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Mazda MX-6 1998 Workshop Manual
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Mazda MX-6 1998 Workshop Manual

Mazda MX-6 1998 Workshop Manual

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Summary of Contents for Mazda MX-6 1998

  • Page 2 VEHICLE IDENTIFICATION NUMBERS (VIN) 1YV G F 2 2 C *W 5 600001— 1YV G F 2 2 D *W 5 600001— RELATED MATERIALS 1998 626 S ervice H ig h lig h ts ............3 3 1 1 -1 0 -9 7 1 E n g in e W o rksh o p M anual FS ............
  • Page 3 GENERAL INFORMATION SECTION GENERAL INFORMATION ..00-00 00-00 GENERAL INFORMATION 0 0 -0 0 -1...
  • Page 4 GENERAL INFORMATION HOW TO USE THIS MANUAL W6UOOOWOI Range of Topics Service Procedure Inspection, adjustment C a u tio n • C o n n e c t t h e g a u g e s a t fro m u n d e r th e v e ­ h ic le t o p re v e n t c o n t a c t w ith t h e d riv e b e lt a n d t h e c o o lin g fa n .
  • Page 5 GENERAL INFORMATION Repair procedure SHOWS SERVICE ITEM (S) LOW ER TR A IU N G U N K. UPPER TRAILING LINK REMOVAL/INSTALLATION “Removal/Installation” Portion “Inspection After SHOWS SPECIAL Installation” Portion SERVICE TOOL (SST) SHOWS PROCEDURE ORDER FOR SERVICE OPERATION FOR SERVICE Install the parts SHOWS APPLICATION by performing...
  • Page 6 GENERAL INFORMATION Symbols Specification Upper and Lower Limits Symbol Meaning Kind Troubleshooting Procedure W 6 U O O O W A 2 Basic flow of troubleshooting W 6 U 0 0 0 W A 3 W 6 U 0 0 0 W A 4 “...
  • Page 7 GENERAL INFORMATION Diagnostic index Symptom troubleshooting Quick diagnosis chart (section 01 and 05) Procedures for Use Using the basic inspection SHOWS INSPECTION SHOWS ITEM NAMES FOR SHOW POINTS REQUIRING ORDER DETAILED PROCEDURES ATTENTION BASED ON INSPECTION RESULTS S T E P REFERENCE COLUMN W 6 U O O O W A B...
  • Page 8 GENERAL INFORMATION Using the quick diagnosis chart PART WHICH MAY BE PARTS WHICH MAY BE THE CAUSE OF THE SYMPTOM PROBLEMS D ischarged batlery Will not Crank or cranks slowly N o combustion C amDusnon o bserved engine will not sian Cranks normally but hard to Stan Low Kfle speed/Engm e stalls or vebrates o o o o...
  • Page 9 GENERAL INFORMATION Using the symptom troubleshooting TROUBLESHOOTING HINTS describes possible TROUBLE SYMPTOM point of malfunction. | E n g in e s t a lls t r o u b l e s h o o t i n g h in t s •...
  • Page 10 GENERAL INFORMATION U N IT S W6UOOOWO2 C o n v e rs io n to SI U nits (S y s tè m e In te rn a tio n a l d ’U n ités ) R o u n d in g O ff U p p e r an d L o w e r L im its 21 0 —...
  • Page 11 GENERAL INFORMATION Previous Standard New Standard Abbr. Name Abbr. Name Remark 0 0 -0 0 -9...
  • Page 12 GENERAL INFORMATION Previous FUNDAMENTAL PROCEDURES Protection of the Vehicle Preparation of Tools and Mesuring Equipment 0 0 -0 0 -1 0...
  • Page 13 GENERAL INFORMATION Special Tools Inspection During Removal, Disassembly W 6 U 0 0 0 W A M Disconnection of the Negative Battery Cable Arrangement of Parts Removal of Parts Cleaning of Parts Warning • Using compressed air can cause dirt and other particles to fly out causing injury to Disassembly the eyes.
  • Page 14 GENERAL INFORMATION Rubber Parts and Tubing Reassembly W 6 U O O O W A T Hose Clamps W 6 U 0 0 0 W A Q W 6 U 0 0 0 W A U Torque Formulas Torque Unit Formula W 6 U O O O W A R Adjustments...
  • Page 15 GENERAL INFORMATION Dynamometer Vise Note INSTALLATION OF RADIO SYSTEM W 6 U 0 0 0 W 0 5 ELECTRICAL SYSTEM Electrical Parts Battery cable W 6 U O O O W A Y Disconnecting connectors Connectors Data link connector Caution •...
  • Page 16 GENERAL INFORMATION Terminals Inspection Locking connector Replacement inspection Caution • To prevent damage to the terminal, wrap a thin wire around the lead before inserting into terminal. 0 0 -0 0 -1 4...
  • Page 17 GENERAL INFORMATION Sensors, Switches, and Relays Wiring Harness Wiring color codes Electrical Troubleshooting Tools Jumper wire Caution • Do not connect a jumper wire from the power source line to a body ground. This may cause burning or other damage to wiring harnesses or electronic components.
