)

0-- 3

Glowindicatorlightlightsup

0--3

except glow indicator light lights up

9 -- 14

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DI--23 DIAGNOSTICS --

ENGINE

S outhAfri c a Engine ECU Terminals

E7

E5

13 12 11 10 9 8 7 6 5 4 3 2 1

E3

E4

5 4 3 2 1

6 5 4 3 2 1

26 25 24 23 22 21 20 19 18 17 16 15 14 16 15 14 13 12 11 10 9

8 7 6

12 11 10 9 8 7

11 10 9

8 7

6 5 4

3 2 1

22 21 20 19 18 17 16 15 14 13 12

A02958

Symbols(TerminalsNo.)

WiringColor

Condition

STDVoltage(V)

BATT(E5--1)--E1(E3--14)

Y--BR

+B(E5--12)--E1(E3--14)

R--L--BR

IGswitchON

9--14

VC(E4--1)--E2(E4--9)

B--G--R

IGswitchON

4.5--5.5

V--LG

IGswitchON

4.5--5.5

VCC(E7--6)--E2C(E7--4) VA (E7--5) -- E2C (E7--4)

VAS (E7--12) -- E2C (E7--4)

IDL (E7--9) -- E2C (E7--4)

Always

B--L -- LG

P -- LG

B--R -- LG

9--14

Accelerator pedal fully closed

0.3 -- 0.8

Accelerator pedal fully opened

2.9 -- 4.9

Accelerator pedal fully closed

0.3 -- 0.8

Acceleratot pedal fully opened

2.9 -- 4.9

Accelerator pedal fully closed

9 -- 14

Acceleratot pedal fully opened

0 -- 3

Apply vacuum 40 kPa (300 mmHg, 11.8 in.Hg) PIM (E4--2) -- E2 (E4--9)

B--Y -- G--R

THA (E4--3) -- E2 (E4--9)

P--L -- G--R

THW(E4--4) -- E2 (E4--9) THF (E4--5)-- E2 (E4--9) DATA (E4--6) -- E1 (E3--14) CLK (E4--14) -- E2 (E4--9) STA(E5--11)--E1(E3--14)

P -- G--R

Apply vacuum 69 kPa (518 mmHg, 20.4 in.Hg) Idling, air intake temp. 0

˚

Idling, engine coolant temp. 60

˚

˚

˚

C (140 F) to 120 C (248 F) ˚

˚

0.2--1.0

˚

0.5 -- 3.4

V -- BR

For 0.5 sec. after IG switch ON

Pulse generation

P -- G--R

For 0.5 sec. after IG switch ON

Pulse generation

P--BR

Cranking Idling

NE+ (E3--19) -- NE-- (E3--18)

W -- B

Idling IG switch ON

SPV (E3--25) -- E1 (E3--14)

0.5--3.4

˚

IG switch ON (at engine cold)

R -- G

SPV+ (E3--12) -- E1 (E3--14)

3.2 -- 3.8

C (32 F) to 80 C (176 F)

LG--B -- G--R

TDC+ (E3--17) -- TDC-- (E3--16)

TCV (E3--11) -- E01 (E3--13)

0.2 -- 0.8

G--B -- W--B

Idling

6.0ormore Pulse generation ( Se epageD I -- 27) Pulse generation ( Se epageD I -- 27) 14 --9 Pulse generation ( Se epageD I -- 30)

IG switch ON

14 --9

Idling

Pulsegeneration

GR -- BR

R--B -- BR

Idling

Pulse generation ( Se epageD I -- 37)

LU+A (E3--10) -- E01 (E3--13)

R -- W--B

Racing (engine warmed up)

Pulse generation

LU-- A(E3--9) -- E01 (E3--13)

Y -- W--B

Racing (engine warmed up)

Pulse generation

LU+ B(E3--8) -- E01 (E3--13)

P -- W--B

Racing (engine warmed up)

Pulse generation

LU-- B(E3--7) -- E01 (E3--13)

LG -- W--B

Racing (engine warmed up)

Pulse generation

IG switch ON MREL (E5--3) -- E1 (E3--14)

L--O -- BR

IG switch OFF (after IG switch OFF for 2 sec.)

14 --9 0 -- 1.5

5L--E ENGINE SUP (RM817E)

CONTINUED

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DI--24 DIAGNOSTICS--

ENGINE

Cranking SREL (E5--2) -- E01 (E3--13) IGSW(E5--14)--E1(E3--14)

B--R -- W--B B--W--BR

14 --9

Idling (engine start and after 600 sec.)

0 -- 1.5

IGswitchON

AC1 (E7--2) -- E1 (E3--14)

Y -- BR

ACT (E7--8) -- E1 (E3--14)

LG--R -- BR

9--14

A/C switch ON (at magnet clutch ON)

0 -- 1.5

A/C switch OFF

7.5 -- 14

IG switch ON

14 --9

at A/C cut controlled

0 -- 3

(Driving below 30km/h, accelerator pedal fully opened for 5 sec.) Accelerator pedal fully closed PDL (E7--3) -- E1 (E3--14) TAC(E7--7)--E1(E3--14) TC(E5--4)--E1(E3--14)

L -- BR B--BR V--BR

Idling IGswitchON

THOP (E4--15) -- E1 (E3--14)

GIND (E7--1) -- E1 (E3--14)

SPD (E5--9) -- E1(E3--14)

5L--E ENGINE SUP (RM817E)

P -- BR

L--R -- BR

R--W -- BR

G--O -- BR

0 -- 3 Pulsegeneration

Check enginewarninglightlights up W (E5--5) -- E1 (E3--14)

9 -- 14

Accelerator pedal fully opened

except check engine warning light lights up

9--14 0 -- 3 9 -- 14

Idling(enginewarmedup)

9--14

IGswitchON(onecewithin5sec.)

0-- 3

Glowindicatorlightlightsup

0--3

except glow indicator light lights up

9 -- 14

IG switch ON Rotate driving wheel slowly

Pulse generation

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DI--25 DIAGNOSTICS--

ENGINE DI064--21

PROBLEM SYMPTOMS TABLE When the malfunction code is not confirmed the DTC check and the problem still can not be confirmed in the basic inspection, then proceed to this step and perform troubleshooting according to the numbered order given in the table below. Symptom Does not crank (Difficult to start)

No initial combustion (Difficult to start)

SuspectArea 1. Starter and starter relay

DI -- 82

2. Pre--heating system

DI -- 88

3. Compression

DI--88

2. STA signal circuit

DI--101

3. Water temperature sensor

ED--12

4. Injection nozzle

*

5. Fuel filter

*

7. Engine ECU 8. Injection pump 1. STA signal circuit

* *

4. Diesel throttle body

1. Fuel filter 2. Diesel throttle body 3. Engine ECU

*

ED--25 FU--7

2. Diesel throttle body 3. Engine ECU

2. Fuel filter 3. Engine ECU

*

ED--25 FU--7 ED--12 *

ED--25 FU--7

1. A/C signal circuit

D I -- 106

2. Water temperature sensor

ED--12

3. Engine ECU

ED--25

4. Injection pump 1. A/C signal circuit 2. Injection nozzle 3. EGR system 4. Water temperature sensor

FU--7 D I -- 106 *

DI -- 96 ED--12

5. Diesel throttle body

*

6. Compression

*

7. Valve clearance

*

8. Fuel line (Air beed) 9. Engine ECU 10. Injection pump

L

*

DI -- 82

4. Injection pump

Lower engine idle speed (Poor idling)

FU--7

1. ECU power source circuit

1. Water temperature sensor

High engine idle speed (Poor idling)

*

ED--25

4. Injection pump

4. Injection pump

Incorrect first idle (Poor idling)

FU--7 D I -- 101

3. Fuel filter

6. Injection pump

Others (Engine stall)

*

ED--25

2. Injection nozzle

5. Engine ECU

Soon after starting (Engine stall)

*

ED--25 FU--7

1. Pre--heating system

6. Diesel throttle body

Hot engine (Difficult to start)

*

1. ECU power source circuit

4. Engine ECU 5. Injection pump

Cold engine (Difficult to start)

Seepage

-ED--25 FU--7

: See Pub. No. RM520E and RM582E CONTINUED

5L--E ENGINE SUP (RM817E)

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DI--26 DIAGNOSTICS--

ENGINE

Symptom

SuspectArea 1. Injection nozzle 2. Fuel line (Air beed) 3. Pre--heating system

Rough idling (Poor idling)

DI -- 96 ED -- 3

8. Engine ECU 9. Injection pump 1. Injection nozzle 2. ECU power source circuit 3. Compression 4. Fuel line (Air beed)

FU -- 7 DI -- 88 DI -- 82

4. Water temperature sensor

ED -- 12

5. Compression

*

--

7. Valve clearance

ED -- 25

8. Engine ECU

ED -- 25 FU -- 7 * *

3. EGR system 4. Compression

DI -- 96

5. Engine ECU

ED -- 25

*

FU -- 7 *

2. EGR system

DI -- 96

3. Water temperature sensor

ED -- 12

4. Engine ECU

ED -- 25

1. Injection nozzle

*

2. EGR system

DI -- 96

3. Diesel throttle body

ED -- 3

4. Intake air temperature sensor

ED--14

5. Engine ECU

ED -- 25

6. Injection pump

FU-7

1. EGR system

DI -- 96

2. Pre--heating system

DI -- 88

3. Injection nozzle

*

4. Fuel filter 5. Diesel throttle body

ED -- 3

6. Water temperature sensor

ED -- 12

7. Intake air temperature sensor

ED -- 14

8. Engine ECU

ED -- 25

9. Injection pump

FU-7

1. Injection nozzle

5L--E ENGINE SUP (RM817E)

*

3. ECU power source circuit

1. Injection nozzle

: See Pub. No. RM520E and RM582E

--

1. Pre--heating system

6. Injection pump

L

*

ED -- 25

2. Fuel filter

Surging/ Hunting (Poor driveability)

*

DI -- 82

7. Injection pump

1. Injection nozzle

White smoke (Poor driveability)

FU -- 7

6. Engine ECU

9. Injection pump

Black smoke (Poor driveability)

*

ED -- 25

ED -- 25

6. Fuel line (Air beed)

Knocking (Poor driveability)

*

5. Valve clearance

2. Injection nozzle

Hesitation/ Poor acceleration (Poor driveability)

-DI -- 88

5. Diesel throttle body 7. Valve clearance

Hunting at cold engine (Poor idling)

*

4. EGR system 6. Compression

Hunting at hot engine (Poor idling)

Seepage

*

*

2. Engine ECU

ED -- 25

3. Injection pump

FU-7

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CIRCUIT INSPECTION: Page 1 of 4 DTC: 12 Crankshaft Position Sensor Circuit Malfunction DI-27 Circuit Description DI-27 Wiring Diagram DI-27 Inspection Procedure DI-28 DTC: 13 Engine Speed Sensor Circuit Malfunction DI-29 Circuit Description DI-29 Wiring Diagram Inspection Procedure DTC: 14 Timing Control System Malfunction DI-30 Circuit Description Wiring Diagram DI-30/ South Africa DI-32 Inspection Procedure DI-32/34 DTC: 15 Throttle Control Motor Circuit Malfunction DI-35 Circuit Description Wiring Diagram Inspection Procedure DI-35/36 DTC: 18 Spill Control Circuit MalfunctionDI-37 Circuit Description Wiring Diagram Inspection Procedure DI-38/39 DTC: 19(1) Accelerator Petrol Position Sensor circuit Malfunction (open / short) DI-40 Circuit Description Wiring Diagram DI-41/ South Africa DI-42 Inspection Procedure DI-43 When using hand-held tester DI-43/ When not using 47 DTC: 19(2) Accelerator Pedal Position Sensor Circuit Malfunction (IDL Switch /Range Malfunction. DI-48 Circuit Description Wiring Diagram Inspection Procedure When using hand-held tester DI-48/ When not using DI-53 DTC: 19(3) Accelerator Pedal Closed Position Switch Circuit Malfunction (Short) DI-53 CONTINUED

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CIRCUIT INSPECTION: Page 2 of 4 DTC: 19(4) Accelerator Pedal Closed position Switch Circuit Malfunction (Open) DI-53 Circuit Description Wiring Diagram Inspection Procedure DI-54 DTC: 22 Water Temp. Sensor Circuit Malfunction DI-55 Circuit Description Wiring Diagram DI-56 Inspection Procedure hand held DI-56/ No hand held DI-59 DTC: 24 Intake Air Temp. Sensor Circuit Malfunction DI-60 Circuit Description Wiring Diagram DI-61 Inspection Procedure hand held DI-61/ No hand held DI-65 DTC: 32 Inspection Pump Correction System MalfunctionDI-66 Circuit Inspection Wiring Diagram Inspection Procedure DI-66/67 DTC: 35 Intake Air Pressure Sensor Circuit Malfunction DI-68 Circuit description Wiring Diagram DI-69 (Australia) (Thailand) South Africa DI-71 Inspection procedure hand heldDI-71/ No hand held DI-74 DTC: 39 Fuel Temp. Sensor Circuit Malfunction Circuit Description Wiring Diagram DI-76 Inspection Procedure Hand heldDI-76/ No hand held DI-79 DTC: 42 Vehicle Speed Sensor Signal Circuit MalfunctionDI-80 Circuit Description DI-80 Wiring Diagram Inspection Procedure DI-81

CONTINUED

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CIRCUIT INSPECTION: Page 3 of 4 ECU: Power Source Circuit DI-82 Circuit Description Wiring Diagram DI-82 (Australia) (South Africa DI-83) Thailand Inspection Procedure DI-85/ DI-87 Pre-Heating Control Circuit DI-88 Circuit Description Wiring Diagram DI-89 (Australia) South Africa DI-90 (Thailand) Inspection Procedure DI-92/95 EGR: Control Circuit Circuit Description Wiring Diagram Inspection Procedure DI-97 When using hand-held tester DI-97/98 When not using hand-held tester DI-98/100 Starter Signal Malfunction DI-101 Circuit Description Wiring Diagram (Australia) South Africa DI-102 (Thailand) Inspection Procedure Di-104 When using hand-held tester DI-104 When not using hand-held tester DI-105 A/C Signal Circuit DI-106 Circuit Description Wiring Diagram Inspection Procedure When using hand-held tester DI-106/107 When not using hand-held tester DI-107/108 CONTINUED

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CIRCUIT INSPECTION: Page 4 of 4 A/C Cut Control Circuit DI-109 Circuit Description Inspection Procedure When using a hand-held tester DI-110/111 When not using a hand-held tester DI-111/112 Diagnostic Connector (DLC3) Circuit DI-113 Circuit Description Wiring Diagram (Australia) South Africa DI-115 (Thailand) Inspection Procedure DI-117/119 Neutral Start Switch Circuit (only for vehicles with A/T) DI-20 Circuit Description Wiring Diagram Inspection DI-121/122

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DI--27 DIAGNOSTICS --

ENGINE DI2ZO--02

CI RCUI TI NS P E CT I O N DTC

12

CrankshaftP osi ti o nS ensorCi rcui t Malfuncti on

CIRCUITDESCRIPTION The crankshaft position sensor in the Engine Control System contains signal plate and a pickup coil for TDC signal. The TDC signal plate has 1 tooth on its outer circumference. The TDC signal sensor generates 1 signal for every engine revolution. The engine ECU detects the top dead center by the TDC signals. The engine speed sensor in the Engine Control System contains signal plate and a pickup coil for NE signal. The NE signal plate has 78 teeth and is mounted in the injection pump. The NE signal sensor generates 78 signals of engine 2 revolutions. The engine ECU detects the engine speed and cam lift position of the injection pump. The engine ECU uses TDC signal and NE signals for injection timing control. And NE signal is used for injection volume control, also. DTCNo.

12

DTCDetectingCondition

TroubleArea

No TDC signal to engine ECU at 400 rpm or more

TDC Signal Waveforms 2V/DIV

TDC

S

Open or short in crankshaft position sensor circuit

S

Crankshaft position sensor

S

Engine ECU

Referenc e: INSPECTION USING OSCILLOSCOP E During cranking or idling, check between terminals TDC+ and TDC-- of engine ECU. HINT:

The correct wavaforms are as shown. NE

20 m sec./Division(Idling)

A02483

WIRINGDIAGRAM Crankshaft Position Sensor

Engine ECU

(Shielded)

1

R

17 *1

TDC+

2

G

16 *1

TDC--

19 *1

NE+

18 *1

NE--

Engine Speed Sensor (inside the Injection Pump)

(Shielded)

2

W

1

B

BR

*2 : EO Australia, Thailand EG South Africa 5L--E ENGINE SUP (RM817E)

*2 *1 : E4 Australia, Thailand E3 South Africa A15520

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DI--28 DIAGNOSTICS--

ENGINE

INSPECTION PROCEDURE 1

Check resistance of cranksh aft position sensor (TDC) (Seepage ED - 18).

NG

Replace crankshaft position sensor.

OK

2

Checkfor openand shortni harness and conn ector between engine ECU and crankshaftposition sensor (See p age IN -- 19).

NG

Repair or replace harness or connector.

NG

Tighten sensor.

OK

3

Inspectio n senso rinstallat io n.

OK

Checkand re place engine EC U (See pageIN --19).

CONTINUED

5L--E ENGINE SUP (RM817E)

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DI--29 DIAGNOSTICS--

ENGINE DI066--13

DTC

13

E ngineSpeed SensorCrcuit i M alfuncti on

CIRCUIT DESCRIPTION RefertoDTC12(CrankshaftPositionSensorCircuitMalfunction)onpageDI -- 27. DTCNo.

DTCDetectingCondition

TroubleArea

No NE signal to engine ECU for 0.5 sec. or more at 580 rpm or SOpen or short

more 13

No NE signal to engine ECU for 2.0 sec. or more during cranking

in engine speed sensor circuit

SEngine speed sensor SEngine ECU

WIRING DIAGR AM RefertoDTC12(CrankshaftPositionSensorCircuitMalfunction)onpageDI -- 27.

INSPECTION PROCEDURE 1

Check resistance o f en gine speed sen sor (See p age F U -- 7).

NG

Check and replace inject ion pump (S ee pageFU - 7).

OK

2

Checkfor openand short in harness dan connector between engine ECU and engine speed sen sor (See p age IN -- 19).

NG

Repair or replace harness or connector.

NG

Tighten sensor.

OK

3

Inspectio n senso rinstallat io n.

OK

Check and replace engine ECU (See pageIN --19). 5L--E ENGINE SUP (RM817E)

CONTINUED

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DI--30 DIAGNOSTICS--

ENGINE DI8NO--01

DTC

14

Timing ControlS ystem Malfunc ti on

CIRCUIT DESCRIPTION The engine ECU control the injection timing by actuating the timing control valve. The timing control valve is mounted on the injection pump and delay one by duty control of pump internal fuel pressure. The engine ECU detects the injection advance angle by TDC and NE signals. DTCNo.

DTCDetectingCondition

TroubleArea SOpen or short

STiming control valve

After engine warm up and during, actual injection timing is 14

in timing control valve circuit

different from target value of engine ECU calculated for several sec.

SFuel filter

(Clogging)

SFuel (Freezing, Air in) SInjection pump (Internal

pressure and timing control valve)

SEngine ECU

WIRING DIAGR AM Australia: Engine Room R/B

Engine ECU

ECD Relay R--B

2

5

2

3

R--L

14 IJ1 R--L

Engine Room R/B 2

1

2

1 2

2

IC3 Timing Control Valve G--B 1 2

R--L

2 ECD

11 E4

TCV

3 *1

MREL

W--B

J1 Junction Connector

1 2

L--O

2 IJ1

L--O

W W--B

Battery

EF *1 : E10 Thailand Made E6 Except Thailand Made

A15521

CONTINUED

5L--E ENGINE SUP (RM817E)

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DI--31 DIAGNOSTICS--

ENGINE

Thailand: Engine Room R/B

Engine ECU

ECD Relay Y

2

5

2

3

R--L

16 IJ4 R--L

Y Engine Room R/B 2

2

1 1 IC10 2

2

R--L

2 ECD

Timing Control Valve G--B 1 2

11 E4

TCV

3 E7

MREL

W--B

J1 Junction Connector

1 2

L--O

20 IJ4

L--O

W W--B Battery EF

CONTINUED A15521

5L--E ENGINE SUP (RM817E)

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DI--32 DIAGNOSTICS--

ENGINE

South Africa: Engine Room R/B

Engine ECU

ECD Relay Y

2

5

2

3

R--L

14 IA2 R--L

Y Engine Room R/B 2

2

1 1 2

2

IB1

R--L

2 ECD

Timing Control Valve G--B 1 2

11 E3

TCV

3 E5

MREL

W--B

J1 Junction Connector

1 2

2 IA2

L--O

L--O

W W--B Battery EF

A15521

INSPECTION PROCEDURE 1

Checktiming control valve(See pageUF--7).