  • Page 18 GENERAL INFORMATION Voltmeter Caution • Do not connect the ohmmeter to any circuit where voltage is applied. This will damage the ohmmeter. Ohmmeter JACKING POSITIONS W6UOOOWO7 Warning • Improperly jacking a vehicle is dangerous. The vehicle can slip off the jack and cause Rear serious injury.
  • Page 19 GENERAL INFORMATION VEHICLE LIFT (2 SUPPORTS) AND SAFETY STAND (RIGID RACK) POSITION W6UOOOWO8 Vehicle Lift Positions Safety Stand Positions Front Front Rear Rear W 6 U 0 0 0 W B K W 6 U 0 0 0 W 0 9 Caution •...
  • Page 20 GENERAL INFORMATION Caution Tiedown Hooks • Do not tow with sling-type equipment. Front This could damage your vehicle. Use wheel-lift or flatbed equipment. W 6 U O O O W B P Rear Caution • Do not use the hook loops under the front and rear bumpers for towing.
  • Page 21 GENERAL INFORMATION Engine Identification Number Automatic Transaxle Number FS ENGINE KL ENGINE ABBREVIATIONS W 6 U 0 0 0 W 1 1 0 0 -0 0 -1 9...
  • Page 22 GENERAL INFORMATION 0 0 -0 0 -2 0...
  • Page 23 GENERAL INFORMATION 0 0 -0 0 -2 1...
  • Page 24 GENERAL INFORMATION P R E -D E L IV E R Y IN S P E C T IO N W 6 U 0 0 0 W 1 2 P re -D e liv e ry In s p e c tio n T able E x te rio r C H E C K A D JU S T,...
  • Page 25 GENERAL INFORMATION SCHEDULED MAINTENANCE W 6 U 0 0 0 W 1 3 Scheduled Maintenance Table (Except Canada) Schedule 1 (Normal driving conditions) Maintenance Interval (Number of months or miles (kilometers), whichever comes first) Months Maintenance Item Miles 22.5 37.5 52.5 X 1000 Kilometers...
  • Page 26 GENERAL INFORMATION Chart symbols Remarks • k : Schedule 2 (Unique driving conditions) Maintenance Interval (Number of months or miles (kilometers), whichever comes first) Months Maintenance Item Miles x 1000 Kilometers ENGINE AIR CLEANER IGNITION SYSTEM FUEL SYSTEM COOLING SYSTEM CHASSIS &...
  • Page 27 GENERAL INFORMATION Maintenance Interval (Number of months or miles (kilometers), whichever comes first) Months Maintenance Item Miles X 1000 Kilometers AIR CONDITIONER SYSTEM (IF EQUIPPED) Chart symbols Remarks Scheduled Maintenance Table (Canada) Maintenance Interval (Number of months or kilometers (miles), whichever comes first) Months Maintenance Item Kilometers...
  • Page 28 GENERAL INFORMATION Maintenance Interval (Number of months or kilometers (miles), whichever comes first) Months Maintenance Item Kilometers X 1000 Miles CHASSIS & BODY AIR CONDITIONER SYSTEM (IF EQUIPPED) Chart symbols Remarks 0 0 -0 0 -2 6...
  • Page 29 ENGINE TROUBLESHOOTING FUEL S Y S T E M ......01-14 [ENGINE CONTROL FS] ..01-01A EXHAUST S Y STEM ....01-15 TROUBLESHOOTING EMISSION SYSTEM ....01-16 [ENGINE CONTROL KL] ..01-01B CHARGING SYSTEM ....01-17 TROUBLESHOOTING [CRUISE IGNITION SYSTEM ....01-18 CONTROL SYSTEM] ....01-01C...
  • Page 30 TROUBLESHOOTING [ENGINE CONTROL FS] FOREWORD ENGINE ON-BOARD DIAGNOSIS [FS] W 6 U 1 0 1 W 0 2 Read/Clear Continuous Memory DTC Access On-Board Diagnostic (OBD) Test Description Self-Test System Pass Parameter Identification (PID) Access Brake On/Off Test MUST Key On Engine Off (KOEO) Self-Test Transaxle Control Switch Test MUST Power Steering Pressure (PSP) Switch Test...
  • Page 31 TROUBLESHOOTING [ENGINE CONTROL FS] W 6 U 1 0 1 W C O VEHICLE AND ENGINE SELECTION. SELECT ITEM AND PRESS TRIGGER TO START W 6 U 1 0 1 W C 2 SELECT NEW VEHICLE W 6 U 1 0 1 W A 5 YEAR &...
  • Page 32 TROUBLESHOOTING [ENGINE CONTROL FS] Read/Clear Continuous DTC Self-Test Procedure DIAGNOSTIC DATA LINK Note AND PRESS TRIGGER TO START READ/CLEAR CONTINUOUS PCM. DTCs. \ \ ' P C M P Q W F R T R A I N C O N T R O L M O D U L E R E A D / C L E A R C O N T I N U O U S...
  • Page 33 TROUBLESHOOTING [ENGINE CONTROL FS] After Repair Procedure CANCEL. GENERIC OBD II Key ON Engine Running Self-Test Procedure FUNCTIONS Note PID/DATA Monitor and Record Procedure KOER ON-DEMAND PID/DATA MONITOR AND SELF-TEST. RECORD. SELECT ITEM START. CANCEL START 0 1 -0 1 A -5...