NG

Check and replace injectionpump (See page FU--7).

OK CONTINUED

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DI--33 DIAGNOSTICS--

2

ENGINE

Checkvoltagebetween terminalTCV of engineECU connectorand bodyground. ON

TCV

(+)

(--)

A04925

PREPARATION: (a) Remove the glove compartment door. (b) Disconnect the connector of engine ECU. (c) Turn the ignition switch ON. CHE CK: Measure voltage between terminal TCV of engine ECU connector and body ground. OK: Voltage: 9 -- 14 V

OK

Go to step3.

NG

Check foropenorshortinharness andconnectorbetweentimingcontrolvalveand engine ECU, timing control valve and ECD lay re (Ma rking: ECD)(See pa ge IN -- 19).

3

Check voltage between terminal TCV of engineECU and body ground. PREPARATION: (a) Remove the glove compartment door. (b) Turn the ignition switch ON. CHE CK: Measure voltage between terminal TCV of engine ECU and body ground. OK: Voltage: 9 -- 14 V

ON TCV

(+)

(--)

A04942

TCV Signal Waveforms 10V/DIV TCV

Reference: INSPECTIONUSING OSCILLOSCOPE During idling, check waveform between terminals TCV and E1 of engine ECU. HINT: The correct waveform is as shown.

10 msec./ Division (Idling)

CONTINUED

A02482

NG 5L--E ENGINE SUP (RM817E)

Check and replace engine ECU (See pa ge IN -- 19).

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DI--34 DIAGNOSTICS--

ENGINE

OK

4

Checkfuelfilterclogging,fuelfreezingand fuelair in.

NG

Replace or repair.

OK

Check and replace injection pump (See pageFU -- 7).

CONTINUED

5L--E ENGINE SUP (RM817E)

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DI--35 DIAGNOSTICS--

ENGINE DI8NP--01

DTC

15

Thrott le Control Motor Ci rcuit M alfuncti on

CIRCUIT DESCRIPTION Throttle control motor is operated by the engine ECU and it opens and closes the throttle valve. The fully opening of the throttle valve is detected by the throttle fully open position switch which is mounted on the throttle body. If this DTC is stored, the engine ECU shuts down the power for the throttle control motor. DTCNo.

DTCDetectingCondition

TroubleArea S

Open or short in throttle control motor circuit

S

15

pen or s or n

ro e con ro mo or c rcu

rott e contro motor

SThrottle valve

Open en or orsshort or nin throttle ro e u full swswitch c c rcu circuit

SEngine ECU

WIRING DIAGR AM Throttle Control Motor LU+A 2 +B1 R--L LU--A

Engine ECU

6

R

4

Y

P

L R

10 *1 9 *1

LG

W--B

From Terminal 3 of ECD MAIN Relay ( S eepageDI -- 82)

LU--A

8 *1

LU+B 3 5 +B2 R--L 1 LU--B

LU+A

LU+B

7 *1

LU--B

13 *1

E01

*1 *2

: E4 Australia, Thailand E3 South Africa *2 : EO Australia, Thailand EG South Africa A15534

INSPECTION PROCEDURE HINT: Read freeze frame data using hand--held tester. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting, it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air--fuel ratio was lean or rich, etc. at the time of the malfunction. CONTINUED

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DI--36 DIAGNOSTICS--

1

Checkthrottle control motorcircuit. Signal Waveform 10 V/ Division

LU+A LU+B

GND

LU--A LU--B

ENGINE

0.5 msec./Division

A11073

PREPARATION: (a) Connect the oscilloscope between terminals LU+A/LU-A/LU+B/LU--B and E01 of the engine ECU connector. (b) Start the engine. CHECK: Check the waveform between terminals LU+A/LU--A/LU+B/ LU--B and E01 of the engine ECU connector when the engine is racing and accele OFF. OK: The correct waveformis as shown. OK

Check and replace engine ECU (See pa ge IN -- 19).

NG

2

Check throt tle controlmotor (SeepageED -- 3).

NG

Replac e throttl e body (See page E D -- 4 ).

OK

3

Checkfor openandshort in harness ndaconnector betw een thrott le controlmo tor and engine ECU (SeepageIN -- 19).

NG

OK

Check and replace engine ECU (See pageED -- 23).

5L--E ENGINE SUP (RM817E)

Repair or replace.

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DI--37 DIAGNOSTICS--

ENGINE DI2ZQ--02

DTC

18

S pill Control Circuit Malfuncti on

CIRCUIT DESCRIPTION The engine ECU controls the fuel injection volume by operating the spill control valve. The spill control valve is mounted on the injection pump, and open or close the injection pressure releasing port by the solenoid valve in the spil l control valve (During injection; valve is close (ON)), The engine ECU decides the basic fuel injection volume by the engine rpm and accelerator pedal opening angle, and calculates the final fuel injection angle to add the variou s corrections on the basi c fuel injection volume. The engine ECU counts the NE pulse to detects the angle from injection starts and operates thespil l control valve from ON to OFF (The injection pressure releasing port is open.) at the position which watches the final fuel injection angle.

NE Pulse

Close (ON) SPV Open (OFF)

Final fuel injection angle

Plunger Lift

Injectionstart DTCNo.

A02626

DTCDetectingCondition

TroubleArea SOpen

18

Open or short in spill control valve at 500 rpm or more

or short in spill control valve circuit

SSpill control valve SEngine ECU

WIRING DIAGR AM Engine ECU Spill Control Valve 2

GR

1

R--B

12 *1

SPV+

25 *1

SPV--

*1 : E4 Australia, Thailand E3 South Africa CONTINUED

5L--E ENGINE SUP (RM817E)

A15522

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DI--38 DIAGNOSTICS--

ENGINE

INSPECTION PROCEDURE 1

Check spill control valve(See ag p e FU -- 14).

NG

Replace injection pump.

OK

2

Ch ec k v o l ta ge b ete wn te rm ni al SPV+ of engi ne ECU c onnector and body ground. ON

SPV+

A04945

PREPARATION: (a) Remove the glove co mpartment door (SeepageED -- 24). (b) Turn the ignition switch ON. CHECK: Measure voltage between terminal SPV+ of engine ECU connector and body ground. OK: Voltage: 9 -- 14 V NG

Check and replace engine ECU (See pa ge IN -- 19).

OK CONTINUED

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DI--39 DIAGNOSTICS--

3

ENGINE

Check voltage between terminal SPV -- of engineECU and body ground. ON SPV--

A04946

SPV-- Signal Waveforms

20 V/ DIV

PREPARATION: (a) Remove the glove compartment door (SeepageED -- 24). (b) Turn the ignition switch ON. CHE CK: Measure voltage between terminals SPV-- of engine ECU and body ground. OK: Voltage: 9 -- 14 V Reference: INSPECTIONUSING OSCILLOSCOPE During idling, check waveform between terminals SPV-- and E1 of engine ECU. HINT: The correct waveform is as shown.

GND

10 msec./ DIV (Idling)

A05025

NG

OK

Check for open or short in harness and connector between spill control valve and engine ECU (See pageIN -- 19).

5L--E ENGINE SUP (RM817E)

Check and replace engine ECU (See pa ge IN -- 19).

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DI--40 DIAGNOSTICS--

ENGINE DI8NQ--01

DTC

19 (1)

Accelerator Pedal Position Sensor circuit Malfunction(Open /Short)

CIRCUIT DESCRIPTION The accelerator pedal position sensor is mounted at the accelerator pedal and detects the accelerator pedal opening angle. When the accelerator pedal is fully closed, a voltage of approximately 1.0 V is applied to terminals VA, VAS of the engine ECU. The voltage applied to the terminals VA, VAS of the engine ECU increases in proportion to the opening angle of the accelerator pedal and becomes approximately 3.8 V when the accelerator pedal is fully opened. The engine ECU judges the vehicle driving conditions from these signals input from terminals VA, VAS and uses them as one of the conditions to control the injection volume and diesel throttle valve position. The idle switch is mounted in the accelerator pedal position sensor and sends the IDL signal to the engine ECU when accelerator pedal is fully closed. This system has 2 way accelerator pedal position sensor and accelerator pedal closed position switch for fail safe. DTCNo.

DTCDetectingCondition

TroubleArea

Open or short in accelerator pedal position sensor circuit for

19 (1)

0.05 sec. or more

SOpen or short

in accelerator pedal position sensor circuit

SAccelerator pedal position sensor SEngine ECU

HINT: After confirming DTC 19 (1) use the hand--held tester to confirm the accelerator pedal opening percentage and accelerator pedal close positi on switch condition. Accelerator pedal opening position expressed as percentage Accelerator pedal fully closed %

0

Approx. 100 %

5L--E ENGINE SUP (RM817E)

Trouble area

Accelerator pedal fully open %

VCC line open

0

VA, VAS line open or short Approx. 100 %

E2C line open

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DI--41 DIAGNOSTICS--

ENGINE

WIRING DIAGR AM Australia: Engine ECU

Accelerator Pedal Position Sensor VAS

E2

VA

IDL

VC

1

R

2

*1

VAS

LG

4 *1

E2C

5

B--L

5 *1

VA

3

B--R

9 *1

IDL

4

V

6 *1

VCC

L

3 *1

PDL

Accelerator Pedal Switch

Center Junction Block W--B

1

2

12

14 3E

21 6

J3 Junction Connector W--B A

3E

*1 : E6 Thailand Made E9 Except Thailand Made

IH

A15523

CONTINUED

5L--E ENGINE SUP (RM817E)

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DI--42 DIAGNOSTICS--

ENGINE

Thailand, South Africa: Engine ECU

Accelerator Pedal Position Sensor VAS

E2

VA

IDL

VC

P

2

LG

4 *1

E2C

5

B--L

5 *1

VA

3

B--R

9 *1 IDL

4

V

1 *2

L--W

Accelerator Pedal Switch W--B 1

2

12 *1 VAS

1

L

2 *2 *1: E7 South Africa E6 Thailand *2: IF1 South Africa IQ1 Thailand

6 *1

VCC

3 *1

PDL

*3: IH South Africa II Thailand W--B *3

A15533

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DI--43 DIAGNOSTICS--

ENGINE

INSPECTION PROCEDURE When using hand-- held tester 1

Connect the han d - held es t ter, read th e accelerat o r pedal o pen in gp ercen tag e.

PREPARATION: (a) Connect the hand--held tester to the DLC3. (b) Turn the ignition switch ON and push the hand--held tester main switch ON. CHECK: Read the accelerator pedal opening percentage. OK: Accelerator pedal

Accelerator pedal opening position expressed as percentage

Fullyopen

Approx.65%

Fullyclosed

Approx.18%

FI7052

OK

Checkfor intermittentproblems (S ee pa geDI -- 4).

NG

2

Check voltage between terminal 4 of wireharness side connector and body ground. ON 4

(+)

BE6653 A05026

(--)

A05257

PREPARATION: (a) Disconnect the acc elerator pedal position sensor connector. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminal 4 of wire harness side connector and body ground. OK: Voltage: 4.5 -- 5.5 V

NG

Go to step 5.

OK CONTINUED

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DI--44 DIAGNOSTICS--

3

ENGINE

Check voltage b etweenterm in als VA, VAS an d E2C of eng ine ECU. ON

VA

E2C

VAS

(+)

BE6653 P23864

PREPARATION: (a) Remove the glove compartment door. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals VA, VAS and E2C of engine ECU. OK:

(--)

Accelerator pedal A04947

OK

Voltage

Fullyclosed

0.7--1.1V

Fullyopen

2.9--4.9V

Check and replace engine ECU (See pa ge IN -- 19).

NG

4

Checkfor openand short in harness and conne ctor betw een engine ECU and accelerato r pedal po sitio n senso r (VA, VAS lin e) (Seepage IN -- 19).

NG

Repair harness or connector.

OK

CONTINUED

Replaceaccelerator pedal position sensor.

5L--E ENGINE SUP (RM817E)

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DI--45 DIAGNOSTICS--

5

ENGINE

Check voltage b etweenterm in als VCC and E2C of engine ECU. ON

PREPARATION: (a) Remove the glove compartment door. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals VCC and E2C of engine ECU connector. OK: Voltage: 4.5 -- 5.5 V

E2C

VCC

(+)

BE6653 P23865

(--) A04948

NG

Check and replace engine ECU (See pa ge IN -- 19).

OK

Check for open in harness and connector between engine ECU and accelerator pedal position sensor (V CC line)(See pa ge IN -- 19) .

When not using hand-- heldtester 1

Check voltage between terminal 4 of wireharness side connector and body ground. ON 4

(+)

BE6653 A05026

(--)

A05257

PREPARATION: (a) Disconnect the acc elerator pedal position sensor connector. (b) Turn the ignition switch ON. CHE CK: Measure voltage between terminal 4 of wire harness side connector and body ground. OK: Voltage: 4.5 -- 5.5 V

NG

Go to step 4.

OK CONTINUED

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DI--46 DIAGNOSTICS--

2

ENGINE

Check voltage b etweenterm in als VA, VAS an d E2C of eng ine ECU. ON VAS

V A

PREPARATION: (a) Remove the glove compartment door. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals VA, VAS and E2C of engine ECU. OK:

E2C

(+)

Accelerator pedal

(--) A04947

OK

Voltage

Fullyclosed

0.7--1.1V

Fullyopen

2.9--4.9V

Check and replace engine ECU (See pa ge IN -- 19).

NG

3

Checkfor openand short in harness and conn ector between engi ne ECU and accelerato r pedal po sitio n senso r (VA, VAS lin e) (Seepage IN -- 19).

NG

OK

Replaceaccelerator pedal position sensor.

5L--E ENGINE SUP (RM817E)

Repair harness or connector.

CONTINUED

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DI--47 DIAGNOSTICS--

4

ENGINE

Check voltage b etweenterm in als VCC and E2C of engine ECU. ON

VCC

PREPARATION: (a) Remove the glove compartment door. (b) Turn ignition switch ON. CHECK: Measure voltage between terminals VCC and E2C of engine ECU connector. OK: Voltage: 4.5 -- 5.5 V

E2C

(+)

(--) A04948

NG

Check and replace engine ECU (See pa ge IN -- 19).

OK

Check for open in harness and connector between engine ECU and accelerator pedal position sensor VCC ( line) (See pa ge IN -- 19).

5L--E ENGINE SUP (RM817E)

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DI--48 DIAGNOSTICS--

ENGINE DI8NR--01

DTC

19 (2)

Accelerator P edal P osi tinoS ensor Circuit Malfuncti on (IDL Switch/Range Malfunc ti on)

CIRCUIT DESCRIPTION Refer to DTC 19 (1) (Accelerator Pedal Position Sensor Circuit Malfunction (Open/Short)) on page DI--40. DTCNo.

DTCDetectingCondition

TroubleArea

Condition (a) or (b) continue 0.5 sec. or more: (a) IDL ON and VA > 1.4 V (b) IDL ON and VAS >1.4 V

19(2)

Condition (a) or (b) continue 0.5 sec. or more:

SOpen or short

(a) IDL OFF and VA < 0.6 V

SAccelerator pedal position sensor

(b) IDL OFF and VAS < 0.6 V

SEngine ECU

in accelerator pedal position sensor circuit

Conditions (a) and (b) continue 0.05 sec. or more: (a)  0.6 V  < VA Fully closed study voltage +0.41 V (c) VAS > Fully closed study voltage +0.41 V

TroubleArea SShort

in accelerator pedal closed position switch circuit

SAccelerator pedal closed position switch SEngine ECU

PDL does not turn ON even once while driving vehicle

19(4)

(2 trip detection logic)

SOpen in accelerator pedal closed position switch circuit

Conditions (a) and (b) continue 5 sec. or more:

SAccelerator pedal closed position switch

(a) PDL OFF

SEngine ECU

(b) IDL ON

WIRING DIAGR AM RefertoDTC19(1)(AcceleratorPedalPositionSensorCircuitMalfunction(Open/Short))onpageDI -- 40.

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DI--54 DIAGNOSTICS--

ENGINE

INSPECTION PROCEDURE 1

Check accelerator pedal closed po sition switch . PREPARATION: Disconnect the accelerator pedal closed position switch connector. CHECK: Measure resistance between terminals of accelerator pedal

1

closed OK: position switch.

2

Terminals A05027

NG

Accelerator pedal

1-- 2

Fullyclosed

1--2

Fullyopen

Resistance ∞

0--20

Ω

Replaceacceler ator pedal closedposition switch(See pa ge ED - 19).

OK

2

Check voltage between terminal PDL ofengineECU and body ground. ON

BE6653 P23864

PREPARATION: (a) Remove the glove compartment door. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminal PDL of engine ECU and body ground. OK:

PDL

(+)

(--)

Accelerator pedal A04950

Fullyclosed Fullyopen

OK

Voltage 9--14V 0--3V

Check and replace engine ECU (See pa ge IN -- 19).

NG

Check for open and short in harness and connectorbetween engine ECU andacceleratorpedal c los ed pos ition s wi tc h and bodygroun d (S ee page N I -- 1 9. )

5L--E ENGINE SUP (RM817E)

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DI--55 DIAGNOSTICS --

ENGINE DI8NS--01

DTC

22

WaterTem p .S ensorCi rcui tM al functi on

CIRCUITDESCRIPTION The water temperature sensor senses the coolant temperature. A thermistor built into the sensor changes the resistance value according to the coolant temperature. The lower the coolant temperature, the greater the thermistor resistance value, and

(Fig.1) 30 20 10

the higher the coolant temperature, the lower the thermistor resistance value (See Fig.1). The water temperature sensor is connected to the engin e ECU (See below). The 5 V power source voltage in the engine ECU is applied to the water temperature sensor from the terminal THW via a resistor R. Tha t is, the resisto r R and the water temperature sensor are connected in series. When the resistance value of the water temperature sensor changes in accordance with changesin the coolant temperature, the potential at theterminalTHW also changes. Based on this signal, the engine ECU increases the fuel injection volume to improve driveability during cold engine operation.

Acceptable

5 Ω k 3 e c 2 n a t 1 is s e R 0.5

0.3 0.2 0.1 100 --20 0 20 40 60 80 (--4) (32) (68) (104) (140) (176) (212)

Temperature C ( F) ˚

DTCNo.

22

˚

FI4741

DTCDetectingCondition

Open or short in water temp. sensor circuit for 0.5 sec. or more

TroubleArea S

Open or short in water temp. sensor circuit

S

Water temp. sensor

S

Engine ECU

HINT: After confirming DTC22 use the hand--held tester to confirm the water temperature from,”CURRENT DATA”. Temperaturedisplayed --40 C (--40 F) ˚

˚

140 C (284 F)ormore ˚

5L--E ENGINE SUP (RM817E)

˚

Malfunction Open circuit Shortcircuit

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DI--56 DIAGNOSTICS --

ENGINE

WIRINGDIAGRAM Engine ECU Water Temp. Sensor 2

1

4

P

*1

THW

9

G--R

1

*

E2

*1 : E5 Australia, Thailand E4 South Africa A15524

INSPECTIONPROCEDURE HINT: If DTC ”22” (Water Temp. Sensor Circuit Malfunction), ”24” (Intake Air Temp. Sensor Circuit Malfunction) and ”39” (Fuel Temp. Sensor Circuit Malfunction) are output simultaneously, E2 (sensor ground) may be open.

W henusinghand -- heldtester 1

Co n n ectth eh an d -- h eldt ester,an dreadvalu eo fwatert emp eratu re.

PREPARATION: (a) Connect the hand--held tester to the DLC 3. (b) TurntheignitionswitchONandpushthehand -- heldtestermainswitchON. CHE CK: Read temperature value on the hand--held tester. OK: Same as act ual water temperature. HINT: If there is open circuit, hand--held tester indicates --40 C (--40 F). If there is short circuit, hand--held tester indicates 140 C (284 F) or more. S S

NG

˚

˚

˚

˚

˚

˚

-- 4 0C s eGpo2t.ostep4. 140 C((2-40 84 F) F)  .. o. rG moorto e ..t.

OK

Che c kfori nte rmi tte ntprobl e m s(S e epa geDI --9 ).