  • Page 34 TROUBLESHOOTING [ENGINE CONTROL FS] Playback of Stored PIDs Procedure Note SELECT IT E » AND PRESS TRIGOER TO START VIEW RECORDER AREAS. OUTPUT TEST MODE. MODE ALL ON LOW FAN, HIGH FAN, ALL OFF. ALL ON. START STOP PIDS CLEAR PIDS.
  • Page 35 TROUBLESHOOTING [ENGINE CONTROL FS] GENERIC OBD II FUNCTIONS. OXYGEN SENSOR TESTS. MANUFACTURING SPECIFIC TEST ID. (41H) OBD II Drive Mode Procedure Caution • When this procedure is carried out, be sure to drive the vehicle at the lawful speed and pay attention to the other vehicles.
  • Page 36 TROUBLESHOOTING [ENGINE CONTROL FS] Diagnostic trouble code table DC’1 OBD Monitor'2 DTC No. Diagnosed Circuit Condition Ignition Ignition Ignition 0 1 -0 1 A -8...
  • Page 37 TROUBLESHOOTING [ENGINE CONTROL FS] DTC No. Diagnosed Circuit Condition D C '1 OBD Monitor'2 — — — — — — — — 0 1 -0 1 A -9...
  • Page 38 TROUBLESHOOTING [ENGINE CONTROL FS] 0 1 -0 1 A -1 0...
  • Page 39 TROUBLESHOOTING [ENGINE CONTROL FS] DTC No. Diagnosed Circuit Condition DC'1 OBD Monitor*2 0 1 -0 1 A-11...
  • Page 40 TROUBLESHOOTING [ENGINE CONTROL FS] MAF sensor circuit low input P0102 DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Note For KOER reading between 0.60 and 1.00 volt: All others: Is MAF V PID less than 0.39 volts? • Is voltage greater than 10.5 volts? Is resistance less than 5.0 ohms? •...
  • Page 41 TROUBLESHOOTING [ENGINE CONTROL FS] INSPECTION ACTION STEP Is resistance less than 5.0 ohms? Is voltage greater than 10.5 volts? Is resistance less than 10 ohms? • Is resistance less than 5.0 ohms? Is each resistance greater than 10,000 ohms? Note Is voltage at idle between 0.34 and 1 volts? c 1-01A - 1 3...
  • Page 42 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION • • Is voltage between 0.34 and volts? • • • • • Is MAF V PID between 0.34 and volts? Note • • • • • • • Is voltage greater than 0.20 volts? 0 1 -0 1 A -1 4...
  • Page 43 TROUBLESHOOTING [ENGINE CONTROL FS] P0103 MAF sensor circuit high input DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Note Note Did MAF V PID drop from previous reading below 0.39 volts? ¡ y Is voltage greater than 10.5 volts? Is resistance greater than 10,000 ohms? 0 1 -0 1 A -1 5...
  • Page 44 TROUBLESHOOTING [ENGINE CONTROL FS] Note P0106 EGR boost sensor circuit input signal out of self-test range DESCRIPTION [Possible Cause] ACTION STEP INSPECTION Note • Is voltage between 4.0 and 6.0 volts? ¡ ¡ y Is each resistance less than 5 ohms? Is resistance greater than 10,000 ohms? 0 1 -0 1 A -1 6...
  • Page 45 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION • Do vacuum lines have any blockage or damage? Is voltage response between volts? Is EGR boost solenoid valve power voltage greater than 10.5 volts? Is resistance between ohms? Is resistance less than 5.0 ohms? 0 1 -0 1 A -1 7...
  • Page 46 TROUBLESHOOTING [ENGINE CONTROL FS] ACTION STEP INSPECTION • Is each resistance greater than 10,000 ohms? Was vacuum signal of 0 3.3 kPa {0 -2 5 mmHg, 0------1 inHg} indicated by the vacuum gauge before Test Pins 98 and 51 were shorted and -2 7 ------33 kPa {-20 3------254 mmHg, - 8 ------10 inHg} after Pins were shorted? 0 1 -0 1 A - 1 8...
  • Page 47 TROUBLESHOOTING [ENGINE CONTROL FS] P0107 EGR boost sensor circuit input signal out of self-test range minimum DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Is voltage between 4.0 and 6.0 volts? Is resistance less than 5 ohms? • • • • Is resistance greater than 10,000 ohms? •...
  • Page 48 TROUBLESHOOTING [ENGINE CONTROL FS] EGR boost sensor circuit input signal out of self-test range maximum P0108 [Possible Cause] ACTION INSPECTION STEP Is voltage between 4.0 and 6.0 volts? Is resistance less than 5 ohms? • Is resistance greater than 10,000 ohms? Is voltage response between 0.8 and 1.5 volts? 0 1 -0 1 A -2 0...
  • Page 49 TROUBLESHOOTING [ENGINE CONTROL FS] KOEO, KOER P0112 IAT sensor circuit low input P0117 ECT sensor circuit low input DESCRIPTION [Possible Cause] INSPECTION ACTION STEP • Is ECT or IAT PID more than 4.2 volts (less than -4 0 °C {-4 0 °F})? Is voltage between 4.5 volts and 5.5 volts? •...