5L--E ENGINE SUP (RM817E)

˚

˚

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DI--57 DIAGNOSTICS --

2

CheckforopeninharnessorengineECU. ON

Water Temp. Sensor

Engine ECU 5V 4

2

*9 *

THW E2

1 BE6653 F17055

ENGINE

E1

PREPARATION: (a) Disconnectthewatertemp.sensorconnector. (b) Connect sensor wire harness terminals together. (c) TurntheignitionswitchON. CHE CK: Read temperature value on the hand--held tester. OK: Temperature valu e: 140 C (28 4 F) or more ˚

* : E5 Australia, Thailand E4 South Africa

˚

A00214

OK

Confirm good connection at sensor. If OK, replace water temp. sensor.

NG

3

CheckforopeninharnessorengineECU. ON

* : E5 Australia, Thailand E4 South Africa

Water Temp. Sensor

Engine ECU 5V 2

4

1

*

*9

BE6653 F17057 A04951

THW

E2

THW

E2 E1

PREPARATION: (a) Removetheglovecompartmentdoor. (b) Connect between terminals THW and E2 of engine ECU

connector. HINT: Water temp. sensor connector is disconnected. Before checking, do a visual and contact pressure check for the engineECUconnector(SeepageIN -- 19). (c) Turn the ignition switch ON. CHE CK: Read temperature value on the hand--held tester. OK: Temperature valu e: 140 C (28 4 F) or more ˚

OK

Open in harness between terminal E2 or THW, repair or replace harness.

NG

Confirm good connec tion at engine ECU. If OK, replace engine ECU.

5L--E ENGINE SUP (RM817E)

˚

A05044

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DI--58 DIAGNOSTICS --

4

Ch eckfo rsh o rtinh arn essan den g in eECU. ON

Water Temp. Sensor

Engine ECU 5V 4

*

9

THW E2

* BE6653 F17054

ENGINE

E1

* : E5 Australia, Thailand E4 South Africa

PREPARATION: (a) Disconnectthewatertemp.sensorconnector. (b) Turn the ignition switch ON. CHE CK: Read temperature value on the hand--held tester. OK: Temper ature value: --40 C (--40 F) ˚

A00216

OK

˚

Replace water temp. sensor.

NG

5

CheckforshortinharnessorengineECU. ON Water Temp. Sensor 2

Engine ECU 5V THW

(c) Turn the ignition switch ON. CHE CK: Read temperature value on the hand--held tester. OK: Temper ature value: --40 C (--40 F)

E2 1

PREPARATION: (a) Remove the glove compartment door. (b) Disconnect the connector of engine ECU. HINT: Water temp. sensor connector is disconnected.

E1

˚

BE6653 F17056 A05037

A05289

OK

Repair or replace harness or connector.

NG

CheckandreplaceengineECU(SeepageIN -- 19).

5L--E ENGINE SUP (RM817E)

˚

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DI--59 DIAGNOSTICS --

ENGINE

W hennotusinghand -- heldtester 1

CheckvoltagebetweenterminalsTHWandE2engineECUconnecto r. ON

THW

PREPARATION: (a) Remove the glove compartment door. (b) Turn the ignition switch ON. CHE CK: MeasurevoltagebetweenterminalsTHWandE2ofengine

E2

(+)

ECU OK: connector.

(--) A04952

Water temp. ˚

˚

20 (68) (Engine is cool) 80 (176) (Engine is hot)

O K

Voltage

C ( F)

0.2 -- 3.8 V

0.1 -- 1.5 V

Che c kfori nte rmi tte ntprobl e m s (S e epa geDI --9 ).

NG

2

Ch eckwatert emp .sen so r( Seep ag eED -- 12).

NG

Replace water temp. sensor.

OK

3

CheckforopenandshortinharnessandconnectorbetweenengineECUand watert emp .sen so r( Seep ag eIN -- 19).

NG

Repair or replace harness or connector.

OK

CheckandreplaceengineECU(SeepageIN -- 19).

5L--E ENGINE SUP (RM817E)

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DI--60 DIAGNOSTICS --

ENGINE DI8NT--01

DT C

24

I ntakeAi rTem p.SensorCi rcuitM alfuncti on

CIRCUITDESCRIPTION The intake air temp. sensor is built into the intake manifold and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the intake air temperature. The lower the intake air temperature, the greater

(Fig.1)

30 20

the thermistor, the lower the thermistor resistance value (See Fig.1).The intake air temperature sensor is connected to the engine ECU. The 5 V power source voltage in the engine ECU is applied to the intake air temperature sensor from the terminal THA via a resistor R. That is the resistor R and the intake air temperature sensor are connected in series. When the resistance value of the intake air tempe rature sensor changes. Based on this signal, the engine ECU increases the fuel injection volume to improve drivability during cold engine operation.

10

Acceptable

5 Ω k 3 e 2 c n ta 1 is s e 0.5 R 0.3

0.2 0.1 --20 0 20 40 60 80 1 00 (--4) 32 68 104 140 176 212

Temp. C ( F) ˚

˚

DTCNo.

24

FI4741

DTCDetectingCondition Open or short in intake air temp. sensor circuit for 0.5 sec. or more

TroubleArea S

Open or short in intake air temp. sensor circuit

S

Intake air temp. sensor

S

Engine ECU

HINT: After confirming DTC 24 use the hand--held tester to confirm the water temperature from ”CURRENT DATA”. Temperaturedisplayed --40 C (--40 F) ˚

˚

140 C (284 F)ormore ˚

5L--E ENGINE SUP (RM817E)

˚

Malfunction Open circuit Shortcircuit

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DI--61 DIAGNOSTICS --

ENGINE

WIRINGDIAGRAM

Engine ECU Intake Air Temp. Sensor 2

P--L

1

G--R

3 *1

THA

9 *1

E2

*1 : E5 Australia, Thailand E4 South Africa

A15524

INSPECTIONPROCEDURE HINT: If DTC”22” (Water Temp. Sensor Circuit Malfunction), ”24” (Intake Air Temp. Sensor Circuit Malfunction), ”35” (Turbo Pressure Sensor Circuit Malfunction) and ”39” (Fuel Temp. Sensor Circuit Malfunction) are output simultaneously, E2 (sensor ground) may be open.

W henusinghand -- heldtester 1

Co n n ectth eh an d -- h eldt ester,an dreadvalu eo fwatert emp eratu re.

PREPARATION: (a) Connect the hand--held tester to the DLC3. (b) Turn the ignition switch ON and push the hand--held tester main switch ON. CHE CK: Read temperature value on the hand--held tester. OK:

Same as actual intake air temperature. HINT: If there is open circuit, hand--held tester indicates --40 C (--40 F). If there is short circuit, hand---held tester indicates 140 C (284 F) or more. S

˚

S

NG

5L--E ENGINE SUP (RM817E)

˚

˚

˚

-- 4 0C (--40 F)...Gotostep2. 140 C(284 F)ormore...Gotostep4. ˚

˚

˚

˚

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DI--62 DIAGNOSTICS--

ENGINE

OK

Chec k for i ntermittent probl mse (S ee pa geDI -- 9).

2

Checkfor openin harness or engineECU. ON

* : E5 Australia, Thailand E4 South Africa

Intake Air Temp. Sensor

Engine ECU 5V 3

2

*

THA

9 E2

*

1

E1

BE6653 FI7055

PREPARATION: (a) Disconnect the intake air temp. sensor connector. (b) Connect sensor wire harness terminals together. (c) Turn the ignition switch ON. CHECK: Read temperature value on the hand--held tester. OK: Temperature value: 140°C (284°F) or more

A00214

OK

Confirm good connection at sensor. If OK, replace intake air temp. sensor.

NG

3

Checkfor openin harness or engineECU. ON

* : E5 Australia, Thailand E4 South Africa

Intake Air Temp. Sensor

Engine ECU 5V 3

2

* 9 *

1

BE6653 FI7057 A04953

THA

E2

THA E2 E1

PREPARATION: (a) Remove the glove compartment door. (b) Connect between terminals THA and E2 of engine ECU connector. HINT: Intake air temp. sensor connector is disconnected. Before checking, do a visual and contact pressure check for the engineECUconnector(SeepageIN -- 19). (c) Turn the ignition switch ON. CONTINUED CHECK: Read temperature value on the hand--held tester. OK: Temperature value: 140°C (284°F) or more

A05045

OK 5L--E ENGINE SUP (RM817E)

Open in harness between terminal E2 or THA, repair or replace harness.

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DI--63 DIAGNOSTICS--

ENGINE

NG

Confirm good connection at engine ECU. If OK, replace engine ECU.

4

Check for sh o rt in harness and engine ECU. ON

Intake Air Temp. Sensor

Engine ECU 5V 3

*

THA

9

* BE6653 FI7054

E2 E1

* : E5 Australia, Thailand E4 South Africa

A00216

PREPARATION: (a) Disconnect the intake air temp. sensor connector. (b) Turn the ignition switch ON. CHECK: Read temperature value on the hand--held tester. OK: Temperature value: --40°C (--40°F) OK

Replace intake air temp. sensor.

NG

5

Checkfor short in harness or engineECU. ON Intake Air Temp. Sensor 2

Engine ECU 5V THA E2

1

E1

PREPARATION: (a) Remove the glove compartment door. (b) Disconnect the connector of engine ECU. HINT: Intake air temp. sensor connector is disconnected. (c) Turn the ignition switch ON. CHECK: Read temperature value on the hand--held tester. OK:

BE6653 F17056 A05037

A05289

Temperature value: --40°C (--40°F)

OK

Repair or replace harness or connector.

CONTINUED

NG 5L--E ENGINE SUP (RM817E)

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DI--64 DIAGNOSTICS --

ENGINE

CheckandreplaceengineECU(SeepageIN -- 19).

W hennotusinghand -- heldtester 1

CheckvoltagebetweenterminalsTHAandE2engineECUconnecto r. ON

PREPARATION: (a) Remove the glove compartment door.

E2

THA

(b) Turn the ignition switch ON. CHE CK: Measure voltage between terminals THA and E2 of engine ECU connector. OK: (+)

Intake air temp.

(--) A04954

˚

C ( F)

20 (68) (Engine is cool) 80 (176) (Engine is hot)

OK

Voltage

˚

0.2 -- 3.8 V

0.1 -- 1.5 V

Checkf or intermittent problem s (S e epa geDI -- 9 ).

NG

2

Ch eckin takeairt emp .sen so r( Seep ag eED -- 14).

NG

OK

5L--E ENGINE SUP (RM817E)

Replace intake air temp. sensor.

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DI--65 DIAGNOSTICS--

3

ENGINE

Checkfor openand sh ort in harness and connector between engine ECU and intake ai r temp. sensor (See page IN -- 19).

NG

Repair or replace harness or connector.

OK

Check and replace engine ECU (See pageIN-- 19).

5L--E ENGINE SUP (RM817E)

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DI--66 DIAGNOSTICS--

ENGINE DI17T--03

DTC

32

Injection P ump Correctin o S ystem M al fun cti on

CIRCUIT DESCRIPTION Th eco rre ctio nsyste misco rre ctin gaf e wva ryb e t we e ne a chin je ctio np u mp s. DTCNo.

DTCDetectingCondition

TroubleArea SInjection pump correction unit circuit

32

SInjection pump correction unit

Open or short in injection pump correction unit circuit

SEngine ECU

WIRING DIAGR AM Engine ECU

Injection Pump (Shielded) DATA

CLK

E1

1

V

6 *1

DATA

4

P

14 *1

CLK

2

BR *1 : E5 Australia, Thailand E4 South Africa

BR *2

*2 : EO Australia, Thailand EG South Africa A15525

INSPECTION PROCEDURE 1

Check for openand shortin harne ss and conne ctor b etween the engine ECU and injection pump co rre ction un it (See page IN -- 19).

NG

Repair harness or connector. CONTINUED

OK

5L--E ENGINE SUP (RM817E)

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DI--67 DIAGNOSTICS--

2

ENGINE

Try to changethe injection pump correctionunitto anotherone.

PREPARATION: (a) Remove the injection pump correction unit from injection pump. (b) Install the another injection pump correction unit. (c) Clear DTC. (d) Turn the ignition switch ON. CHECK: Read DTC again. OK: Does not output DTC ”32” (Injection Pump Correction System Malfuncti on). OK

Check and replace injection pump (S ee page FU - 7).

NG

Check and replace engine ECU (See pageIN --19).

5L--E ENGINE SUP (RM817E)

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DI--68 DIAGNOSTICS--

ENGINE DI31Z--07

DTC

35

Intake Air P ressureen S sor Ci rcui tMalfunc ti on

CIRCUIT DESCRIPTION The intake air pressure sensor is connected to the air cleaner. The engine ECU detects the air cleaner pressure as a voltage by the sensor. The engine ECU calculates the atmospheric in-

V

take air pressure by using the output voltage and uses this atomospheric value for correcting the injection volume and injection timing control.

0.9

0.5 60.0

206.7

kPa

mmHg 1,550 450 (17.7) (61.0) (in. ∙Hg) Air Cleaner Pressure A06532

DTCNo.

35

DTCDetectingCondition

TroubleArea

Open or short in intake air pressure sensor circuit for 2 sec. or more

SOpen

or short in intake air pressure sensor circuit

SIntake air pressure sensor SEngine ECU

HINT: After confirming DTC 35, use the hand--held tester to confirm the air cleaner pressure from ”CURRENT DATA”. Intakemanifoldpressure(kPa) Approx. 0

Malfunction SPIM SVC

192 or more

circuit short

circuit open or short

SPIM circuit SE2 circuit

open

open

CONTINUED

5L--E ENGINE SUP (RM817E)

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DI--69 DIAGNOSTICS--

ENGINE

WIRING DIAGR AM Australia: Engine ECU

Intake Air Pressure Sensor

B

1 E5

VC

2

B--Y

2 E5

PIM

1

G--R

9 E5

E2

12 *1

+B

3 *1

MREL

3

Engine Room R/B ECD Relay R--B

2

R--L

2

5

14

R--L

IJ1

3

2 1

2 IJ1

L--O

2

L--O

2 A

A

W--B

W--B J1 Junction Connector 2

ECD

Battery

1

2

2 Engine Room R/B

W

EF

*1 Thailand Made : E10 E6 Except Thailand Made

A15526

CONTINUED

5L--E ENGINE SUP (RM817E)

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DI--70 DIAGNOSTICS--

ENGINE

Thailand: Intake Air Pressure Sensor

Engine ECU

3

1 E5

B

2

B--Y

1

G--R

2 E5 9 E5

VC PIM E2

12 E7

+B

3 E7

MREL

Engine Room R/B ECD Relay Y

2

R--L

2

5

16

R--L

IJ4

3

2 2

20 IJ4

L--O

2

L--O

1

Y

A

A

W--B

W--B J1 Junction Connector 2

ECD

Battery 1

2

2

W

EF

Engine Room R/B A15526

CONTINUED

5L--E ENGINE SUP (RM817E)

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DI--71 DIAGNOSTICS--

ENGINE

South Africa: Engine ECU

Intake Air Pressure Sensor

3

1 E4

B

2

B--Y

1

G--R

VC

2 E4 PIM 9 E4 E2 12 E5

+B

3 E5

MREL

Engine Room R/B ECD Relay Y

2

R--L

2

5

14

R--L

IA2

3

2 2

2 IA2

L--O

2

L--O

1

Y

A

A

W--B

W--B J1 Junction Connector 2

ECD

Battery 1

2

2

W

EF

Engine Room R/B A15526

INSPECTION PROCEDURE HINT: If DTC ”22” (Water Temp. Sensor Circuit Malfunction), ”24” (Intake Air Temp, Sensor Circuit Malfunction), ”35” (Intake air Pressure Sensor Circuit Malfunction) and ”39” (Fuel Temp. Sensor Circuit Malfunction) are output simultaneo usly, E2 (sensor ground) may be open.

When using hand-- held tester 1

Co nnect the han d--h eldester t , and read value o f air clean er pressure.

PREPARATION: (a) Connect the hand--held tester to the DLC3. (b) Turn the ignition switch ON and push the hand--held tester main switch ON. CHECK: Read value of air cleaner pressure on the hand--held tester. OK: Same as atmospheric pressure. OK 5L--E ENGINE SUP (RM817E)

CONTINUED

Repair or replace connection the vacuumhose.

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DI--72 DIAGNOSTICS--

ENGINE

NG

2

Check intake air pressre u sensor (See page ED - 15).

NG

Replace inatake air pressure sensor.

OK

3

Check voltage b etweenterm in als VC an d E2 of engine ECU. ON

PREPARATION: (a) Remove the glove compartment door. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals VC and E2 of engine ECU. OK: Voltage: 4.5 -- 5.5 V

E2

VC

(--)

(+) A04956

NG

Checkpa age ndIN repl ace engine ECU (See -- 19).

OK

4

Check voltage b etweenterm in als PIM and E2 of en gine ECU. PREPARATION:

ON PIM

(a) Remove the glove compartment door. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals PIM and E2 of engine ECU. OK: CONTINUED Voltage: 1.0 -- 2.2 V

E2

(+)

(--) A04957

OK 5L--E ENGINE SUP (RM817E)

Check and replace engine ECU (See pa ge IN -- 19).

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DI--73 DIAGNOSTICS--

ENGINE

NG

Check for open and short in harness and connector between engine ECU and intake air pressure sen sor (See pag eIN -- 19).

OK

Replaceintake airpressure sensor.

When not using hand-- heldtester 1

Check intake air pressre u sensor (See page ED - 15) .

NG

Replace intake air pressure sensor.

OK

2

Check voltage b etweenterm in als VC an d E2 of engine ECU. ON

PREPARATION: (a) Remove the glove compartment door. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals VC and E2 of engine ECU. OK: Voltage: 4.5 -- 5.5 V

E2

VC

(--)

(+) A04956

OK

5L--E ENGINE SUP (RM817E)

NG

Check and replace engine ECU (See pa ge IN -- 19).

CONTINUED

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DI--74 DIAGNOSTICS--

3

ENGINE

Check voltage b etweenterm in als PIM and E2 of en gine ECU. ON

PREPARATION: (a) Remove the glove compartment door. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals PIM and E2 of engine ECU. OK: Voltage: 1.0 -- 2.2 V

E2

PIM

(+)

(--) A04957

OK

Check and replace engine ECU (See pa ge IN -- 19).

NG

4

Checkfor openand shortin harness and con nector between engine ECU and intake air pressure senso r(See p age IN -- 19).

NG

OK

Replace for intake air pressure sensor.

5L--E ENGINE SUP (RM817E)

Repair or replace harness or connector.

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DI--75 DIAGNOSTICS --

ENGINE DI8NU--01

DT C

39

FuelTem p.SensorCi rcuitM alfuncti on

CIRCUITDESCRIPTION The fuel temperature sensor senses the fuel temperature. A thermistor built into the sensor changes the resistance value according to the fuel temperature. The lower the fuel temperature, the greater the thermistor resistance value, and the higher

(Fig.1) 30 20

the fuel temperature, the lower the thermistor resistance value (See Fig.1). The fuel temperature sensor is connected to the engine ECU (See below). The 5 V power source voltage in the engine ECU is applied to th e fuel temperature sensor from the terminal THF via a resistor R. That is, the resistor R and the fuel temperature sensor are connected in series. When the resistance value of the fuel temperature sensor changes in accordance with changes in the fuel temperature, the potential at the terminal THF also changes. Based on this signal, the engine ECU increases the fuel injection volume to improve driveability during low engine revoluti on and high fuel temperature.

Acceptable

10 5 Ω k 3 e c 2 n a t 1 is s e R 0.5

0.3 0.2 0.1 100 --20 0 20 40 60 80 (--4) (32) (68) (104) (140) (176) (212)

Temperature C ( F) ˚

DTCNo.

39

˚

FI4741

DTCDetectingCondition

Open or short in fuel temp. sensor circuit for 0.5 sec. or more

TroubleArea S

Open or short in fuel temp. sensor circuit

S

Fuel temp. sensor

S

Engine ECU

HINT: After confirming DTC 39, use the hand--held tester to confirm the water temperature from ”CURRENT DATA”. Temperaturedisplayed --40 C (--40 F) ˚

˚

140 C (284 F)ormore ˚

˚

5L--E ENGINE SUP (RM817E)

Malfunction Open circuit Shortcircuit

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DI--76 DIAGNOSTICS --

ENGINE

WIRINGDIAGRAM Engine ECU Fuel Temp. Sensor 2

LG--B

5 *1

1

G--R

9

THF

1

*

E2

*1 : E5 Australia, Thailand E4 South Africa A15524

INSPECTIONPROCEDURE HINT: If DTC ”22” (Water Temp. Sensor Circuit Malfunction), ”24” (Intake Air Temp. Sensor Circuit Malfunction), ”35” (Turbo Pressure Sensor Circuit Malfunction) and ”39” (Fuel Temp. Sensor Malfunction) are output simultaneously, E2 (sensor ground) may be open.

W henusinghand -- heldtester 1

Co n n ectth eh an d -- h eldt ester,an dreadvalu eo ffu eltemp eratu re.

PREPARATION: (a) Connect the hand--held tester to the DLC3. (b) TurntheignitionswitchONandpushthehand -- heldtestermainswitchON. CHE CK: Readtemperaturevalueonthehand -- heldtester. OK: Same as act ual fuel temperature. HINT: If there is open circuit, hand--held tester indicates --40 C (--40 F). If there is short circuit, hand--held tester indicates 140 C (284 F) or more. S S

NG

˚

˚

-- 4 0C (--40 F)...Gotostep2. 140 C(284 F)ormore...Gotostep4.

OK

Che c kfori nte rmi tte ntprobl e m s(S e epa geDI --9). 5L--E ENGINE SUP (RM817E)

˚

˚

˚

˚

˚

˚

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DI--77 DIAGNOSTICS --

2

ENGINE

CheckforopeninharnessorengineECU. ON Engine ECU

Fuel Temp. Sensor

5V 5

2

*9 *

THF E2

1

E1

PREPARATION: (a) Disconnectthefueltemp.sensorconnector. (b) Connect sensor wire harness terminals together. (c) Turn the ignition switch ON. CHE CK: Read temperature value on the hand--held tester. OK: Temperature valu e: 140 C (28 4 F) or more ˚

* : E5 Australia, Thailand E4 South Africa

˚

A00214

OK

Confirm good connection at sensor. If OK, replace fuel temp. sensor.

NG

3

CheckforopeninharnessorengineECU. ON

* : E5 Australia, Thailand E4 South Africa

Fuel Temp. Sensor

Engine ECU 5V 5

2

*

9

*

1

THF

THF E2 E1

E2

BE6653 F17055 A04958

PREPARATION: (a) Remove the glove compartment door.

(b)

Connect between terminals THF and E2 of engine ECU connector. HINT: Fuel temp. sensor connector is disconnected. Before checking, do a visual and contact pressure check for the engine ECU connector(SeepageIN -- 19). (c) Turn the ignition switch ON. CHE CK: Read temperature value on the hand--held tester. OK: Temperature valu e: 140 C (28 4 F) or more ˚

OK

Open in harness between terminal E2 or THF, repair or replace harness.

NG

Confirm good connec tion at engine ECU. If OK, replace engine ECU.

5L--E ENGINE SUP (RM817E)

˚

A05046

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DI--78 DIAGNOSTICS --

4

ENGINE

CheckforshortinharnessorengineECU. ON

* : E5 Australia, Thailand E4 South Africa

Fuel Temp. Sensor

Engine ECU 5V 2

5

* 9 1

*

THF E2 E1

BE6653 F17054

A05047

PREPARATION: (a) Disconnect the fuel temp. sensor connector. (b) Turn the ignition switch ON. CHE CK: Read temperature value on the hand--held tester. OK: Temper ature value: --40 C (--40 F) ˚

OK

˚

Replace fuel temp. sensor.

NG

5

CheckforshortinharnessorengineECU. ON

Fuel Temp. Sensor 2

Engine ECU 5V THF

(c) Turn the ignition switch ON. CHE CK: Read temperature value on the hand--held tester. OK: Temper ature value: --40 C (--40 F)

E2 1

PREPARATION: (a) Remove the glove compartment door. (b) Disconnect the connector of engine ECU. HINT: Fuel temp. sensor connector is disconnected.

E1

˚

BE6653 F17056 A05037

A05289

OK

Repair or replace harness or connector.

NG

CheckandreplaceengineECU(SeepageIN -- 19).

5L--E ENGINE SUP (RM817E)

˚

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DI--79 DIAGNOSTICS --

ENGINE

W hennotusinghand -- heldtester 1

CheckvoltagebetweenterminalsTHFandE2engine ECUconnector. ON

PREPARATION: (a) Remove the glove compartment door. (b ) TurntheignitionswitchON. CHE CK: MeasurevoltagebetweenterminalsTHFandE2ofengineECU

E2

THF

(+)

connecter. OK:

(--)

Fuel temp. A04959

˚

C ( F)

20 (68) (Engine is cool) 80 (176) (Engine is hot)

OK

Voltage

˚

0.2 -- 3.8 V

0.1 -- 1.5 V

Check for intermittent problems (S e epa geDI -- 9 ).

NG

2

Ch eckfu eltemp .sen so r( Seep ag eED -- 13).

NG

Replace fuel temp. sensor.

OK

3

CheckforopenandshortinharnessandconnectorbetweenengineECUand fu eltemp .sen so r( Seep ag eIN -- 19).

NG

Repair or replace harness or connector.

OK

CheckandreplaceengineECU(SeepageIN -- 19).

5L--E ENGINE SUP (RM817E)

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DI--80 DIAGNOSTICS --

ENGINE DI06D--19

DTC

42

VehicleSpeedSensorSignalCircuit Malfuncti on

CIRCUITDESCRIPTION The vehicle speed sensor outputs a 4--pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more pre cise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the engine ECU. The engine ECU determines the vehicle speed based on the frequency of these puls e signals.

4--pulse

Cable

Combination Meter

Transmission

ECU A06493

DTCNo.

DTCDetectingCondition

TroubleArea

All conditions below are detected continuously for 8 sec. or more: 42

(a) Vehicle speed signal: 0 km/h (0 mph) (b) Engine speed: 2,400 4,000 rpm (c) Engine coolant temp.: 60 C (176 F) or more

Open or short in vehicle speed sensor circuit

S

Vehicle speed sensor

S

∼

˚

S

S

˚

Combination meter Engine ECU

(d) Accelerator pedal opening angle : 60 % or more

WIRINGDIAGRAM

Center J/B

Combination Meter G--O (*1 )

1 *4

2 3E

1 3E

Engine ECU G--O (*1 )

G--O (*2 )

9 *3

*5

*12 : Australia * : South Africa, Thailand *3 : E10 Australia (Thailand Made) E6 Australia (Except Thailand Made) E5 South Africa E7 Thailand *4 : C11 Australia, Thailand C9 South Africa *5 : SPD South Africa SP1 Except South Africa A15527

5L--E ENGINE SUP (RM817E)

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DI--81 DIAGNOSTICS--

ENGINE

INSPECTION PROCEDURE 1

Check operat ion of speedom eter.

CHECK: Drive the vehicle and check if the operation of the speedometer in the combination meter is normal. HINT: The vehicle speed sensor is operating normally if the speedometer display is normal. NG

Check speedometer.

OK

2

Check voltage between terminal SP1 of engineECU and body ground. ON

SP1 or SPD

(--)

(+) A04960

PREPARATION: (a) Remove the glove compartment door. (b) Shift the shift lever to neutral. (c) Jack up one of the front wheels. (d) Turn the ignition switch ON. CHECK: Measure voltage between terminal SP1 or SPD of engine ECU and body ground when the wheel is turned slowly. OK: Voltage is generated intermittently.

4.5 -- 5.5 V

0

Turn the wheel AT7809

NG

Check and repair harness and connector between combina tion meter and engine ECU (See pa ge IN -- 19).

OK

Checkand re place engine EC U (See pageIN --19).

5L--E ENGINE SUP (RM817E)

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DI--82 DIAGNOSTICS--

ENGINE DI8NV--01

ECU Power SourceCircuit CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery positive voltage is applied to the coil, closing the contacts of the ECD main relay (Marking: ECD) and supplying power to the terminal +B of the engine ECU.

WIRING DIAGR AM Australia: Engine ECU Driver Side J/B

Center J/B

IGN

6

1

1H

B--W

1D

11

10

3D

3D

14

B--W

*1

IGSW

B--R Ignition Switch 6

W--R

7

W--R Engine Room R/B

R--B

5

ECD Relay

3

2

2

1

2

2

2

R--L

14 IJ1

R--L

12 *1

+B

L--O

2 IJ1

L--O

3 *1

MREL

J1 Junction Connector A A

W--B

14 E4

W--B

E1

Engine Room R/B ECD 2

2

1

2

W

BR Battery

2 2

AM2

1

EF

EO CONTINUED

*1 : E10 Thailand Made : E6 Except Thailand Made A15528

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DI--83 DIAGNOSTICS--

ENGINE

South Africa:

IGN

6 1H

1

B--W

1D

B--R

Engine ECU

J4 Junction Connector B B

Driver Side J/B

B--W

14 E5

IGSW

Ignition Switch 6

W--R

7

W--R Engine Room R/B

5

Y

ECD Relay

3

2

2

2

2

1

2

R--L

14 IA2

R--L

12 E5

+B

L--O

2 IA2

L--O

3 E5

MREL

14 E3

E1

J1 Junction Connector A A

W--B

W--B

Engine Room R/B

2

2

ECD 1

2

BR

W Battery

2 2

AM2

1

EF

EG CONTINUED

A15535

5L--E ENGINE SUP (RM817E)

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DI--84 DIAGNOSTICS--

ENGINE

Thailand: Engine ECU Driver Side J/B IGN

6

1

1H

B--W

1D

B--R

14 E7

IGSW

Ignition Switch 6

W--R

7

W--R Engine Room R/B

5

Y

ECD Relay

3

2

2

2

1

2

2

R--L

16 IJ4

R--L

12 E7

+B

L--O

20 IJ4

L--O

3 E7

MREL

14 E4

E1

J1 Junction Connector A A

W--B

W--B

Engine Room R/B

2

2

ECD 1

2

BR

W Battery

2 2

AM2

1

EF

EO

A15536

5L--E ENGINE SUP (RM817E)

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DI--85 DIAGNOSTICS--

ENGINE

INSPECTION PROCEDURE 1

Check voltage between terminals + B or +BG andE1 of engineECU. ON

E1

(--)

PREPARATION: (a) Remove the glove compartment door. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals +B or +BGand E1 of en-

+B or +BG

gine OK: ECU. Voltage: 9 -- 14 V

(+) A04962

OK

Proceed to next circuit inspection shown on probl e ms y m ptoms tabl e(S e epa geDI -- 2 5).

NG

2

Checkfor openn i harness and conn ector between terminal E1 of engine ECU and body ground (SeepageIN-- 19).

NG

Repair or replace harness or connector.

OK

3

Check ECD relay (M arkin g: ECD) (See p age ED - 9).

NG

OK

5L--E ENGINE SUP (RM817E)

Replace ECD relay.

CONTINUED

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DI--86 DIAGNOSTICS--

4

ENGINE

Check ECD fu se.

PREPARATION: Remove the ECD fuse from the engine room J/B. CHECK: Check continuity of ECD fuse. OK: Continuity NG

Check for short in all the harness and components connected to ECD fuse.

OK

5

Checkfor openin harness and connectorbetwe en engine ECU and CD E main relay (Marking: ECD), ECD main relay and y (See batter pageIN-- 19).

NG

Repair harness or connector.

OK

6

Check voltage between terminals IGSW and E1 fo eng ine ECU. ON E1

(--)

PREPARATION: (a) Remove the glove compartment door. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals IGSW and E1 of engine ECU. OK: Voltage : 9 -- 14 V

IGSW

(+) A04963

OK

NG

5L--E ENGINE SUP (RM817E)

Go to step 9.

CONTINUED

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DI--87 DIAGNOSTICS--

7

ENGINE

Check ignition switch(See Pu b. No. RM585E BE sectio n).

NG

Replace ignition switch.

OK

8

Check for open in harne ss and connector between ignition switch and engine ECU (See page IN -- 19).

NG

Repair or replace harness or connector.

OK

9

Checkvoltagebetween terminalMREL of engineECU and bodyground. ON

PREPARATION:

MREL

(--)

(a) Turn Remove the glove compartment door. (b) the ignition switch ON. CHECK: Measure voltage between terminal MREL of engine ECU and body ground. OK: Voltage: 9 -- 14 V

(+) A04964

OK

Check and replace engine ECU (See pa ge IN -- 19).

NG

Che n in harnground ess an deconn or een engine ECU and ECD relay (Marking: ECD), E CDck refor l ayop aend body (S e paect geN I --be 1 t9w).

5L--E ENGINE SUP (RM817E)

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DI--88 DIAGNOSTICS --

ENGINE DI8NW--01

P re -- Heati n gControlCi rcui t CIRCUITDESCRIPTION When the ignition switch turns ON, the engine ECU calculates the glow indicator lighting time/heating corresponding to the coolant temperature at that time and turns ON the glow indicator light/glow plug relay. As the ceramics is used for a flow plug material, the current control is not performed. ). c e S ( e im T g in t h g i L t h ig L

After Glow Time 6

120

5 4 3 2 1

100 80 60 40 20

0

Light Lighting Time

5L--E ENGINE SUP (RM817E)

--20

0

20

40 50 55 60 80

Water Temp. ( C) ˚

0

A ft e r G lo w T im e (S e c .) A15544

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DI--89 DIAGNOSTICS--

ENGINE

WIRING DIAGR AM Australia:

Combination Meter (GLOW)

Center J/B 1 5 3D 3D

R--L

5 C10

R--L

1 C9

Engine ECU 1

GR--L

*1

GIND

R--L Driver Side J/B 2 1F

GAUGE

Driver Side J/B

Ignition SW 5 1H

R

1 1H

W 4

2

1 1I

W Engine Room R/B No. 2 W--B

4

4

A

J2 Junction Connector

A

J1

B

4

3

4

1 2 SUB GLW RLY

2

B--R

7 IJ1

B--R

2 *2

SREL

B--Y

4

Engine Room R/B ABS, GLOW 2 1

EB2 2

AM1 W

2

2

1 ALT

W

2

1

2

B--Y 1

W--B Glow Plug EF

Battery

*1 : E6 Thailand Made E9 Except Thailand Made *2 : E10 Thai Made E6 Except Thailand Made A15537

CONTINUED

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DI--90 DIAGNOSTICS--

South Africa: Y

J3 Junction Connector C C

Combination Meter (GLOW) 5 C8

Y

Driver Side J/B GAUGE

2 1F

ENGINE

1 C7

R

1H

GIND

1

1 1H

W 4

R--W

Driver Side J/B

Ignition SW

5

Engine ECU 1 E7

2

1I

W Engine Room R/B No. 2 W--B

4

4

4

3

4

1 2 SUB GLW RLY

B--R

J2 Junction Connector

A

J1

B

2

2 E5 SREL

EB1 2

ABS, GLOW 2 1 AM1

W

2

2

1 ALT

W--B

B--R

B--Y

4

Engine Room R/B A

7 IA2

W

2

1

2

B--Y 1

Glow Plug EF

Battery

A15538

CONTINUED

5L--E ENGINE SUP (RM817E)

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DI--91 DIAGNOSTICS--

ENGINE

Combination Meter (GLOW)

Thailand:

5

Y

1 C9

C10

Engine ECU 1 E6

R--W

GIND

Driver Side J/B

2 1F

Driver Side J/B GAUGE 5 1H

Ignition SW R 4

1 1I

1 1H

W 2 W

Engine Room R/B No. 2 W--B

4

4

4

3

4

1 2 SUB GLW RLY

B--R

J2 Junction Connector

A

J1

B

2

EB2 2

ABS, GLOW 2 1 AM1

W

2

2

1 ALT

W--B

2 E7 SREL

B--R

B--Y

4

Engine Room R/B A

12 IJ4

W

2

1

2

B--Y 1

Glow Plug EF

Battery

A15539

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DI--92 DIAGNOSTICS--

ENGINE

INSPECTION PROCEDURE 1

Doesglowindicator lightup?

PREPARATION: Turn ignition switch ON. CHECK: Does the glow indicator light up? OK: The glow indicator lights up for 0.5 sec. or more.

OK

Go to step 5.

NG

2

Check voltage between terminal GIND of engineECU connectorand body ground. ON

PREPARATION: (a) Remove the glove c ompartment door (SeepageED -- 24). (b) Disconnect the connector of engine ECU.

GIND

A04965

(c) Turn ignition switch ON. CHECK: Measure voltage between terminal GIND of engine ECU connector and body ground. OK: Voltage: 9 -- 14 V

OK

Check and replace engine ECU (See pa ge IN -- 19).

NG

3

Check GLOW fu se.

PREPARATION: Remove the GLOW fuse. CHECK: Measure continuity of GAUGE fuse. OK: Continuity

CONTINUED

NG 5L--E ENGINE SUP (RM817E)

Check for short in all the harness and components connected to GLOWfuse.

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DI--93 DIAGNOSTICS--

ENGINE

OK

4

Checkglowindicator lightbulb.

NG

Replaceb ulb.

OK

Check foropen inharnessandconnectorbetween combinationmeterand engineECU,combination meter and G L O Wfus (Se e pa geI N -- 1 9).

5

Check glow indic ator lig hting time and after glow(Refer time to Pub. No. RM582E on ST section.)

NG

Check and replace engine ECU (See pa ge IN -- 19).

OK

6

Are there any DTC beingoutput?

YES

Go to relevant DTC chart.

NO

7

Check glow plug relay(Refer ot Pub. No. RM582E o n ST sectio n). NG

OK

5L--E ENGINE SUP (RM817E)

Replace glow plug relay.

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DI--94 DIAGNOSTICS--

8

ENGINE

Check voltage between terminal SRE L of engineECU and body gr oundat cranking. ON SREL

A04966

PREPARATION: (a) Remove the glove co mpartment door (SeepageED -- 24). (b) Disconnect the connector of engine ECU. (c) Turn ignition switch STA. CHE CK: Measure voltage between terminal SREL of engine ECU and body ground at cranking. OK: Voltage: 9 -- 14 V NG

Check and replace engine ECU (See pa ge IN -- 19).

OK

9

Checkfor openand short in harness and conn ector betwe en glow plug relay and engine ECU, glow plug relay and body ground (SeepageIN-- 19).

NG

Repair harness or connector.

OK

10

Check resistan ce of glo wplug (Refer to Pu b. No. RM582E o n ST sectio n).

NG

Replace glow plug.

OK

CONTINUED

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DI--95 DIAGNOSTICS--

11

ENGINE

Inspectglow plug installation.

NG

Tighten glow plug.

OK

12

Che ck for open in harne ss and connec tor be tween glow plug relay and glow plug(SeepageIN -- 19).

NG

Repair harness or connector.

OK

Proceed to next circuit inspection shown on problem symptoms e (See page tabl DI -- 25).

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DI--96 DIAGNOSTICS--

ENGINE DI302--02

EGR Control Circuit CIRCUIT DESCRIPTION The EGR system recirculates exhaust gas, which is controlled to the proper quantity to suit the driving conditions into the intake air mixture to slow down combustion, reduce the combustion temperature and reduce NOx emissions. The lift amount of EGR valve is controlled by the vacuum which is regulated by the VRV operated by the engine ECU. Under the following conditions, EGR is cut to maintain driveability. S Before the engine is warmed up S During deceleration (Diesel throttle valve closed) S Light engine load (amount of intake air very small) S Full speed over 3,200 rpm

WIRING DIAGR AM

Engine Room R/B

Engine ECU

ECD Relay Y

R--L 2

5

2

3

16 IJ4 R--L

Engine Room R/B 2

2

1

1 IC10 2

2

VRV (EGR)

R--L

2 2 ECD

24 G--W E4 1

EGR

W--B A

1 2

J1 Junction Connector

A

L--O

20 IJ4

L--O

3 E7

MREL

W W--B Battery EF

A15521

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DI--97 DIAGNOSTICS--

ENGINE

INSPECTION PROCEDURE When using hand-- held tester 1

Checkthe connectionof vacuumhose between vacuumpump and VRV for EGR, VRV for EG R and ER G v al v e.

NG

Repair or replace.

OK

2

Checkopera tionof VRVfor EGR. ON

Air Filter

E

F

VRV: ON

E

VRV: OFF

A10591

PREPARATION: (a) Disconnect the vacuum hoses from the VRV for EGR. (b) Connect the hand--held tester to the DLC3. (c) Turn ignition switch ON and push hand--held tester main switch ON. (d) Select the active test mode on the hand--held tester. CHECK: Check operation of VRV for EGR, when it is operated by the hand--held tester. OK: (a) VRV ON: Air from pipe E is flowing out through pipe F. (b) VRV OFF: Air from pipe E is flowing out through air filter. OK

Go to step 5.

NG

3

Chec k VRV for EG R(Se ep age EC -- 7).

NG

Replace the VRV for EGR.

OK CONTINUED

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DI--98 DIAGNOSTICS--

4

ENGINE

Checkfor openand short in harness and connectorbet ween VRV for EGR dan engine ECU, VRV for EGR and ECD relay (Marking ) (See : ECD pageIN-- 19).