  • Page 50 TROUBLESHOOTING [ENGINE CONTROL FS] IAT sensor circuit low input CONTINUOUS P0112 IAT sensor circuit high input P0113 sensor intermittent P0117 ECT sensor circuit low input ECT sensor circuit high input P0118 P1117 ECT sensor intermittent DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Is there any change in temperature reading?
  • Page 51 TROUBLESHOOTING [ENGINE CONTROL FS] KOEO, KOER P0113 IAT sensor circuit high input P0118 ECT sensor circuit high input DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Note Is ECT or IAT PID less than 0.2 volts (greater than 120 ”C {248 °F})? •...
  • Page 52 TROUBLESHOOTING [ENGINE CONTROL FS] TP sensor circuit low input P0122 DESCRIPTION [Possible Cause] INSPECTION ACTION STEP Note • Is DTC P0123 present (ignore all other DTC’s)? • Is voltage between 4.0 and 6.0 volts? Is resistance less than 5.0 ohms? •...
  • Page 53 TROUBLESHOOTING [ENGINE CONTROL FS] Note P0123 TP sensor circuit high input DESCRIPTION [Possible Cause] INSPECTION ACTION STEP • Is TPV PID less than 0.1 volts? • Is voltage between 4.0 and 6.0 volts? • Is each resistance greater than 0,000 ohms? Note 0 1 -0 1 A -2 5...
  • Page 54 TROUBLESHOOTING [ENGINE CONTROL FS] Insufficient engine coolant temperature for enter a closed loop fuel control P0125 DESCRIPTION [Possible Cause] INSPECTION ACTION STEP • Is coolant level correct? Heated oxygen sensor (Front) (H 02S 11) circuit low response P0133 DESCRIPTION [Possible Cause] INSPECTION ACTION STEP...
  • Page 55 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION • • • • • • • • • Are there any air leaks? • • • • • • • • Note • • Is voltage greater than 1.50 volts? Is resistance less than 5.0 ohms? Is resistance greater than 10,000 ohms? 0 1 -0 1 A -2 7...
  • Page 56 TROUBLESHOOTING [ENGINE CONTROL FS] Heated oxygen sensor heater (Front) (HTR 11) circuit malfunction P0141 Heated oxygen sensor heater (Rear) (HTR 12) circuit malfunction DESCRIPTION [Possible Cause] ACTION INSPECTION STEP Note Were any concerns found during visual inspection? Are DTCs P0135 and/or P0141 present? •...
  • Page 57 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION Is resistance less than 4.0 ohms? Is resistance between 3 and 30 ohms? Is resistance greater than 10,000 ohms? Is resistance greater than 10,000 ohms? 0 1 -0 1 A -2 9...
  • Page 58 TROUBLESHOOTING [ENGINE CONTROL FS] ACTION INSPECTION STEP • is resistance less than 4.0 ohms? 0 1 -0 1 A -3 0...
  • Page 59 TROUBLESHOOTING [ENGINE CONTROL FS] Heated oxygen sensor (Rear) (H 02S 12) circuit malfunction P0136 P1137 Lack of heated oxygen sensor (Rear) (H 02S 12) switch sensor indicates lean Lack of heated oxygen sensor (Rear) (H 02S 12) switch sensor indicates rich P1138 •...
  • Page 60 TROUBLESHOOTING [ENGINE CONTROL FS] ACTION STEP INSPECTION Is resistance greater than 10,000 ohms? Is resistance reading less than 5.0 ohms? Note Is voltage greater than 1.5 volts? 0 1 -0 1 A -3 2...
  • Page 61 TROUBLESHOOTING [ENGINE CONTROL FS] INSPECTION ACTION STEP • Is resistance reading less than 5.0 ohms? • Is PID voltage greater than .5 volts? • Are voltage readings greater than 1.5 volts? 0 1 -0 1 A -3 3...
  • Page 62 TROUBLESHOOTING [ENGINE CONTROL FS] P0171 Adaptive fuel control system too lean Adaptive fuel control system to rich P0172 Lack of heated oxygen sensor (Front) (H 02S 11) switch adaptive fuel at limit P1130 Lack of heated oxygen sensor (Front) (H 02S 11) switch sensor indicates too lean P1131 Lack of heated oxygen sensor (Front) (H 02S 11) switch sensor indicates too rich P1132...
  • Page 63 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION Note Is reading 1.30 volts or greater? Is resistance reading less than 5.0 ohms? Is resistance reading less than 5.0 ohms? Is resistance reading less than 5.0 ohms? 0 1 -0 1 A -3 5...
  • Page 64 TROUBLESHOOTING [ENGINE CONTROL FS] ACTION STEP INSPECTION &■ • Is each resistance greater than 10,000 ohms? Is resistance greater than 10,000 ohms? Is reading 0.2 volt or less? u ■ Is resistance greater than 10,000 ohms? Note Is heated oxygen sensor voltage greater than 0.45 volt? 0 1 -0 1 A -3 6...
  • Page 65 TROUBLESHOOTING [ENGINE CONTROL FS] ACTION STEP INSPECTION If engine will start: No start: • Is fuel pressure between 210 280 kPa {2.1— 2.9 kgf/cm2, 30— 45 psi}? Is voltage greater than 10.5 volts? • Is resistance less than 5.0 ohms? Is resistance greater than 10,000 ohms? 0 1 -0 1 A -3 7...