NG

Repair or replace harness or connector.

OK

5

Check EGR valv e (See p age EC -- 4).

NG

Replace the EGR valve.

OK

6

Check EGR system(Seepag e EC - 4).

NG

Repair or replace.

OK

Proceed to next circuit inspection shown on problem symptoms (See page table DI -- 25).

When not using hand-- heldtester 1

Checkthe connectionof vacuumhose between vacuumpump and VRV for EGR, VRV for EG R and ER G v al v e.

NG

OK

5L--E ENGINE SUP (RM817E)

Repair or replace. CONTINUED

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DI--99 DIAGNOSTICS--

2

ENGINE

Checkopera tionof VRV for EGR. EGR

OFF ON ON

Air Filter Air E

Air E

F

PREPARATION: (a) Removeglovecompartmentdoor(SeepageED -- 24). (b) DisconnecttheconnectorofengineECU. (c) Turn the ignition switch ON. CHE CK: Check E VRV operation. (1) ConnectbetweenterminalEGRofengineECU connector and body ground (ON). (2) Disconnect between terminal EGR of engine ECU connector and body ground (OFF). OK: (3) VRV ON : Air from pipe E is flowing out through pipe F. (4) VRV OFF : Air from pipe E is flowing out through air filter.

A10168 A10591

VRV: ON

VRV: OFF A10169

OK

Go to step 5.

NG

3

Chec k VRV for EG R (Se e p ag e EC -- 7 ).

NG

Replace the VRV for EGR.

OK CONTINUED

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DI--100 DIAGNOSTICS--

4

ENGINE

Checkfor openand short in harness and connectorbet ween VRV for EGR nda engine ECU, VRV for EGR and ECD relay (Marking ) (See : ECD pageIN-- 19 .)

NG

Repair or replace harness or connector.

OK

Checkand re place engine EC U (See pageIN-- 19).

5

Check EGR valve (See p age EC -- 4).

NG

Replace the EGR valve.

OK

6

Check EGR system(Seepage EC - 4). NG

Repair or replace.

OK

Proceed to next circuit inspection shown on problem symptoms e (See page tabl DI -- 25).

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DI--101 DIAGNOSTICS--

ENGINE DI8NZ--01

Starter S ignalCircuit Malfuncti on CIRCUIT DESCRIPTION When the engine is being cranked, the intake air flow is slow, so fuel vaporization is poor. A rich mixture is therefore necessary in order to achieve good start ability. While the engine is being cranked, the battery positive voltage is applied to terminal STA of the engine ECU. The starter signal is mainly used to increase the fuel injection volume for the starting injection control and after--start injection control.

WIRING DIAGR AM Australia: J12 Junction Connector

Engine Room R/B B 8

STA 2

1

2

2

P

23

P

IJ1

Engine ECU 11 P

C

C

*1

STA

C AM2 7

W--R

2

2

P--L 1 25

Ignition Switch

2 1

2

2

1

ALT

IJ1

W

P--L 4

4 AM1 3

1 Y L R T S

2 Engine Room R/B No.2 W

2

4 4

4 B--W

W--B

1 EB2

B--R

A

B--W Battery

S2 1 S3

1

J1 Junction Connector

A W--B EF

CONTINUED

Starter *1 : E10 Thailand Made E6 Except Thailand Made A15212

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DI--102 DIAGNOSTICS--

ENGINE

South Africa: Engine ECU

Engine Room R/B B 8

STA 2

1

2

2

P

23

P

P

IA2

W--R

2

2

STA

P

AM2 7

11 E5

1 IA2 25

Ignition Switch 2 1

W

P--L

2

ALT

4

4 AM1

2

3

1

1

Y L R T S

2 Engine Room R/B No.2 W

2

4 4

4 B--W

W--B

1 EB1

B--R

A

B--W Battery

S1 1 S2

1

A

W--B EF

Starter

J1 Junction Connector

CONTINUED

A15211

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DI--103 DIAGNOSTICS--

P--L (A/T) Neutral Start IC9 2 Switch P--L (M/T)

P (A/T)

Thailand:

IC9 4 P (A/T)

ENGINE

9

5

P--L (A/T)

IJ4 6 Engine Room R/B

2 8

B

P--L

P--L (M/T)

1 STA 2

2

Engine ECU

P 11 E7

STA

P--L AM2 7

W--R

2

2

1 IJ4 17

Ignition Switch

1

V--Y

W

2 2

ALT

4

4 AM1

2

1

1

3

Y L R T S

2

2

Engine Room R/B No.2 W

4 4

4

B--W 1 EB2 B--R B--W Battery

S2 1 1

S3

W--B A J1 Junction Connector A W--B EF

Starter A15543

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DI--104 DIAGNOSTICS--

ENGINE

INSPECTION PROCEDURE When using hand-- held tester HINT: This diagnostic chart is based on the premise that the engine is being cranked under normal conditions. If theenginedoesnotcrank,proceedtotheproblemsymptomstableonpageDI -- 25.

1

Co nnect the han d--h eldeste t r and check STA sig n al.

PREPARATION: (a) Connect the hand--held tester to the DLC3. (b) Turn the ignition switch ON and push the hand--held tester main switch ON. CHE CK: ReadSTAsignalonthehand -- heldtesterwhilestarteroperates. OK: Ignitionswitchposition STA signal

ON

STA

OFF

OK

ON

Proceed to next circuit inspection shown on probl e ms y m ptoms tabl e(S e epa geDI -- 2 5).

NG

2

Check for o pen in harness and connector between en gine ECU and starter relay (Marki ng : START ER ) ( Se ep ag e I N -- 1 9 ).

NG

Repair or replace harness or connector.

OK

Check and replace engine ECU (See pageIN --19).

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DI--105 DIAGNOSTICS--

ENGINE

When not using hand-- heldtester HINT: This diagnostic chart is based on the premise that the engine is being cranked under normal conditions. If theenginedoesnotcrank,proceedtotheproblemsymptomstableonpageDI -- 25.

1

Check the start er sign al. ON

PREPARATION: (a) Remove the glove compartment door.

STA

(--)

(b) Turn the ignition switch ON. CHECK: Measure voltage between terminal STA of engine ECUconnec tor and body ground during cranking. OK: Voltage: 6.0 V or more

(+) A04968

OK

Proceed to next circuit inspection shown on probl e ms y m ptoms tabl e(S e epa geDI -- 2 5).

NG

2

Check for o pen in harness and connector between en gine ECU and starter relay (Marki ng : START ER()Se ep ag e I N -- 1 9 ).

NG

Repair or replace harness or connector.

OK

Check and replace engine ECU (See pageIN --19).

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DI--106 DIAGNOSTICS--

ENGINE DI8NX--01

A/C Signal Circuit CIRCUIT DESCRIPTION When the A/C compressor is ON, the A/C amplifier sends the A/C signal to the engine ECU, then engine ECU increases the fuel injection volume to improve driveability during engine idling.

WIRING DIAGR AM Engine ECU

A/C Amplifier

AC1

8

8 *2

*3

Y

2 *1

AC1

*1 : E9 Australia E7 South Africa E6 Thailand *2 : ID1 Australia, South Africa IN1 Thailand

*3 : L--Y Australia, South Africa Y Thailand

A15529

INSPECTION PROCEDURE When using hand-- held tester 1

Co nnect the han d--h eldeste t r and check A/C sig nal.

PREPARATION: (a) Connect the hand--held tester to the DLC3. (b) Turn the ignition switch ON and push the hand--held tester main switch ON. CHE CK: Read A/C signal on the hand--held tester while A/C compressor is ON. OK: A/C switch condition

OFF

ON

A/C signal

OFF

ON

OK

NG

5L--E ENGINE SUP (RM817E)

Proceed to next circuit inspection shown on probl e ms y m ptomstable (S e epa geDI -- 2 5).

CONTINUED

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DI--107 DIAGNOSTICS--

2

ENGINE

Check voltage between terminal AC1 of engineECU and body ground . STA

PREPARATION: (a) Remove the glove compartment door. (b) Start the engine. CHE CK: Measure voltage between terminal AC1 of engine ECU and body ground when A/C switch is turned to ON and OFF. OK:

AC1

(+)

(--)

A/C switch condition A04969

ON OFF

OK

Voltage Below 1.5 V 7.5--14 V

Check and replace engine ECU (See pa ge IN -- 19).

NG

3

Checkfor open and short in har ness and connector between engine ECU and A/C amp lifier(See p age IN-- 19).

NG

Repair or replace harness or connector.

OK

Check and replace A/C amplifier.

When not using hand-- heldtester 1

Check voltage between terminal AC1 of engineECU and body ground.

STA

PREPARATION: (a) Remove the glove compartment door. (b) Start the engine. CHECK: Measure voltage between terminal AC1 of engine ECU and body ground when A/C switch is turned to ON and OFF. OK:

AC1

(+)

(--)

A/C switch condition A04969

ON OFF

Voltage Below 1.5 V 7.5--14 V

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DI--108 DIAGNOSTICS--

OK

ENGINE

Proceed to next circuit inspection shown on probl e ms y m ptoms tabl e(S ee page DI -- 25).

NG

2

Checkfor open and short in ness har and connector between engine ECU and A/C amp lifier (See pag eIN -- 19).

NG

OK

Check and replace A/C amplifier.

5L--E ENGINE SUP (RM817E)

Repair or replace harness or connector.

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DI--109 DIAGNOSTICS --

ENGINE DI115--04

A/ CCutControlCircuit CIRCUITDESCRIPTION This circuit cuts air conditioning operation during vehicle acceleration in order to increase acceleration performance. During acceleration with the vehicle speed at 30 km/h (19 mph) or less and accelerator pedal opening angle at 45 or more, the A/C magnetic switch is turned OFF for several seconds. The air conditioning is also controlled by the ECUout putting the engine coolant temperature to A/C amplifier. ˚

WIRINGDIAGRAM Engine ECU

A/C Amplifier

ACT

3

L--B

1 *2

LG--R

8 *1

ACT

*1 : E9 Australia E7 South Africa E6 Thailand *2 : ID1 Australia, South Africa IN1 Thailand A15529

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DI--110 DIAGNOSTICS--

ENGINE

INSPECTION PROCEDURE When using hand-- held tester 1

Connect the hand-- held ester t and check operat ion of airconditioning cutcontrol.

PREPARATION: (a) Connect the hand held tester to the DLC3. (b) Turn the ignition switch ON and push the hand--held tester main switch ON. (c) Start the engine and air conditioning switch ON. HINT: A/C magnetic clutch is turned ON. (d) Select the ACTIVE TEST mode on the hand--held tester. CHE CK: Check operation of A/C magnetic clutch cut when air conditioning cut control is operated by the hand--held tester. OK: A/C magnet c lutch i s turned O FF.

OK

Proceed to next circuit inspection shown on probl e ms y m ptoms table (S e epa geDI -- 2 5).

NG

2

Checkfor open and short inrne hass and connec tor be tween engine E CU and A/C amp lifier (See pag eIN -- 19).

NG

OK

5L--E ENGINE SUP (RM817E)

Repair or replace harness or connector.

CONTINUED

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DI--111 DIAGNOSTICS--

3

ENGINE

Checkvoltagebetween terminalACT of engineECU and bodyground. PREPARATION: (a) Remove the glove compartment door. (b) Start the engine. CHECK: Measure voltage between terminal ACT of engine ECU connector and body ground when A/C switch is turned to ON and OFF. OK:

STA ACT

(+)

(--) A04970

A/C switch condition

NG

Voltage

ON

14 V --9

OFF

V3--0

Check and replace A/C amplifier.

OK

Check and replace engine ECU (See pageIN --19).

When not using hand-- heldtester 1

Checkvoltagebetween terminalACT of engineECU and bodyground (See p age DI -- 111,Step 3).

OK

Check and replace engine ECU (See pa ge IN -- 19).

NG

2

Check voltage betw een ter minal THWO of engine ECU and body ground (See p age DI -- 109,Step 4).

OK

Check and replace engine ECU (See pa ge IN -- 19). CONTINUED

NG

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DI--112 DIAGNOSTICS--

3

ENGINE

Checkfor open and short inrne hass and connec tor be tween engine E CU and A/C amp lifier(See pag eIN -- 19).

NG

OK

Check and replace A/C amplifier.

5L--E ENGINE SUP (RM817E)

Repair or replace harness or connector.

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DI--113 DIAGNOSTICS--

ENGINE DI8NY--01

Diagnosti c Connector(DLC3) Ci rcuit CIRCUIT DESCRIPTION Terminals TC and CG are located in the DLC3. The DLC3 is located under the finish lower panel. When terminals TC and CG are connected, DTC in normal mode or test mode can be read from the check engine warning light in the combination meter. Also, terminal SIL is located in the DLC3. This terminal is used by the M--OBD communication with hand-held tester.

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DI--114 DIAGNOSTICS--

ENGINE

WIRING DIAGR AM Combination Meter (Check Engine)

Australia: Center J/B 5 3D

1 3D

R--L

2

Driver Side J/B GAUGE 5

1F

8 C10

5 C10

R--L

R

1

1

1H

1I

W 4

2 W

Engine Room J/B 2

2

1

1

2

AM1

ALT

OBD

TC

2

SIL

2

W

V

4 *1

TC

R

15 *1

SIL

J5 Junction Connector

DLC3

1

2

*1

Driver Side J/B

Ignition Switch

1H

5

P

BAT CG

13 V C

C

7 R B

B 4

W--B

16 GR--L

W

22 3E 4 Center J/B

IJ1 18 GR--L

21 3E

A

W--B J3 Junction Connector

Battery IH *1 : E10 Thailand Made E6 Except Thailand Made

CONTINUED

A15532

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DI--115 DIAGNOSTICS--

South Africa: J3 Junction Connector Y C C

2 1F

ENGINE

Combination Meter (Check Engine)

Driver Side J/B GAUGE 5 1H

8 C8

5 C8

Y

1 1H

W 4

2 W

Engine Room J/B 2

2

1

1

2

AM1

ALT

OBD

TC

2

SIL

2

W

4 E5

TC

15 E5

SIL

BAT CG

1 1I

J8 Junction Connector

DLC3

1

2

5 E5

Driver Side J/B

Ignition Switch R

P

13 V B 7

V B R

R A

A

4

16 GR--L

W

IA2 18 W--B GR--L

Battery IK

CONTINUED

A15540

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DI--116 DIAGNOSTICS--

Combination Meter (Check Engine)

Thailand:

8 C10

5 C10

Y

2 1F

ENGINE

Driver Side J/B GAUGE 5 1H

1 1H

W 4

W

Driver Side J/B

Ignition Switch R

5 E7

P

2

1 1I

W Engine Room J/B 2

2

AM1

ALT 1

1

2

OBD

DLC3

1

TC

2

SIL

2

2

BAT CG

13

7

J24 Junction Connector V V B B R

R A

A

4 E7 TC 15 E7

SIL

4

16 GR--L

W

IJ4 7 W--B GR--L

Battery IL

A15541

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DI--117 DIAGNOSTICS--

ENGINE

INSPECTION PROCEDURE 1

Checkthe check enginewarninglightcondition. PREPARATION: (a) Turn the ignition switch ON. (b) Using SST, connect the terminals TC and CG of DLC3. SST 09843 -- 18020 CHE CK:

FI2547

Check OK: the check engine warning light condition. Check engine warning light: Blinking HINT: If this inspection OK and there is no hand--held tester, do not need to do the following steps and this circuit is OK. Proceed to next circuit inspec tion shown on problem symptom table (SeepageDI -- 25).

OK

Go to step 7.

NG

2

Check voltage b etweenterm in als TC and CG of DL C3. ON

TC

PREPARATION: Turn the ignition switch ON. CHECK: Measure the voltage between terminals TC and CG of DLC3. OK: Voltage : 9 -- 14 V

DLC3

CONTINUED

CG A04971

OK

NG

5L--E ENGINE SUP (RM817E)

Go to step 5.

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DI--118 DIAGNOSTICS--

3

ENGINE

Checkcontinuityterminal CG of DLC3 and bodyground.

NG

Repair or replace harness or connector.

OK

4

Check for openand shortin harnes s and connector bet ween terminal TC of DL C3and termin al TC o f engine ECU (See p ag eIN -- 19).

NG

Repair or replace harness or connector.

OK

Check and replace engine ECU (See pageIN --19).

5

Check voltage between terminal W of engineECU connector and body ground. ON W

(--)

(+)

A04972

PREPARATION: (a) Remove the glove compartment door. (b) Disconnect the connector of engine ECU. (c) Turn the ignition switch ON. CHE CK: Measure voltage between terminal W of engine ECU connector and body ground. OK: Voltage : 9 -- 14 V OK

Check and replace engine ECU (See pa ge IN -- 19). CONTINUED

NG

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DI--119 DIAGNOSTICS--

6

ENGINE

Checkthe bulbof check enginewarninglight.

NG

Replaceb ulb.

OK

Check for open in harness and connector between terminal W of engine ECU and combination meter(See pageIN -- 19).

7

Can you re ad the DTC (inc luding norma l DTC) usi ng hand-- held ester? t

YES

Proceed to next circuit inspection shown on proble m s y m ptomtable (S e epa geDI -- 2 5).

NO

8

Check voltage between terminal BATT of DLC3 and body ground. ON

CHECK: Measure voltage between terminal BATT of DLC3 and body ground. OK: Voltage : 9 -- 14 V

DLC3

BATT A04973

NG

Check for open and short in harness and connectorbetweenterminal BATT of DLC3 and fusible link bloc k (See pa ge IN -- 19).

OK

Check for open and shortin harness and connector between terminal SIL of DLC3and terminal SIL of e ngine ECU (See pageIN -- 19).

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DI--120 DIAGNOSTICS--

ENGINE DI3SF--02

Neutral tS artSwitch Ci rcuit (only for vehic les with A/T) CIRCUIT DESCRIPTION The neutral start switch goes on when the shift lever is in theN or P shift position. When it goes on the terminal NSW of the engine ECU is grounded to body ground via the starter relay thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the neutral start switch goes off, so the voltage of the engine ECU terminal NSW becomes battery positive voltage, the voltage of the engine ECU internal power source. If the sh ift lever is moved from the N position to the D position, this signal is used for air--fuel ratio correction, for idle speed control (estimated control), etc.

WIRING DIAGR AM

Ignition Switch B 8

2

1

2 2 STA Engine Room R/B

From Battery

7

6 IJ4

P

P

P

Engine ECU

22 E7

NSW

P IC9 4 6

1 B--W EB2 W--B B--W

Neutral Start Switch

W

From Battery

4 4

P

Engine Room R/B

5 P--L

ST RLY

IC9 2

2

1

4

3

A

4 4

V--Y 17 IJ4

P--L

J1 Junction Connector 1 S2

A W--B EE

Starter

A15542

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DI--121 DIAGNOSTICS--

ENGINE

INSPECTION PROCEDURE HINT: This diagnosis chart is based on the premise that the engine is being cranked under normal conditions. If theenginedoesnotcrank,proceedtotheproblemsymptomstableonpageDI -- 25.

1

Check neu tral start switch . PREPARATION: Disconnect the neutral start switch connector. CHE CK: Check continuity between each terminal shown below when the shift lever is shifted to each position. OK: Shift position P Q07545

R N

NG

OK

5L--E ENGINE SUP (RM817E)

Terminal No. to continuity 6--5 8 -- 2 6--5

7--2 -9--2

D

10-- 2

2

3 -- 2

--

--

L

4 -- 2

--

Replace neutral start switch.

CONTINUED

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DI--122 DIAGNOSTICS--

2

ENGINE

Check voltage between terminal NSW of engineECU connector and body ground. ON

PREPARATION: (a) Remove the glove compartment door. (b) Turn the ignition switch ON. CHE CK: Measure voltage between terminal NSW of engine ECU connector and body ground after the shift lever is moved to the following positions. OK:

NSW

A05981

Shiftleverposition

PorN

L,2,DorR

Voltage

0--3V

9--14V

OK

Check and replace engine ECU (See pa ge IN -- 19).

NG

Check for open and short in harness and connector between neutral start switch and engine ECU (See p age IN -- 19).

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ENGINE MECHANICAL INJECTION TIMING ......................

EM--1

IDLE SPEED AND MAXIMUM SPEED ......

EM--2

CYLINDER HEAD ........................

EM--3

CYLINDER BLOCK .......................

EM--11

RE FE  RTOF O LLO WI NGRE PAI RMANUALS : ManualName 2L,3LEngineRepairManual 2L, 2L--T, 3L, 5L Engine Repair Manual Supplement (Aug., 1997)

Pub.No. RM520E RM582E

NOTE: The above pages contain only the points which differ from the above listed manuals.

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EM--1 ENGINE MECHANICAL -- INJECTION TIMING

INJECTIONT IMING EM0HS--02

INSPECTION

1. INSPECTINJ ECTIONTIMING Using mirror, check that the punching line of the injection pump flange and the punching line of the timing belt case aligned.

A15203

2 . (a)

(b) (c) A15204

ADJ US TI NJ E CTI O NTI MI NG Loosen these nuts and bolt: S Bolt holding injection pump to injection pump stay. S 2 nuts holding injection pump to timing belt case. Align the pun ching line by slightly tilting the inj ection pump. Tighten these nuts and bolt: S 2 nuts holding injection pump to timinig belt case. Torque: 20.5 N m (210 kgf cm, 15 ft lbf) S Bolt holding injection pump to injection pump stay. Torque: 26 N m (270 kgf cm, 19 ft lbf) ∙

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5L--E ENGINE SUP (RM817E)

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EM--2 ENGINE MECHANICAL -- IDLE SPEED AND MAXIMUM SPEED

IDLESPEEDANDMAXIMUMSPEED EM1MH--01

INSPECTION 1. (a) (b) (c) (d) (e) (f) (g) (h) 2 . 3. (a) (b)

INITIALCONDITIONS Engine at normal operating temperature. Air cleaner installed. All pipes and hoses of air induction system connected. All accessories switched OFF. All vacuum lines properly connected. ECD system wiving connectors fully plugged. Valve clearance set correctly. Injection timing set correctly. CO NNE CTTACHO ME TE R INSP ECTIDLESPEED Start the engine. Check the idle speed. Idle spee d: 720 -- 820 rpm If the idle speed is not as specified, check the troubleshooting in DI section. 4. INSP ECTMAXIMUMSPEE D (a) Depress the accelerator pedal all the way. (b) Check the maximum speed. Maximum speed: 4, 770 -- 5,030 rpm If the maximum speed is not as specified, replace the injection pump.

5L--E ENGINE SUP (RM817E)

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EM--3 ENGINE MECHANICAL -- CYLINDER HEAD

CYLINDERHEAD EM1MI--01

COM P ONE NT S No.1 Timing Belt Cover

Timing Belt Gasket

Drive Belt Water Pump Pulley

Timing Belt Guide x9 Fan and Fluid Coupling Assembly

235 (2,400, 173)

Crankshaft Pulley Collar Glow Plug Wire

Oil Filler Cap Glow Plug No.2 Cylinder Head Cover

Glow Plug Connector Spacer

Camshaft Timing Pulley

PCV Hose

98 (1,000, 72)

CONTINUED

N∙m (kgf∙cm, ft∙lbf) : Specified torque

5L--E ENGINE SUP (RM817E)

A15209

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EM--4 ENGINE MECHANICAL -- CYLINDER HEAD

Cylinder Head Cover Pipe Clamp Injection Pipe

Gasket

PCV Hose

29.5 (300, 22)

z

w/ EGR: EGR Pipe z Gasket

Exhaust Manifold

Heat Insulator

Injection Pipe

Gasket

Injection Nozzle 64 (650, 47)

Nozzle seat Gasket

z 19 (195, 14) 108 (1100, 79)

EGR Valve 1st 78 (800, 58) 2nd Turn 90

z

z

Gasket

Gasket

˚

3rd Turn 90

˚

Cylinder Head Assembly

No. 2 Timing belt Cover

EGR Valve Adapter 19 (195, 14)

Throttle Body z z

Gasket

Cylinder Head Gasket

z 18 (185, 13)

Gasket

Intake Manifold

Fuel Hose LH Engine Hanger 24 (240, 17)

z

N∙m (kgf∙cm, ft ∙lbf) z

: Specified torque

Non--reusable part

Gasket Water Outlet and Outlet Housing Assembly

Engine Wire Water Temp. Sender Gauge Connector A15208

5L--E ENGINE SUP (RM817E)

CONTINUED

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EM--5 ENGINE MECHANICAL -- CYLINDER HEAD

25 (255, 18)

Camshaft Bearing Cap Camshaft Bearing Camshaft

Adjusting Shim Valve Lifter Keeper Spring Retainer Valve Spring Spring Seat

Cylinder Head

L

z

Oil Seal

z

Valve Guide Bushing

Semi--Circular Plug

Camshaft Oil Seal Retainer

z z

Oil Seal

Gasket

Adjusting Shim

Combustion Chamber Valve

N∙m (kgf∙cm, ft ∙lbf) : Specified torque z Non--reusable part L Precoated part

5L--E ENGINE SUP (RM817E)

S04371

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EM--6 ENGINE MECHANICAL -- CYLINDER HEAD EM1MJ--01

RE M O VAL HINT: If replacing the timing belt before the timing belt warning light comes on, (light comes on after 100,000 km of driving), be sure to reset the timing belt counter of the speedometer to zero. 1 . DRAI NE NG I NECO O L ANT 2. REMOVEPCVHOSE 3. w/EGR: RE MO V EE G RVALV EANDE G RADAP TE R (a)

Loosen the union nut holding the EGR valve to the EGR pipe.

(b)

Remove the 2 bolts, 4 nuts, EGR valve and EGR adapter and gasket.

A15205

A15206

4 .

RE MO V ETHRO TTLEBO DY (S e epa geE D -- 5 ) 5 . RE MO V ENO . 2CY LI NDE  RHE ADCO V E R (SeePub.No.RM520EonpageEG -- 30) 6. REMOVEGLOW PLUGS (SeePub.No.RM520EonpageEG -- 30) 7 . RE MO V EDRI V EBE LT S ,FAN,FLUI DCO UP  LI NGAS S E MBLYANDWATE RP UMPP ULLE Y (SeePub.No.RM520EonpageEG -- 162) 8 . RE MO V ETI MI NGBE LT (SeePub.No.RM520EonpageEG -- 21) 9 . RE MO V ECAMS HAFTT I MI NGP ULLE Y (SeePub.No.RM520EonpageEG -- 22a) 1 0 . RE M O V EI NJ  E CTI O NNO ZZLE S (SeePub.No.RM520EonpageEG -- 91) 11 . RE MO V ENO . 2TI MI NGBE LTCO V E R (SeePub.No.RM520EonpageEG -- 31) 12 .  R E  MO V E WAT E  R O UTLE T AN D HO  US I N G AS SEMBLY (SeePub.No.RM520EonpageEG -- 31) 5L--E ENGINE SUP (RM817E)

CONTINUED

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EM--7 ENGINE MECHANICAL -- CYLINDER HEAD

1 3 . RE MO V ELHE NG  I NEHANG E R (SeePub.No.RM520EonpageEG -- 31) 14.  REMOVEINTAKEMANIFOLDASSEMBLY (SeePub.No.RM520EonpageEG -- 31) 1 5 . RE MO V EE X HAUS  TMANI FO  LD (SeePub.No.RM520EonpageEG -- 32) 1 6 . RE MO V ECY LI NDE  RHE ADCO V E R (SeePub.No.RM520EonpageEG -- 32) 17.  REMOVECYLINDERHEADASSE MBLY (SeePub.No.RM520EonpageEG -- 32)

5L--E ENGINE SUP (RM817E)

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EM--8 ENGINE MECHANICAL -- CYLINDER HEAD EM1MK--01

INSPECTION

EM2011

INSPECTCAMLOBES Using a micrometer, measure the cam lobe height. Standard cam lobe height: Intake 54.890 -- 54 .910 mm (2.1610 -- 2.1618 in.) Exhaust 54.990 -- 55 .010 mm (2.1650 -- 2.1657 in.) Minimum cam lobe height: Intake 54.39 mm (2.14 13 in.) Exhaust 54.49 mm (2.1453 in.) If the cam lobe height is less than minimum, replace the camshaft.

5L--E ENGINE SUP (RM817E)

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EM--9 ENGINE MECHANICAL -- CYLINDER HEAD EM1ML--01

INSTALLATION 1.

2 . 3. 4.

CHECKPISTONPROTRUSIONANDSELECT CYLINDER HEAD GASKET (SeePub.No.RM520EonpageEG -- 48) S E TNO . 1CY LI NDE  RTO9 0 BTDC/ CO  MP RE  S S I O N (SeePub.No.RM520EonpageEG -- 49) INSTALLCYLINDERHEAD (SeePub.No.RM520EonpageEG -- 49) INSTALLCYLINDERHEADCOVER ˚

(SeePub.No.RM520EonpageEG -- 50) I NS  TALLE X HAUS TMANI FO  LD (SeePub.No.RM520EonpageEG -- 50) 6. INSTALLINTAKEMANIFOLDASSEMBLY (SeePub.No.RM520EonpageEG -- 50) 7 . I NS TALLL HE NG  I NEHANG E R (SeePub.No.RM520EonpageEG -- 51) 8. INSTALLWATEROUTLETANDOUTLETHOUSING ASSEMBLY (SeePub.No.RM520EonpageEG -- 51) 9 . I NS TALLNO . 2TI MI NGBE LTCO V E R (SeePub.No.RM520EonpageEG -- 51) 1 0 . I NS TALLI NJ E CTI O NNO ZZLE S (SeePub.No.RM520EonpageEG -- 51) 11 . I NS TALLTHRO TTLEBO DY 5 .

(S e epa geE D -- 6 )

12. w/EGR: I NS TALLE G RVALV EANDE G RADAP TE  R Install the new gasket, EGR valve and EGR pipe with the 2 bolts, 4 nuts and union nut. Torque: 13 N m (130 kgf cm, 9 ft lbf) for bolts 19 N m (19 5 kgf cm, 14 ft lbf) for nuts 108 N m (1100 kgf cm, 79 ft lbf) for union nuts ∙

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A15210

1 3 . I NS TALLCAMS HAFTT I MI NGP ULLE Y (SeePub.No.RM520EonpageEG -- 25) 14.  INSTALLTIMINGBELT (SeePub.No.RM520EonpageEG -- 26) 15. INSTALLWATERPUMPPULLEY,FAN,FLUIDCOU PLINGASSEMBLYANDDRIVEBELTS (SeePub.No.RM520EonpageEG --164) 1 6 . I NS TALLG LO WP L UG  S (SeePub.No.RM520EonpageEG -- 51) 5L--E ENGINE SUP (RM817E)

CONTINUED

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EM--10 ENGINE MECHANICAL -- CYLINDER HEAD

1 7 . I NS  TALLNO . 2CY LI NDE  RHE ADCO V E R (SeePub.No.RM520EonpageEG -- 52) 1 8 . I NS  TALLP CVHO S E 1 9 . FI LLWI THE NG  I NECO O L ANT 2 0 . S TARTE NG  I NEANDCHE CKFO RL E AKS 21. RECHECKENGINECOO LANTLEVELANDOILLEVEL

5L--E ENGINE SUP (RM817E)

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EM--11 ENGINE MECHANICAL -- CYLINDER BLOCK

CYLINDERBLOCK EM1MM--01

DI SASSEMBLY RE  MO V ECRANKP O S I TI O NS E NS O R (a) Disconnect the connector. (b) Remove the bolt, crank position sensor.

5L--E ENGINE SUP (RM817E)

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EM--12 ENGINE MECHANICAL -- CYLINDER BLOCK EM1MN--01

REASSEMBLY I NS  TALLCRANKP O S I TI O NS E NS O R (a) Install a new O--ring and crank position sensor with bolt. Torque: 5 N m (51 kgf cm, 4 ft lbf) (b) Connect the connector. ∙

5L--E ENGINE SUP (RM817E)

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EMISSION CONTROL PA R T SL AY O U TA N D SCHEMATIC DRAWING . . . . . . . . . . . . . . . .

EC--1 EC -2

POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM ........................ E X HA US TG A SRE CI RCULAT I O N (EGR)S YSTEM.. . .. .. . .. .. . .. .. .. .. . .. On vehicle inspection Components Inspection

EC--3 C E -- 4 EC - 4/ 4/5 5 EC - 6 EC - 7

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EC--1 EMISSION CONTROL -- PARTS LAYOUTAND SCHEMATIC DRAWING

PARTS L AY OUT AND SCHEMATIC DRAWING EC09A--02

LOCATION

EGR Valve Engine ECU Acclerator Pedal Position Sensor

Intake Air Temperature Sensor

Intake Air Pressure Sensor Vacuum Damper

E--VRV for EGR Water Temperature Sensor Vacuum Pump

Engine Speed Sensor

B13281

5L--E ENGINE SUP (RM817E)

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EC--2 EMISSION CONTROL -- PARTS LAYOUTAND SCHEMATIC DRAWING EC09B--04

DRAWI NG Throttle Full Switch Throttle Body Vacuum Pump

Vacuum Damper Throttle Control Motor

E--VRV for EGR EGR Valve Engine Speed Sensor

Injection Pump

Accelerator Pedal Position Sensor

Engine ECU

Water Temperature Sensor

Intake Air Temperature Sensor Intake Air Pressure Sensor

B13275

5L--E ENGINE SUP (RM817E)

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5L-E Pages From Supplement TO MODEL INDEX EMISSION CONTROL -- POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM

EC--3

POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM EC09C--03

INSPECTION VISUALLY INSPECT HOSE AND CONNECTION Check for cracks, leaks or damage.

B06104

5L--E ENGINE SUP (RM817E)

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EC--4 EMISSION CONTROL -- EXHAUST GAS RECIRCULATION (EGR) SYSTEM

EXHAUST GAS RECIRCULATION (EGR) SYSTEM EC0J0--01

ON -- VEHICLE INSPECTION HINT: In a malfunction where the EGR system is always on, black smoke or white smok e may be output from the exhaust pipe. If this occurs, inspect the EGR system also. NOTICE: Always stop the engine when installing or removing the vacuum gauges, or removing the vacuum hoses.

Vacuum Gauge

1. INSTALL VACUUM GAUGE Using a 3 way connector, connect a vacuum gauge to the hose between the EGR valve and E--VRV. 2. INSPECT SEATING OF EGR VALVE Start the engine and check that the engine starts and run at idle. 3. INS PECT COLD ENGINE CONDITION (a) The coolant temperature should be below 20 C (64 F). (b) Check that the vacuum gauge indicates 0 at idle. 4. INS PECT HOT ENGINE CONDITION (a) Warm up the engine, the coolant temperature should be above 70 C (104 F) and below 96 C (205 F). (b) Check that the vacuum gauge indicates about more than 28.0 kPa (210 mmHg, 8.3 in.Hg) at idle. (c) Check that the vacuum gauge indicator increases about more than 28.0 kPa (210 mm Hg, 8.3 in.Hg) at 1,500 rpm. (d) When the accelerator pedal is quickly depress to the full open, check that the vacuum gauge indicator drops momentarily. (e) Keep the engine speed at more than 4,000 rpm. (f) Check that the vacuum gauge indicates 0. (g) When the accelerator pedal is releaced, check that the vacuum gauge indicator drops momentarily while the engine speed decreases from more than 4,000 rpm to idle. 5. REMOVE VACUUM GAUGE ˚

B06839

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CONTINUED

5L--E ENGINE SUP (RM817E)

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EC--5 EMISSION CONTROL -- EXHAUST GAS RECIRCULATION (EGR) SYSTEM

6. (a) (b)

Disconnect

Vacuum Gauge

B06622

5L--E ENGINE SUP (RM817E)

CHECK OUTPUT VACUUM WITH VACUUM G AUG E Connect a vacuum gauge to the output pipe. Warm up the engine and check that the vacuum gauge indicates above 86.7 kPa (650 mmHg, 25.59 in.Hg). If a problem is found, repair the vacuum pump.

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EC--6 EMISSION CONTROL -- EXHAUST GAS RECIRCULATION (EGR) SYSTEM EC09G--03

COMP ONENT S

108 (1,100, 80)

z

z

Gasket

Gasket

EGR Adaptor Wire Harness Clamp EGR Valve

A/T:

19(195, 14) 13(130, 9) 13(130, 9)

E--VRV for EGR Air Pipe Sub--Assembly 19(195, 14)

N∙m (kgf∙cm, ft ∙lbf) : Specified torque z

Non--reusable part

5L--E ENGINE SUP (RM817E)

B13279

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EC--7 EMISSION CONTROL -- EXHAUST GAS RECIRCULATION (EGR) SYSTEM EC0J1--01

INSPECTION 1. (a) (b) IN

(c)

OUT B06625

INSPECT EGR VALVE Remove the EGR valve. When a vacuum of 26.7 kPa (200 mmHg, 7.88 in. Hg) is applied to the diaphragm chamber, check that the shaft rises up and that air flows from IN to OUT. When applying more than 67 kPa (500 mmHg, 19 in. Hg) of the vacuum, check if there is any leakage of the vacuum.

(d) Check the valve for sticking and heavy carbon deposits. If a problem is found, replace it. (e) Reinstall the EGR valve with the new gasket. 2. INSPECT E -- VRV FOR EGR(See pageED -- 11) 3. INSPECT ACCE LE RATOR PE DAL POSITI ON SE NSOR (See pageDI-- 40) 4. INSPECT ENGINE SPEED SENSOR(See page ED - 17) 5. INSPECT INTAKE AIR TEMPERATURESENSOR(See page ED -- 1 4 ) 6. INSPECT WATER TEMPERATURE SE NSOR (See page ED -- 1 2 ) 7. INSPECT THROTTLE FULL SWITCH (See page ED - 3) 8. INSPECT THROTTLE CONTROL MOTOR(S ee page

ED - 3)

5L--E ENGINE SUP (RM817E)

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ELECTRONIC CONTROL DIESEL ECDSYST EMPrecaution.

............. D -- 1

E

THROTTLEBODY . . . . . . . . . . . . . . . . . . . . . . .

ED -- 3

TIMING CONTROL VALVE ................

ED--7

SPILL CONTROL VALVE ..................

ED--8

ECD MAIN RELAY ....................... E-- VRV FOR EGR ED--10 Inspection . .

ED--9 ED-11

WAT ERT EMPERAT URESENSO R ........ D -- 12E FUEL TEMPERATURE SENSOR ..........

ED--13

INTAKE AIR TEMPERATURE SENSOR ....

ED--14

I NTAKEAI RPRESSURESENSO R........

15/16 ED --

ENGINE SPEED SENSOR . . . . . . . . . . . . . . . .

ED--17

CRANKSHAFT POSITION SENSOR .......

ED--18 D E -- 19

ACCELERATO RPEDAL PO SI T I O NSENSO R INSPECTION

20 ED --

ACCELERATOR PEDAL CLOSED POSITION SWITCH .................... INJECTION PUMP CORRECTION UNIT .... ENG I NEECU............................ D --

ED--21 ED--22 E 23/26

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ED--1 ELECTRONIC CONTROL DIESEL -- ECD SYSTEM

ECDSYSTEM ED00I--04

PRECAUTION HINT: S Any DTC code retained by the computer will be erased when the negative (--) terminal cable is removed from the battery. S The refore, if necessary, read the diagnosis before removing the negative (--) terminal cable from the battery. 1. BEFORE WORKIN GONFUELSYSTEM ,DISCONNE CTNE G ATI V E( -- )TE RMI NALCABLEF RO  MBAT TE RY 2 . DONO TS MO KEO RWO RKNE ARANO P E NFLAME WHENWORKINGONFUELSYSTEM 3.  KE EP DI ES EL FU EL AWAYFR OM RU BB E RO R LE AT HE RPARTS 4 . AI RI NDUCTI O NSYSTEM (a) Separation of the en gine oil dipstick, oil filler cap, PCV hose, etc. may cause the engine to run out of tune. (b) Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause the engine to run out of tune. 5. ELECTRONICCONTROLSYSTEM (a) BeforeremovingECDwiringconnectors,terminals,etc., first disconnect the power by either turning the ignition switch OFF or disconnecting the negative (--) terminal cable from the battery. HINT: Always check the DTC before disconnecting the negative (--) terminal cable from the battery. (b) When installing the battery, be especially careful not to in correctly connect the positive (+) and negative (--) cables. (c) Do not permit parts to receive a severe impact daring removal or installation. Handle all ECD parts carefully, especially the engine ECU. (d) Do not be careless during troubleshooting as there are numerous transistor circuits and even slight terminal contact can further troubles. (e) Do not open the engine ECU cover. (f) When inspecting during rainy weather, take care to prevent entry of water. Also, when washing the engine compartment, prevent water from getting on the ECD parts and wiring connectors. (g) Parts should be replaced as an assembly. CONTINUED

5L--E ENGINE SUP (RM817E)

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ED--2 ELECT RONIC CONTROL DIESE L -- ECD SYSTEM

(h)

Care is required when pulling out and inserting wiring connectors. (1) Release the lock and pull out the connector, pulling on the connectors.