  • Page 66 TROUBLESHOOTING [ENGINE CONTROL FS] ACTION INSPECTION STEP • Is vacuum line free of damage? Was a vacuum signal present? • Is vacuum line free of damage? Note Is vacuum signal indicated by vacuum gauge? 01-01A-38...
  • Page 67 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION Note • Did vacuum gauge reading drop from -2 7 33 kPa {-203 247 mmHg, - 8 — -1 0 inHg} toO 3.3 kPa {0 mmHg, 0 1 inHg} when Test Pin 19 was jumpered to Pin 103? Note Is voltage reading between Pin 19 and...
  • Page 68 TROUBLESHOOTING [ENGINE CONTROL FS] ACTION INSPECTION STEP Does fuel pressure remain within 34 kPa {0.35 kgf/cm2, 5 psi}? Is vacuum hose and regulator port free of fuel? • Does fuel pressure reading hold steady within 21 kPa {0.21 kgf/cm2, 3 psi} during test? Does fuel pressure gauge reading increase as vacuum gauge reading...
  • Page 69 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION Is flow rate for each injector within specification? Is the voltage greater than 10.5 volts? Does air flow freely through supply line? For Continuous DTCs P1130 and P0171: For DTCs P0172: • Does the fuel pressure remain within 34 kPa {0.35 kgf/cm2, 5 psi} of the highest reading after 10 seconds? Was there a pressure drop greater than...
  • Page 70 TROUBLESHOOTING [ENGINE CONTROL FS] ACTION STEP INSPECTION Note Note W 6 U 1 0 1 W D 0 • Is resistance between 12.0— 16.0 ohms? 71/97 • Is each resistance less than 5.0 ohms? 97, 24 • Is each resistance greater than 10,000 ohms? 0 1 -0 1 A -4 2...
  • Page 71 TROUBLESHOOTING [ENGINE CONTROL FS] INSPECTION ACTION STEP Note W 6 U 1 0 1 W D 1 Note • Does test lamp have a dim glow while cranking or running engine? DTCs P0171, P1130 and P1131: • Is leakage and flow within specification? DTCs P0172: For DTCs P1132: &■...
  • Page 72 TROUBLESHOOTING [ENGINE CONTROL FS] ACTION INSPECTION STEP Note Is voltage greater than volt during or at the end of self-test? Are DTCs P1131 present? • Does voltage reading indicate less than volt within seconds? 0 1 -0 1 A -4 4...
  • Page 73 TROUBLESHOOTING [ENGINE CONTROL FS] INSPECTION ACTION STEP Note Did heated oxygen sensor voltage stay high (greater than 0.45 volt) or low (less than 0.45 volt)? Note • Does heated oxygen sensor appear to switch properly? 0 1 -0 1 A -4 5...
  • Page 74 TROUBLESHOOTING [ENGINE CONTROL FS] Fuel pump primary circuit malfunction KOEO P0230 DESCRIPTION [Possible Cause] INSPECTION ACTION STEP Is voltage greater than 10.5 volts? • Is fuel pump relay okay? Is voltage less than 1.0 volt? • • • • • •...
  • Page 75 TROUBLESHOOTING [ENGINE CONTROL FS] P0300 Random misfire detected P0301 Cylinder No.1 misfire detected P0302 Cylinder No.2 misfire detected Cylinder No.3 misfire detected P0303 P0304 Cylinder No.4 misfire detected • DESCRIPTION • [Possible Cause] • • • Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: •...
  • Page 76 TROUBLESHOOTING [ENGINE CONTROL FS] ACTION STEP INSPECTION • Is the resistance between 12.0— 16.0 ohms? Note W 6 U 1 0 1 W D 2 • Does test lamp emit dim glow while engine is running? • Is fuel pressure between 210— 310 kPa {2.1—...
  • Page 77 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION • Is flow rate for each fuel Injector within specification? • Is the vehicle vacuum system okay? • Is there excess amount of liquid fuel present in charcoal canister. • Is there fault indicated? Caution •...
  • Page 78 TROUBLESHOOTING [ENGINE CONTROL FS] Ignition engine speed input circuit malfunction P0320 DESCRIPTION [Possible Cause] ACTION STEP INSPECTION For No starts: For Intermittent faults: • Are any of the above present? Verify all 2-way radio installation instructions All others: regarding routing of antenna and power lead.
  • Page 79 TROUBLESHOOTING [ENGINE CONTROL FS] ACTION STEP INSPECTION • Is resistance less than 5.0 ohms? • • • • • Is resistance greater than 10,000 ohms? • • • • • • Is voltage less than 0.5 volts? • • • •...
  • Page 80 TROUBLESHOOTING [ENGINE CONTROL FS] CMP sensor circuit malfunction P0340 DESCRIPTION [Possible Cause] ACTION STEP INSPECTION • Will engine start? Is DTC P0340 present? Is voltage greater than 10.5 volts? Is resistance less than 5.0 ohms? Are resistance measurements less than 5.0 ohms? Is voltage less than 1.0 volt? 0 1 -0 1 A -5 2...
  • Page 81 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION • Is each resistance greater than 10,000 ohms? Is each resistance greater than 500 ohms? Does AC voltage vary greater than 0.1 volt AC? 01-01A-53...
  • Page 82 TROUBLESHOOTING [ENGINE CONTROL FS] P0400 EGR flow malfunction DESCRIPTION [Possible Cause] ACTION STEP INSPECTION Are any other DTCs displayed on NGS tester? Are there any air leaks? Are cylinder compression readings within specification? Note Does EGR valve initialization noise heard? Is EGR valve power voltage greater than 10.5 volts? •...
  • Page 83 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION W 6 U 1 0 1 W D 3 t s r • Is each resistance less than 5.0 ohms? • Is each resistance greater than 10,000 ohms? • Is EGR boost solenoid valve power circuit voltage greater than 10.5 volts? •...
  • Page 84 TROUBLESHOOTING [ENGINE CONTROL FS] INSPECTION ACTION STEP Is each resistance greater than 10,000 ohms? Was vacuum signal indicated at any time by vacuum gauge? 0 1 -0 1 A -5 6...
  • Page 85 TROUBLESHOOTING [ENGINE CONTROL FS] P0420 Catalyst efficiency below threshold (Except California) P0421 Catalyst efficiency below threshold (California) DESCRIPTION [Possible Cause] Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: •...
  • Page 86 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION Note Note • Were any of following heated oxygen sensor monitor DTCs recorded in step 1: P0136? Note • Were any of following ECT sensor DTCs recorded: P0117, P0118, P0125 and P1117? Were any other DTCs recorded in step Note •...
  • Page 87 TROUBLESHOOTING [ENGINE CONTROL FSj STEP INSPECTION ACTION Is ratio of 0 2 S 1 1 and 0 2 S 1 2 greater than 2.0? Note Is fuel pressure between 210 310 kPa {2.2— 3.1 kgf/cm2, 31— 46 psi}? Note Are above components free of cracks and punctures, etc.? Are above components free of dents and areas of collapsed material or...
  • Page 88 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION Note • Did manifold vacuum rise above 54 kPa {407 mmHg, 16 inHg} with engine rpm at 2,000? Note Note Is the rate of speed that vacuum gauge needle rises back to normal range (above 54 kPa {407 mmHg, 16 inHg}) much slower than non-restricted system?
  • Page 89 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION • Did vacuum needle quickly rise above 54 kPa {407 mmHg, 16 inHg} with engine Note rpm at 2,000? Note • Did vacuum needle quickly rise above 54 kPa {407 mmHg, 16 inHg} with engine rpm at 2,000? 0 1 -0 1 A-61...
  • Page 90 TROUBLESHOOTING [ENGINE CONTROL FS] P0442 Evaporative emission control system leak detected (Small leak) DESCRIPTION [Possible Cause] Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Page 91 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION • Is fault detected? Is fault detected? • Is fault detected? • Is fault detected? Is FTP PID values same as atmospheric pressure (approx. • Is the FTP V PID value between 4.0 and 6.0 volts? 0 1 -0 1 A -6 3...
  • Page 92 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION t p r • Is constant voltage between 4.0 and 6.0 volts? Is each resistance greater than 10,000 ohms? Did FTP PID value maintain negative pressure? Is fault detected? • Is fault detected? 0 1 -0 1 A -6 4...
  • Page 93 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION • Is fault detected? Is fault detected? • Is fault detected? 0 1 -0 1 A -6 5...
  • Page 94 TROUBLESHOOTING [ENGINE CONTROL FS] P0443 Evaporative emission control system purge solenoid valve circuit malfunction DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Note is voltage greater than 0.5 volts? Is resistance between and 35 ohms? • Is the resistance less than 5.0 ohms? Is each resistance greater than 0,000 ohms? •...
  • Page 95 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION • Is fault detected? P0446 Evaporative emission control system vent control malfunction DESCRIPTION [Possible Cause] Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous.
  • Page 96 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION • Is constant voltage between volts? • Is obstruction indicated? • Does air flow? • Is fault detected? Is fault detected? 01-01A -68...
  • Page 97 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION Does CDCV hold vacuum for one minute? • Is each resistance less than 45 ohms? Is each resistance greater than 10,000 ohms? • Is fault detected? t e r 0 1 -0 1 A -6 9...
  • Page 98 TROUBLESHOOTING [ENGINE CONTROL FS] P0452 Evaporative emission control system fuel tank pressure sensor circuit low input DESCRIPTION [Possible Cause] ACTION STEP INSPECTION Does FTP sensor and/or connector show signs of fuel contamination? Note Is FTP V PID voltage less than 0.22 volt? Is the FTP V PID value between 4.0 and 6.0 volts? •...
  • Page 99 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION • • • • Is each resistance greater than ohms? • • Is MIL illuminated? 01-01A-71...
  • Page 100 TROUBLESHOOTING [ENGINE CONTROL FS] P0453 Evaporative emission control system fuel tank pressure sensor circuit high input DESCRIPTION [Possible Cause] ACTION INSPECTION STEP Note Is FTP V PID voltage greater than 4.50 volts? Is voltage greater than 10.5 volts? Is voltage greater than 10.5 volts? Is FTP V PID voltage less than 0.10 volt? •...