Lock Press Down B01172

P03244

(i) Insert

Lock P03245

5L--E ENGINE SUP (RM817E)

B01173

(2) Fully insert the connector and check that it locked. When inspecting a connector with a volt/ohmmeter. (1) Carefully take out the water--proofing rubber if it is a water--proof type connector. (2) Insert the test probe in to the connector fromthe wiring side when checking the continuity, amperage or voltage. (3) Do not apply unnecessary force to the terminal. (4) After checking, install the water--proofing rubber on the connector securely.

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ELECTRONIC CONTROL DIESEL: THROTTLE BODY 1. ON VEHICLE INSPECTION ED-3 2. COMPONENTS ED-4 3. REMOVAL ED-5 4. INSTALLATION ED-6

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ED--3 ELECTRONIC CONTROL DIESEL -- THROTTLE BODY

Ohmmeter

THROTTLE BODY ED02R--03

ON -- VEHICLE INSPECTION 1. (a) (b)

B13265

Continuity

Fullyclosed

Nocontinuity

Fullyopen

Continuity

Reconnect the throttle full switch connector.

2. (a) (b)

INSPECT THROTTLE CONTROL MOTOR Disconnect the throttle control motor connector. Using an ohmmeter, measure theresi stance between terminals 1 and 2, 3 and 2, 4 and 5, and 6 and 5. Resistanc e: 18 -- 2 2 Ω at 20 C (68 F) Reconnect the throttle control motor connector.

(c)

5L--E ENGINE SUP (RM817E)

ThrottleValve

(c)

Ohmmeter

B13266

INSPECT THROTTLE FULL SWITCH Disconnect the throttle full switch connector. Using an ohmmeter, check the continuity between the terminals.

˚

˚

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ED--4 ELECT RONIC CONTROL DIESE L -- THROTTLE BODY ED04H--01

COM P ONE NT S 12 (120, 9)

Check Connector Intake Air Connector Bracket 12 (120, 9)

Wire Harness Clamp Throttle Full Switch Connector Throttle Body Assembly

z

Gasket

Throttle Control Motor Connector

N∙m (kgf∙cm, ft∙lbf) : Specified torque z

Non--reusable part

5L--E ENGINE SUP (RM817E)

B13267

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ED--5 ELECTRONIC CONTROL DIESEL -- THROTTLE BODY ED04I--01

RE M O VAL RE MO VETHRO TTLEBO DYASSEMBLY (a) Disconnect thechec k connector from thethro ttle body assembly. (b) Remove the bolt and intake air connector bracket. (c) Disconnect the 2 connectors. (d) Remove the 3 nuts and wire harness clamp. (e) Remove the throttle body assembly and gasket. B13268

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ED--6 ELECT RONIC CONTROL DIESE L -- THROTTLE BODY ED04J--01

INSTALLATION INSTALLTHRO TTLEBO DYASSEMBLY (a) Install the gasket, throttle body assembly and wire harness clamp with the 3 nuts. Torque: 12 N m (12 0 kgf cm, 18 ft lbf) (b) Connect the 2 connectors. (c) Install the intake air connector bracket with the bolt. (d) Connect the check connector. ∙

B13268

5L--E ENGINE SUP (RM817E)

∙

∙

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ED--7 ELECTRONIC CONTROL DIESEL -- TIMING CONTROL VALVE

TIMING CONTROL VALVE ED04K--01

Ohmmeter

INSPECTION INSPECT TIMING CONTROL VALVE (a) Disconnect the timing control valve connector. (b) Using an ohmmeter, measure the resistance between the terminals. Resistanc e: 10 -- 1 4 Ω at 20 C (68 F) If the resistance is not specified, replace the injection pump assembly(SeepageFU -- 11). ˚

B12766

(c)

+B

TCV

B13129

Inspect the timing control valve solenoid operation. (1) Connect the battery positive the terminal to the timing control valve terminal +B. (2) Connect the battery negative terminal to the timing control valve terminal TCV. (3) Check that the solenoid makes a ”clicks” sound. If operation is not as specified , replace the timing control valve. NOTICE: Do no t app ly vol tage for mor e than 30 secon ds to avoid burning out the timing control valve solenoid. If repeating this step, wait until the solenoid coils become cool enough that it can be touched by hand. (d) Reconnect the timing control valve connector. S S

S S

5L--E ENGINE SUP (RM817E)

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ED--8 ELECT RONIC CONTROL DIESE L -- SPILL CONTROL VALVE

Ohmmeter

SPILL CONTROL VALVE ED02U--03

INSPECTION INSPECT SPILL CONTROL VALVE (a) Disconnect spill valve connector.

(b)

Using an ohmmeter, measure the resistance between the terminals. Resistanc e: 1 -- 2 Ω at 20 C (68 F) If the resistance is not specified, replace the injection pump assembly(SeepageFU -- 11). (c) Reconnect the spill valve connector. ˚

B12767

5L--E ENGINE SUP (RM817E)

˚

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ED--9 ELECTRONIC CONTROL DIESEL -- ECD MAIN RELAY

ECD MAIN RELAY ED04L--01

INSPECTION

ECD Relay

1.

REMOVEECDRELAY

B09252

Continuity Ohmmeter

Ohmmeter

2

1

5

3 No Continuity

2. (a)

INSPECTECDRELAY Inspect the ECD relay continuity. (1) Using an ohmmeter, check that th ere is continuity between terminals 1 and 2. If there is no continuity, replace the ECD relay. (2) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the ECD relay.

S04970

(b) 2

Ohmmeter

1 5

Inspect the ECD relay operation. (1) Apply battery positive voltage across terminals 1 and 2. (2) Using an ohmmeter, check that th ere is continuity between terminals 3 and 5. If there is no continuity, replace the ECD relay.

3 Battery Continuity S04969

3 . ECD Relay

B09252

5L--E ENGINE SUP (RM817E)

RE I NS TALLE CDRE LAY

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ED--10 ELECT RONIC CONTROL DIESE L -- E--VRV FOR EGR

E --  VRV FOR EGR ED02X--02

COM P ONE NT S

Vacuum Hose (from VSV for EGR Valve)

E--VRV for EGR Vacuum Hose (from Vacuum Pump) E--VRV Connector for EGR

B13280

5L--E ENGINE SUP (RM817E)

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ED--11 ELECTRONIC CONTROL DIESEL -- E--VRV FOR EGR EC0DA--02

INSPECTION

Ohmmeter

1. REMOVE E--VR V 2. INSPECT E--VR V FOR OPEN CIRCUIT Using an ohmmeter, measure the resistance between terminals as shown. Resistanc e: 46 -- 5 0 Ω at 20 C (68 F) If the resistance is not specified, replace the E--VRV. ˚

Continuity

˚

B05587

3. INS PECT E--VR V FOR GRO UND Using an ohmmeter, check that there is no continuity between terminals and E--VRV body. If there is continuity, replace the E--VRV.

Ohmmeter

No Continuity B05591

Vacuum

4. INSPECT E--VR V FOR AIR TIGHTNESS Check that when vacuum is applied to the vacuum outlet port shown, the needle of vacuum pump indicates an increase of 66.7 kPa (500 mmHg, 19.7 in. Hg) or more. If a problem is found, replace the E--VRV

B05592

6V

Vacuum

B05593

5L--E ENGINE SUP (RM817E)

5. (a) (b)

INSPECT E--VR V OPE RATIO N Apply about 6 V of DC power to the terminals. Check that when vacuum is applied to the vacuum outlet port shown, the need does not move. If operation is not as specified, replace the E--VRV. 6. REINSTALL E--VRV

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ED--12 ELECT RONIC CONTROL DIESE L -- WATER TEMPERATURE SENSOR

WATERT EMPERAT URESENSOR ED00M--04

INSPECTION 1 . 2. (a) (b)

DRAI NE NG I NECO O L ANT REMOVEWATERTEMPERATURESENSOR Disconnect the water temperature sensor connector. Using a 19 mm deep socket wrench, remove the water temperature sensor and gasket.

B13271

3. INSPECTWATERTEMPERATURESENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the chart graph If the resistance is not as specified, replace the water temperature sensor. 4. REINSTALLWATERTEMPERATURESENSOR (a) Using a 19 mm deep socket wrench, install a new gasket and the water temperature sensor. Torque: 25 N m (25 0 kgf cm, 18 ft lbf) (b) Connect the water temperature sensor connector. 5 . RE FI LLWI THE NG  I NECO O L ANT

Ohmmeter

30 20

Ω k e c n a t s i s e R

10 5 Acceptable

3 2

∙

1 0.5 0.3 0.2 0.1 --20 0

20 40 60 8 0 100

(--4) ( 32) (6 8) (104) (140)(176) (212)

S01196 S01699

Temperature C ( F)

5L--E ENGINE SUP (RM817E)

˚

˚

Z17274

∙

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ED--13 ELECTRONIC CONTROL DIESEL -- FUEL TEMPERATURE SENSOR

FUELTEMPERAT URESENSOR ED04M--01

INSPECTION 1. (a) (b)

REMOVEFUELTEMPERATURESENSOR Disconnect the fuel temperature sensor connector. Using a 19 mmdee p socket wrench, remove the fuel temperature sensor and O--ring.

B12768

2. INSPECTFUELTEMPERATURESENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the chart graph If the resistance is not as specified, replace the fuel temperature sensor. 3. REINSTALLFUELTEMPERATURESENSOR (a) Install a new O--ring to the fuel temperature sensor. (b) Using a 19 mm deep socket wrench, install the fuel temperature sensor. Torque: 22. 1 N m (22 5 kgf cm, 16 ft lbf) (c) Connect the fuel temperature sensor connector.

Ohmmeter

30 20

Ω k e c n a t s i s e R

10 5 Acceptable

3 2

∙

1 0.5 0.3 0.2 0.1 --20 0

20 40 60 8 0 100

(--4) ( 32) (6 8) (104) (140)(176) (212)

S01196 S01699

Temperature C ( F)

5L--E ENGINE SUP (RM817E)

˚

˚

Z17274

∙

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ED--14 ELECT RONIC CONTROL DIESE L -- INTAKE AIR TEMPERATURE SENSOR

INTAKEAIRT EMPERAT URE SENSOR ED031--02

INSPECTION 1. (a) (b)

REMOVEINTAKEAIRTEMPERATURESENSOR Disconnect the intake air temperature sensor connector. Remove the intake air temperature sensor.

B09259

2. INSPECTINTAKEAIRTEMPERATURESENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the chart graph If the resistance is not as specified, replace the intake air temperature sensor. 3 . RE I NS TALLI NTAKEAI RT E MP E RAT URES E NS  O R (a) Install the intake air temperature sensor. (b) Connect the intake air temperature sensor connector.

Ohmmeter

30 20

Ω k e c n a t s i s e R

10 5 Acceptable

3 2 1 0.5 0.3 0.2 0.1 --20 0

20 40 60 8 0 100

(--4) ( 32) (6 8) (104) (140)(176) (212)

S01196 S01699

Temperature C ( F)

5L--E ENGINE SUP (RM817E)

˚

˚

Z17274

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ED--15 ELECTRONIC CONTROL DIESEL -- INTAKE AIR PRESSURE SENSOR

INTAKEAIRPRESSURESENSOR

Voltmeter

ED04N--01

INSPECTION 1. Disconnect

(a) (b) (c)

E2 VC B05475

(d) (e)

INSPE CTPOWERSOURCEV O LTAG EO FTURBO PRESSURESENSOR Disconnect the intake air pressure sensor connector. Turn the ignition switch ON. Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.75 -- 5.25 V Turn the ignition switch OFF. Reconnect the intake air pressure sensor connector.

2.

PIM

Voltmeter E2

Disconnect

INSPECTSUPPLYPOWEROFTURBOP RESSURE SENSOR (a) Turn the ignition switch ON. (b) Disconnect the vacuum hose from the intake air pressure sensor. (c) Connect a voltmeter to terminals PIM and E2 of the engine ECU, and measure the output voltage under ambient atmospheric pressure. (d) Apply vacuum to the intake air pressure sensor in 13.3 kPa (100 mmHg, 3.94 in.Hg) segments to 40.0 kPa (300 mmHg, 11.81 in.Hg). (e) Measurethevoltagedropfromstep(c)aboveforeach segment. Vol ta gedrop: Applied vacuum kPa (mmHg, in.Hg)

Vacuum B03168 B05475

13.3(100,3.94)

B13283

Voltage drop V 0.3-- 0.5

26.7(200,7.87)

0.6-- 0.8

40.0(300,11.81)

0.95 -- 1.15

CONTINUED

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ED--16 ELECT RONIC CONTROL DIESE L -- INTAKE AIR PRESSURE SENSOR

(f)

Using SST (turbocharger pressure gauge), apply pressure to the intake air pressure sensor in 19.6 kPa (0.20 kgf/cm2, 2.84 psi) segments to 98.0 kPa (1.00 kgf/cm 2, 14.2 psi). SST 09992 -- 00242 (g) Measurethevoltageupfromstep(c)aboveforeachsegment. Vol ta geup:

PIM

Voltmeter E2

Applied pressure kPa (kgf/cm 2, psi)

Disconnect

(h)

Pressure B03168 B05477

5L--E ENGINE SUP (RM817E)

B13284

Voltage up V

19.6(0.20,2.84)

0.4-- 0.7

39.2(0.40,5.69)

0.8-- 1.2

58.8(0.60,8.53)

1.4-- 1.8

78.5(0.80,11.4)

2.0-- 2.3

98.0(1.00,14.2)

2.5-- 2.8

Reconnect the vacuum hose to the intake air pressure sensor.

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ED--17 ELECTRONIC CONTROL DIESEL -- ENGINE SPEED SENSOR

Ohmmeter

ENGINE SPEED SENSOR ED03F--03

INSPECTION INSPECTENGINESPEEDSENSOR (a) Disconnect the engine speed sensor connector. (b) Using an ohmmeter, measure the resistance between the terminals. Resistance: 205 -- 255 Ω at 20 C (68 F) If the resistance is not specified, replace the injection pump assembly (See page FU --11). (c) Reconnect the engine speed sensor connector. ˚

B12956

5L--E ENGINE SUP (RM817E)

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ED--18 ELECT RONIC CONTROL DIESE L -- CRANKSHAFT POSITION SENSOR

CRANKSHAFT POSITION SENSOR ED035--02

INSPECTION NOTICE: ”Cold” and ”Hot” in the following sentences express the temperature of the senso rs themselves . ”Cold” is from -- 1 0 C (14 F) to 50 C (122 F) and ”Hot” is from 50 C (122 F) to 100 C (212 F). INSPECTCRANKS HAFTP O S I T I O NS E NS O R (a) Disconnect the crankshaft position sensor connector. ˚

˚

˚

(b)

Ohmmeter

˚

˚

˚

˚

˚

Using an ohmmeter, measure the resistance between the terminals. Resistance: Cold

19 32 --

Ω

Hot

24 37 --

Ω

B13274

Ohmmeter

(c)

TDC-- TDC+

Using an ohmmeter, measure the resistance between TDC-- terminal and body. Resistance: 10 M Ω or more If the resistance is not as specified, replace the crankshaft position sensor. Torque: 5 N m (50 kgf cm, 43 in. lbf) HINT: Apply engine oil to a new O--ring on the crankshaft position sensor, and install them. NOTICE: Be careful not drop and shock the sensor. (d) Reconnect the crankshaft position sensor connector. ∙

B13277

5L--E ENGINE SUP (RM817E)

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ED--19 ELECTRONIC CONTROL DIESEL -- ACCELERATOR PEDAL POSITION SENSOR

ACCELERATORPEDALPOSITIONSENSOR ED04O--01

COM P ONE NT S

M/T: 5.0 (50, 43 in .lbf) ∙

Accelerator Pedal Position Sensor Accelerator Pedal Closed Position Switch Connector

Accelerator Pedal Closed Position Switch

Accelerator Pedal Position Sensor Connector

5.0 (50, 43 in .lbf) ∙

Accelerator Pedal Assembly

A/T:

5.0 (50, 43 in .lbf) ∙

Accelerator Pedal Position Sensor

Accelerator Pedal PositionSensor Connector

Accelerator Pedal Closed Position Switch Accelerator Pedal Closed Position Switch Connector

5.0 (50, 43 in .lbf) ∙

Accelerator Pedal Assembly

N∙m (kgf∙cm, ft ∙lbf) : Specified torque

5L--E ENGINE SUP (RM817E)

B13282

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ED--20 ELECT RONIC CONTROL DIESE L -- ACCELERATOR PEDAL POSITION SENSOR ED037--01

INSPECTION INSPECTACCE LE RATO RP E DALP O S I TI O NS E NS O R(S e ep a g eDI -- 4 0 )

5L--E ENGINE SUP (RM817E)

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ED--21 ELECTRONIC CONTROL DIESEL --

ACCELERATOR PEDAL CLOSED POSITION SWITCH

ACCELERATORPEDALCLOSED POSITIONSWITCH

Ohmmeter

ED038--04

2

INSPECTION

1

B13380

INSPECTACCELE RATO RP E DALCLO  S E DP  O S I TI  O N SWITCH (a) Disconnect the accelerator pedal closed position switch connector. (b) Using an ohmmeter, check the continuity between the ac-

celerator pedal closed position switch terminals. Conti nui ty : Accelerator Pedal Fullyclosed Fully open

Continuity Nocontinuity Continuity (0 -- 20

Ω)

If the is not as continuity, replace the accelerator pedal closed positionswitch(SeepageED -- 19). (c) Reconnect the accelerator pedal closed position switch connector.

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ED--22 ELECT RONIC CONTROL DIESE L -- INJECTION PUMP CORRECTION UNIT

INJ E CTIONP UMPCORRECTION UNIT ED03B--03

INSPECTION INSPECTINJ ECTIONPUMPCORRECTIONUNIT(Seepage DI  -- 66) Correction Unit B12957

5L--E ENGINE SUP (RM817E)

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ELECTRONIC CONTROL DIESEL: ENGINE ECU 1. COMPONENTS ED-23 2. REMOVAL ED-24 3. INSPECTION ED-25 4. INSTALLATION ED-26

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ED--23 ELECTRONIC CONTROL DIESEL -- ENGINE ECU

ENGINEECU FI01Z--02

COM P ONE NT S

Lower Finish No. 2 Panel

Engine ECU Engini ECU Connector

5L--E ENGINE SUP (RM817E)

Glove Compartment Door

A01743

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ED--24 ELECT RONIC CONTROL DIESE L -- ENGINE ECU FI020--02

RE M O VAL 1. 2. 3. (a) (b)

B13381

5L--E ENGINE SUP (RM817E)

REMOVEGLOVECOMPARTMENTDOOR REMOVELOWERFINIS HNO.2PANEL REMOVEENGINEECU Disconnect the 4 engine ECU connector. Remove the 2 bolts and engine ECU.

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ED--25 ELECTRONIC CONTROL DIESEL -- ENGINE ECU FI021--02

INSPECTION (SeepageDI -- 1 7)

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ED--26 ELECT RONIC CONTROL DIESE L -- ENGINE ECU FI022--02

INSTALLATION Installationisinthereverseorde rofremoval(Seepa geED -- 24).

5L--E ENGINE SUP (RM817E)

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ENGINE FUEL INJECTION NOZZLE .....................

FU--1

INJECTION PUMP .......................

FU--7

RE FE  RTOF O LLO WI NGRE PAI RMANUALS : ManualName 2L,3LEngineRepairManual 2L, 2L--T, 3L, 5L Engine Repair Manual Supplement (Aug., 1997)

Pub.No. RM520E RM582E

NOTE: The above pages contain only the points which differ from the above listed manuals.

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FU--1 ENG INE FUE L -- INJECTION NOZZLE

INJECTIONNOZZLE FU00P--02

COM P ONE NT S

Throttle Body

Oil Filter Cap

z

Glow Plug Wire

Coller

Gasket Glow Plug Connector

Spacer

Nozzle Leakage Pipe No. 2 Cylinder Head Cover

27.0 (275, 20)

Coller z

Gasket

Injection Nozzle 64 (650, 47)

PCV Hose

Nozzle seat Fuel Return Hose

z

Gasket

29.5 (300, 22)

Pipe Clamp 24.5 (250, 18)

Injection Pipe

N∙m (kgf∙cm,ft ∙lbf) : Specified torque z Non--reusable part

5L--E ENGINE SUP (RM817E)

CONTINUED B13322

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FU--2 ENG INE FUE L -- INJECTION NOZZLE

Nozzle Holder Body 46.58 (475, 42)

Nozzle Assembly

Adjusting Shim

Pressure Spring

Nozzle Holder Retaining Nut

Pressure Pin Distance Piece

N∙m (kgf∙cm, ft ∙lbf)

: Specified torque

5L--E ENGINE SUP (RM817E)

S03970

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FU--3 ENG INE FUE L -- INJECTION NOZZLE FU093--01

RE M O VAL 1.

2 . 3 .

w/EGR: RE MO V EE G RVALV EANDE G RADAP TE R (S e epa geE M -- 6 ) RE MO V ETHRO TTLEBO DY(S e epa geE D -- 5 ) RE MO V EG L O WP L UGCO NNE  CTO R (SeePub.No.RM520EonpageEG -- 30)

4. (a) (b)

REMOVEINJE CTIO NPIPE S Loosen the 8 union nuts of the 4 injection pipes. Remove the 2 nuts, 2 upper pipe clamps, 4 injection pipes and lower pipe clamps.

5 . (a) (b)

RE MO V ENO ZZLELE AKAG  EP I P E Disconnect the fuel return hose from the leakage pipe. Remove the 4 nuts, leakage pipe and 4 gaskets.

S04635

Fuel Return Hose

S04641

6 . RE MO V EI NJ E CTI O NNO ZZLE Using SST, remove the 4 injection nozzles, 4 seats and 4 gaskets. SST 09268 -- 64010(09268 -- 64020) HINT: Arrange the injection nozzles in correct order.

SST

S04651

5L--E ENGINE SUP (RM817E)

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FU--4 ENG INE FUE L -- INJECTION NOZZLE FU00U--03

TEST 1. (a)

FU2702

INJE CTIONPRESSURETEST Install the injection nozzle to the injection nozzle hand tester and bleed air from the union nut. CAUTI O N: Do not plate your finger over the nozzle injection hole. (b) Pump the tester handle a few times as fast as possible to discharge the carbon from the injection hole. (c) Pump the tester handle slowly and observe the pressure

gauge. Read the pressure gauge just as the injection pressure begins to drop. Opening pressure: new nozzle 15,790 -- 16 ,570 kP a (16 1 -- 16 9 kgf/cm2, 2,290 -- 2,40 4 psi ) Reuse d nozzle 15,200 -- 16 ,180 kP a (15 5 -- 16 5 kgf/cm2, 2,205 -- 2,34 7 psi ) HINT: Proper nozzle operation can be determined by a switching sound. If the opening pressure is not as specified, disassemble the nozzle holder and change the adjusting shim on the top of the (d)

FU2728

pressure spring. Adjusting opening pressure 15,200 -- 16 ,180 kP a (15 5 -- 16 5 kgf/cm2, 2,205 -- 2,34 7 psi ) Adjusting shim thick ness: 0.900(0.0354)

1.300(0.0512)

1.700(0.0669)

0.950(0.0374)

1.350(0.0531)

1.750(0.0689)

1.000(0.0394)

1.400(0.0551)

1.800(0.0709)

1.050(0.0413)

1.450(0.0571)

1.850(0.0728)

1.100(0.0433)

1.500(0.0591)

1.900(0.0748)

1.150(0.0453)

1.550(0.0610)

1.950(0.0768)

1.200(0.0472)

1.600(0.0630)

--

1.250(0.0492)

1.650(0.0650)

--

HINT: S

Varying the adjusting shim pressure thicknessby byabout 0.05 mm in.) changes the injection 628(0.0020 kPa (6.4 kgf∙cm2, 91 psi) S Only one adjusting shim should be used. (e) There should be dripping after injection. CONTINUED

5L--E ENGINE SUP (RM817E)

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FU--5 ENG INE FUE L -- INJECTION NOZZLE

Good

2 . LE AKAG ET E S T While maintaining pressure at about 981 -- 1,961 kPa (10 -- 20 kgf∙cm2, 142 -- 284 psi) below opening pressure (adjust by tester handle), check that there is no dripping for 10 sec onds from the injection hole or around the retaining nut. If the nozzle drips with in 10 seconds, replace or clean andover haul the nozzle assembly.

Faulty FU1347

3. (a)

SPRAYPATTERNTEST The injection nozzle should shudder at a certain pumping speed between 15 -- 60 times (old nozzl e) or 30 60 times (new nozzle) per minute. (b) Check the spray pattern during shuddering. If the spray pattern is not correct during shuddering, the no zzle must be replaced or cleaned. Good

5L--E ENGINE SUP (RM817E)

Faulty

FU1481

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FU--6 ENG INE FUE L -- INJECTION NOZZLE FU094--01

INSTALLATION

SST

1 . (a)

I NS  TALLI NJ E CTI O NNO ZZLE S Place 4 new gaskets and the 4 nozzle seats into the injection nozzle holes of the cylinder head. (b) UsingSST,installthe4injectionnozzles. SST 09268 -- 64010(09268 -- 64020) Torque: 64 N m (65 0 kgf cm, 47 ft lbf) NO TI CE  : Ove r torquing could cau se nozzle deformation and needle ∙

S04652

∙

∙

adhesio n or other defects.

2 . (a)

I NS  TALLNO ZZLELE AK AG  EP I P E Install 4 new gaskets and the leakage pipe withthe 4 nuts. Torque: 27. 0 N m (27 5 kgf cm, 20 ft lbf) Connect the fuel hose to the leakage pipe. ∙

(b)

Fuel Return Hose

∙

S04641

3. (a) (b)

(c)

4 . S04635

5 . 6.

7 .

5L--E ENGINE SUP (RM817E)

∙

INSTALLINJ ECTIO NPIP ES Place the 2 lower clamps on the intake manifold. Install the 4 injection pipes. Torque: 24. 5 N m (25 0 kgf cm, 18 ft lbf) Secure the injection pipes with the 2 upper pipe clamps and 2 bolts. Torque: 29. 5 N m (30 0 kgf cm, 22 ft lbf) I NS  TALLG LO  WP LUGCO NNE CTO R (SeePub.No.RM520EonpageEG -- 51) I NS  TALLT HRO  TTLEBO DY(S e epa geE D -- 6 ) ∙

∙

∙

∙

∙

∙

w/EGR: I NS  TALLE G RVALV EANDE G RADAP TE  R (S e epa geE M -- 9 ) S TARTE NG  I NEANDCHE CKFO RL E AKS

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FU--7 ENG INE FUE L -- INJECTION PUMP

INJECTIONPUMP FU095--01

ON  -- VEHICLEINSPECTION 1. 2. 3. 4.

INSPECTENGINESPEEDSENSOR (SeepageED -- 17 ) INSPECTSPILLCONTROLVALVE(Seepa geED -- 8) INSPECTINJ ECTIO NPUMPCORRECTIONRESISTORS(SeepageED -- 22) INSPECTTIMINGCONTROLVALVE(SeepageED -- 7 )

5L--E ENGINE SUP (RM817E)

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FU--8 ENG INE FUE L -- INJECTION PUMP FU096--01

COM P ONE NT S No.1 Timing Belt Cover

Gasket Timing Belt

Drive Belt Water Pump Pulley

Timing Belt Guide x9 Fan and Fluid Coupling Assembly

235 (2,400, 173)

Crankshaft Pulley

Throttle Body Collar Glow Plug Wire

Oil Filler Cap

Glow Plug Connector

Glow Plug

Spacer No.2 Cylinder Head Cover PCV Hose w/ EGR: EGR Valve z Gasket Injection Pump Drive Pulley

64 (650, 47)

z

Gasket

EGR Valve Adapter

19 (195, 14)

N∙m (kgf∙cm,ft ∙lbf) : Specified torque z Non--reusable part B13323

CONTINUED

5L--E ENGINE SUP (RM817E)

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FU--9 ENG INE FUE L -- INJECTION PUMP

Injection Pipe

Pipe Clamp

24.5 (250, 18)

Cylinder Block Insulator Fuel Return Hose Fuel Return Hose

Spill Control Valve Connector z O--ring Engine Speed Sensor Connector 20.5 (210, 15)

Fuel Temp. Sensor Connector Correction Resistor Connector

N∙m (kgf∙cm, ft ∙lbf) z

: Specified torque

TimingConnector Control Valve

CONTINUED

Non--reusable part B13324

5L--E ENGINE SUP (RM817E)

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FU--10 ENG INE FUE L -- INJECTION PUMP

Fuel Inlet Hollow Screw 36.8 (375, 27)

26.55 (271, 20)

z

Gasket

Fuel Inlet Pipe Overflow Screw 26.55 (271, 20)

z

Gasket z

Distributive Head Plug Gasket

z

Fuel Outlet Pipe

Fuel Temperature Sensor z

Gasket

O--Ring

Delivery Valve Holder z

z

Gasket

58.85 (600, 43)

O--Ring Spring

z

Gasket

Delivery Valve

Injection Pump Timing Control Valve z

N∙m (kgf∙cm, ft∙lbf) : Specified torque Non--reusable Part

z

5L--E ENGINE SUP (RM817E)

O--Ring

B13320

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FU--11 ENG INE FUE L -- INJECTION PUMP FU097--01

RE M O VAL 1. 2.

(a)

(e)

(b)

(c) (d)

3. (a) (b) (c) (d) (e) (f)

REMOVEINJE CTIO NPUMP Disconnect the engine speed sensor connector. Disconnect the spill control valve connector. Disconnect the correction resistor connector. Disconnect the timing control valve connector. Disconnect the fuel temperature sensor connector. Disconnect the engine wire clamp and fuel hose.

(g) (h)

Remove the 3 bolts and injection pump stay. Remove the 2 nuts and injection pump and cylinder block insulator.

B13329

A15207

5L--E ENGINE SUP (RM817E)

REMOVEINJE CTIO NPIPE (S e epa geFU -- 3 ) REMOVEINJECTIONPUMPDRIVEPULLEY (SeePub.No.RM520EonpageEG -- 22a)

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FU--12 ENG INE FUE L -- INJECTION PUMP FU098--01

DI SASSEMBLY 1. 2.

MOUNTPUMPASSE MBLYTOSST(STAND) SST 09241 -- 76022,09245 -- 54010 REMOVESETKEYOFDRIVE PULLEY FRO MDRI V ES HAFT

SST

B13328

(b)

3. (a)

(a)

(b) (c)

(c)

REMOVEFUELPIPE SANDINLETHOLLOWSCREW Remove the overflow screw, fuel outlet pipe and 2 gaskets. Remove the cap nut, bolt, fuel inlet pipe and 2 gaskets. Remove the fuel inlet hollow screw and gasket.

(b)

B13321

4 . RE MO V ETI MI NGCO NTRO LVALV E Using a 5 mm hexagon wrench, remove the 2 bolts and timing control valve. 5mm Hexagon Wrench

B13327

5. REMOVEFUELTEMPERATURESENSOR Using a 19 mm deep socket wrench, remo ve the fuel temperaturesensor.

B13326

6 . RE MO V EDI S T RI BUTI V EHE ADP LUG Using SST, remove the distributive head plug. SST 09260--54012(09262--54010) SST CONTINUED

B13112

5L--E ENGINE SUP (RM817E)

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FU--13 ENG INE FUE L -- INJECTION PUMP

7. (a)

SST

B13113

5L--E ENGINE SUP (RM817E)

REMOVEDELIVERYVALVEHOLDERS Using SST, remove the 4 delivery valve holders and springs. SST 09260--54012(09269--54020) (b) Remove the 4 delivery valves and gaskets. NO  TI CE  : Donottouc htheslidings urfacesofthedeliveryvalvewith y ourha nd. HINT: Arrange the delivery valves, springs, and holders in order.

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FU--14 ENG INE FUE L -- INJECTION PUMP FU099--01

INSPECTION

S03193 S03194

B01267

NO TI CE  : Donottouc htheslidings urface softhedeliveryvalves. INSPECTDELIVERYVALVES (a) Pull up the valve, release it. (b) Check that it sinks smoothly to the valve seat. If operation is not as specified, replace the valve as a set. HINT: Before using a new valve set, wash off the rust prevention com-

pound with diesel fuel. Then re--wash with diesel fuel and perform the above test.

5L--E ENGINE SUP (RM817E)

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FU--15 ENG INE FUE L -- INJECTION PUMP FU09A--01

RE AS S E M BLY 1 .

MO UNTP UMPBO DYTOS S T(S TAND) SST 09241--76022,09245--54010

2. (a) (b) (c)

INSTALLDELIVERYVALVEHOLDERS Install new gaskets and the valves into distributive head. Install the springs into the delivery valve holders. Using SST, install the delivery valve holders. SST 09260--54012(09269 --54020) Torque: 58.85 N m (600 kgf cm, 43 ft lbf)

SST

B13328

SST

∙

∙

∙

S04413

3. (a) (b)

INSTALLDISTRIBUTIVEHEADPLUG Install a new O--ring to the distributive head plug. Using SST, install the head plug. SST 09260--54012(09262--54010) Torque: 88 N m (90 0 kgf cm, 65 ft lbf) ∙

∙

∙

SST

B13114

4. (a) (b)

INSTALLFUELTEMPERATURESENSOR Install a new O--ring to the fuel temperature sensor. Using a 19 mm deep socket wrench, install the fuel temperature sensor. Torque: 21. 6 N m (22 0 kgf cm, 16. 5 ft lbf) ∙

∙

∙

B13326

5mm Hexagon Wrench

B13327

5L--E ENGINE SUP (RM817E)

5. INSTALLTIMINGCONTROLVALV E Using a 5 mm hexagon wrench, install the timing control valve with the 2 bolts. CONTINUED

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FU--16 ENG INE FUE L -- INJECTION PUMP

(A)

6 . (a)

(c)

I NS  TALLF UE  LI NL E  THO LLO WS CRE WF UE  LP I P E S Install a new gasket and the hollow screw. Torque: 36. 8 N m (37 5 kgf cm, 27 ft lbf) Install the fuel inlet pipe with 2 new gaskets, the cap nut (A) and bolt (B) . Torque: 26.55 N m (27 1 kgf cm, 20 ft lbf) for (A) 24.5 N m (250 kgf cm, 18 ft lbf) for (B) Install the fuel outlet pipe with a new gasket and the overflow screw. Torque: 26. 55 N m (271 kgf cm, 20 ft lbf) RE MO V EI NJ E CTI O NP UMPFRO MS S T(S TAND) SST 09241--76022,09245--54010 INSTALLSETKEYOFINJ ECTIONPUMPDRIVE P ULLE YO NDRI V ES HAFT ∙

(b) (a) (B)

∙

∙

∙

∙

B13321

(c)

∙

∙

7 . 8.

5L--E ENGINE SUP (RM817E)

∙

∙

∙

∙

∙

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FU--17 ENG INE FUE L -- INJECTION PUMP FU012--02

INSTALLATION 1. (a)

(b)

INSTALLINJ ECTIONPUMP Install injection pump to timing belt case, and temporary tightening two nuts. Install injection pump stay to injection pump rear end, and temporary tightening three bolts.

A15207

(c)

Rotate the pu mp bo dy to mak e the marking of pu mp flange conform to the marking of timing belt case.

(d)

Tighten the fixing nuts and bolts to secure the pump body.Installing order of injection pump stay (after temporary tightening) . Block side bolts tightening

A15203

pump side bolt tightening Torque:

Injection pump Belt case : 20.5 N m (210 kgf cm, 15 ft lbf) Block side bolts: 26 N m (270 kgf cm, 19.6 ft lbf) Pump side bolt: 26 N m (27 0 kgf cm, 19.6 ft lbf) ∙

∙

∙

∙

∙

(e) (f)

(i) (j)

∙

∙

(e) (f) (g) (h) (i) (j)

Connect the engine speed sensor connector. Connect the spill control valve connector. Connect the correction resistor connector. Connect the timing cotrol valve connector. Connect the fuel temperature sensor connector. Connect the engine wire clamp and fuel hose.

2.

INSTALLINJ ECTIONPUMPDRIVEPULLY (SeePub.No.RM520EonpageEG -- 24) INSTALLINJ ECTIONPIP E (S e epa geFU -- 6 )

(g) (h) B13329

3.

5L--E ENGINE SUP (RM817E)

∙

∙

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ALPHABETICAL INDEX

ID-- 1

ALPHABETICAL INDEX (A -- W)

A

H Page

ABBREVIATIONS USED IN THIS MANUAL (TERMS) ..................................... ACCELERATOR PEDAL CLOSED POSITION SWITCH ........................... ACCELERATOR PEDAL POSITION SENSOR ...........................

IN--24 ED--21 ED--19

C CIRCUIT INSPECTION (ENGINE) (DIAGNOSTICS) .............................. CRANKSHAFT POSITION SENSOR ............... CUSTOMER PR OBLEM ANALYSIS CHECK (ENGINE) (DIAGNOSTICS) .............................. CYLINDER BLOCK .............................. CYLINDER HEAD ...............................

DI--27 ED--18

DI--14

ED--10 ED--9 ED--1

ELECTRONIC CONTROL DIESEL (PREPARATION).............................. --3 PP ELECTRONIC CONTROL DIESEL (SERVICE SP ECIFICATIONS) .................. --7 SS EMISSION CONTROL (PRE PARATION) ............ --2 PP EMISSION CONTROL (SERVICE SP ECIFICATIONS) .................. --6 SS ENGINE (DIAGNOSTICS) ........................ DI--1 ENGINE ECU ................................... ED--23 ENGINE FUEL (PREPARATION)................... --6 PP ENGINE FUEL (SERVICE SP ECIFICATIONS) ....... --9 SS ENGINE MECHANICAL (PREPARATION)........... --1 PP ENGINE MECHANICAL (SERVICE SP ECIFICATIONS) .................. --4 SS ENGINE SERIAL NUMBER (IDENTIFICATIONINFORMATION) .............. IN--3 ENGINE SPEED SENSOR ........................ ED--17 EXHAUST GAS RECIRCULATION (EGR) SYSTEM ............................... --4 EC

IN--7 ED--13

G GENERAL INFORMATION (HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS) ..................... GENERAL INFORMATION (HOW TO USE THIS MANUAL) ................. GENERAL INFORMATION (REPAIR INSTRUCTIONS) .....................

IN--8

IN--19 IN--1

IDENTIFICATIONINFORMATION .................. IDLE SPEED AND MAXIMUM SPEED .............. INJ ECTION NOZZLE ............................. INJ ECTION PUMP ............................... INJ ECTION PUMP CORRECTION UNIT ............ INJ ECTION TIMING ............................. INTAKE AIR PRESSURE SENSOR ................ INTAKE AIR TEMPERATURE SENSOR.............

IN--3 EM--2 FU--1 FU--7 ED--22 EM--1 ED--15 ED--14

PARTS LAYOUT ANDSCHEMATIC DRAWING ...... PARTS LOCATION (ENGINE) (DIAGNOSTICS) .............................. POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM ............................... PRE --CHECK (ENGINE) (DIAGNOSTICS) .............................. PRECAUTION (FOR ALL OF VEHICLES) ........... PROBLEM SYMPTOMS TABLE (ENGINE) (DIAGNOSTICS) ..............................

--1 EC DI--16 EC--3

DI--4 IN--7

DI--25

R REPAIR INSTRUCTIONS .........................

IN--4

S SPILL CONTROL VALVE ......................... STANDARD BOLT (SERVICE SPECIFICATIONS) ....

ED--8 SS--1

T

F FOR ALL OF VEHICLES .......................... FUEL TEMPERATURE SENSOR ..................

IN--9

P

E E--VRV FOR EGR ............................... ECD MAIN RELAY ............................... ECD SYST EM ..................................

INSPECTION PROCEDURE ECU (HOW TO TROUBLESHOOT CONTROLLED SYSTEMS) ..................... HOW TO USE THIS MANUAL .....................

DI--1

I DI--3 EM--11 EM--3

D DIAGNOSTIC TROUBLE CODE CHART (ENGINE) (DIAGNOSTICS) ..............................

Page HOW TO PROCEED WITH TROUBLESHOOTING (ENGINE) (DIAGNOSTICS) .............................. HOW TO PROCEED WITH TROUBLESHOOTING (HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS) ..................... HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS ...................... HOW TO USE THE DIAGNOSTIC CHART AND

IN--8 IN--1 IN--4

TERMINALS OF ECU (ENGINE) (DIAGNOSTICS) .............................. TERMS ........................................ THROTTLE BODY ............................... TIMING CONTROL VALVE ........................

DI--17 IN--24 ED--3 ED--7

W WATER TEMPERATURE SENSOR ................

ED--12