  • Page 101 TROUBLESHOOTING [ENGINE CONTROL FS] INSPECTION STEP ACTION • Is resistance greater that 10,000 ohms? • Is MIL illuminated? 0 1 -0 1 A -7 3...
  • Page 102 TROUBLESHOOTING [ENGINE CONTROL FS] P0455 Evaporative emission control system leak detected (Gross leak) DESCRIPTION [Possible Cause] Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Page 103 TROUBLESHOOTING [ENGINE CONTROL FSj INSPECTION ACTION STEP Note • Is fault detected? Is fault detected? Is fault detected? • Is fault detected? • • • Did manifold vacuum rise above 54 kPa {407 mmHg, 16 inHg}. • Is fault detected? 0 1 -0 1 A -7 5...
  • Page 104 TROUBLESHOOTING [ENGINE CONTROL FS] ACTION STEP INSPECTION • Are FTP PID values same as atmospheric pressure (approx. Is FTP PID value between 4.0 and 6.0 volts? • Is constant voltage between 4.0 and 6.0 volts? Is each resistance greater than 10,000 ohms? Does FTP PID value change on...
  • Page 105 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION Is fault detected? Is fault detected? ¡y Is fault detected? Is fault detected? Does FTP V PID value maintained negative pressure? 0 1 -0 1 A -7 7...
  • Page 106 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION is fault detected? Is fault detected? Is fault detected? e r r Is fault detected? Is fault detected? 0 1 -0 1 A -7 8...
  • Page 107 TROUBLESHOOTING [ENGINE CONTROL FS] P0460 Fuel gauge sender unit circuit malfunction (Open/short and functional) DESCRIPTION [Possible Cause] ACTION INSPECTION STEP Is fuel level in fuel tank between one quarter on FLI PID) and three quarters on FLI PID) filled? Is FLI V PID voltage between 1.24 and 2.90 volts? For either voltage reading greater than 10 volts: For either voltage reading greater than 2.90 volts or...
  • Page 108 TROUBLESHOOTING [ENGINE CONTROL FS] P0500 Vehicle speed sensor (VSS) malfunction DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Is each resistance less than 5.0 ohms? Is each resistance greater than 500 ohms? Is resistance between 90 and 250 ohms? 01 -0 1 A-80...
  • Page 109 TROUBLESHOOTING [ENGINE CONTROL FS] P0505 Idle air control (IAC) system malfunction P1504 Idle air control (IAC) valve circuit malfunction P1507 Idle air control (IAC) system underspeed error DESCRIPTION [Possible Cause] ACTION STEP INSPECTION Is voltage greater than 10.5 volts? Note •...
  • Page 110 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION • Is resistance less than 5.0 ohms? Is voltage less than 1.0 volt? • Is each resistance greater than 10,000 ohms? Is voltage between 3.0 and 11.5 volts? 0 1 -0 1 A -8 2...
  • Page 111 TROUBLESHOOTING [ENGINE CONTROL FS] ACTION STEP INSPECTION For idle quality, starting, or stalling symptoms currently present: All others: • Do IAC or RPM PIDs suddenly change in value indicating fault? 0 1 -0 1 A -8 3...
  • Page 112 TROUBLESHOOTING [ENGINE CONTROL FS] P0603 PCM Keep alive memory (KAM) test error P0605 PCM Read only memory (ROM) test error DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Note • Are battery terminal connections in good condition? Is wiring too close to ignition components or wires? Is voltage less than 10.5 volts? •...
  • Page 113 TROUBLESHOOTING [ENGINE CONTROL FS] P0704 Clutch switch input circuit malfunction DESCRIPTION [Possible Cause] ACTION STEP INSPECTION Note Does reading change from ON to OFF for both switches? Is resistance less than 5.0 ohms for both switches? Is each resistance less than 5.0 ohms? •...
  • Page 114 TROUBLESHOOTING [ENGINE CONTROL FS] P1001 Active self-test standard protocol communication error DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Was the correct self-test activation method used? Was voltage between volts? • Could Continuous Memory DTCs be accessed before this OBD Test was entered? •...
  • Page 115 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION Note Note Were any Continuous Memory DTCs present. Is voltage greater than 10.5 volts? Is resistance less than 5.0 ohms? Is resistance less than 5.0 ohms? Is resistance less than 5 ohms? 0 1 -0 1 A -8 7...
  • Page 116 TROUBLESHOOTING [ENGINE CONTROL FS] 01-01A-88...
  • Page 117 TROUBLESHOOTING [ENGINE CONTROL FS] P1100 MAF sensor intermittent DESCRIPTION [Possible Cause] INSPECTION ACTION STEP Note Does MAF PID go below minimum 0.39 volts or above maximum 3.90 volts? Does voltage go below minimum 0.39 volts or above maximum 3.90 volts? 0 1 -0 1 A -8 9...
  • Page 118 TROUBLESHOOTING [ENGINE CONTROL FS] P1101 MAF sensor out of self-test range DESCRIPTION [Possible Cause] INSPECTION ACTION STEP For Continuous Memory DTC P0102: For Continuous Memory DTC P0103: For all other Continuous Memory DTCs: Is Continuous Memory DTC present with KOER DTC P1101? Note Is voltage greater than 0.20 volts? Is resistance less than 10 ohms?
  • Page 119 TROUBLESHOOTING [ENGINE CONTROL FS] ACTION INSPECTION STEP Is each resistance greater than 10,000 ohms? Is resistance greater than 10,000 ohms? Note Is voltage between and 1 volts at idle? Is voltage between and 1 volts? PID between and 1 volts? 0 1 -0 1 A -91...
  • Page 120 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION • Is resistance less than 5.0 ohms? • Is each resistance greater than 10,000 ohms? Is each resistance greater than 10,000 ohms? Is resistance less than 5.0 ohms? • Is voltage greater than 10.5 volts? 0 1 -0 1 A -9 2...
  • Page 121 TROUBLESHOOTING [ENGINE CONTROL FS] ECT sensor input signal out of self-test range P1116 DESCRIPTION [Possible Cause] ACTION INSPECTION STEP For symptom of cooling system concern: All others: • Is DTC P1116 present? • Is voltage between volts and volts? For ECT sensor with NO START: All others: Is resistance within specification? Note...
  • Page 122 TROUBLESHOOTING [ENGINE CONTROL FS] P1120 TP sensor out of range low DESCRIPTION [Possible Cause] STEP INSPECTION ACTION • Is a fault present? While opening throttle, is TP below 0.49 volts? • Is voltage between 4.0 and 6.0 volts? Is resistance less than 5.0 ohms? Is voltage between 0.17 to 0.49 volts? 0 1 -0 1 A -9 4...
  • Page 123 TROUBLESHOOTING [ENGINE CONTROL FS] P1121 TP sensor input signal inconsistent with MAF sensor DESCRIPTION [Possible Cause] STEP INSPECTION ACTION • Does engine run? While opening and closing the throttle, is there a sudden drop In TP V PID below 0.66 volts or sudden jump in TP V PID above 1.20 volts? Is TP PID greater than 2.44 volts and...
  • Page 124 TROUBLESHOOTING [ENGINE CONTROL FS] P1124 TP sensor input signal out of self-test range DESCRIPTION [Possible Cause] STEP INSPECTION ACTION • Is KOEO or KOER DTC present? • Does throttle move freely and return to closed throttle position? P1125 TP sensor circuit intermittent DESCRIPTION [Possible Cause] STEP...
  • Page 125 TROUBLESHOOTING [ENGINE CONTROL FS] Exhaust system too cool P1127 DESCRIPTION [Possible Cause] ACTION INSPECTION STEP • Do all PIDs indicate on? Pressure regulator control (PRC) solenoid valve circuit malfunction P1250 DESCRIPTION [Possible Cause] ACTION INSPECTION STEP • Is voltage greater than 10.5 volts? •...
  • Page 126 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION • Is resistance less than 5.0 ohms? P1409 EGR valve (Stepper motor) malfunction DESCRIPTION [Possible Cause] STEP INSPECTION ACTION • Is connection okay? Is each voltage greater than 10.5 volts? is each resistance greater than 10,000 ohms? Is each resistance less than 5.0 ohms? 0 1 -0 1 A -9 8...
  • Page 127 TROUBLESHOOTING [ENGINE CONTROL FS] P1410 EGR boost solenoid valve stuck DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Are any of above concerns present? Are any continuous memory DTCs displayed? Are any KOEO DTCs displayed? Are any KOER DTCs displayed? Is voltage greater than 10.5 volts? •...
  • Page 128 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION • • • Is voltage less than 1.0 volts? • • • • • • Is resistance greater than 10,000 ohms? • Is resistance less than 5.0 ohms? Is voltage between 4.0 and 6.0 volts? •...
  • Page 129 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION • Is resistance greater than 10,000 ohms? • • • • Is each voltage greater than 10.5 volts? • Is each resistance greater than 10,000 ohms? Is each resistance less than 5.0 ohms? 0 1 -0 1 A -1 01...
  • Page 130 TROUBLESHOOTING [ENGINE CONTROL FS] P1450 Evaporative emission control system unable to bleed up fuel tank vacuum DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Does vacuum to the solenoid on purge solenoid valve release rapidly? e z r Is resistance between 30 and ohms? Is each resistance greater than 10,000 ohms?
  • Page 131 TROUBLESHOOTING [ENGINE CONTROL FS] P1451 Canister drain cut valve (CDCV) malfunction DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Is voltage greater than 10.5 volts? Is the resistance between 45 and 65 ohms? • Is resistance less than 5.0 ohms? Is resistance greater than 10,000 ohms? Is voltage less than 1.0 volts? 01-01A -1 03...
  • Page 132 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION Is voltage between 10.0 and 14.0 volts? • Is MIL illuminated? KOEO, KOER P1460 Wide open throttle air conditioning cutoff circuit malfunction DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Note • Is voltage greater than 10.5 volts? 1 0 0 10 ,0 0 0 •...
  • Page 133 TROUBLESHOOTING [ENGINE CONTROL FS] INSPECTION STEP ACTION • Is voltage less than 1.0 volt? • Is resistance greater than 10,000 ohms? • Is resistance less than 5.0 ohms? 0 1 -0 1 A -1 05...
  • Page 134 TROUBLESHOOTING [ENGINE CONTROL FS] CONTINUOUS P1460 Wide open throttle air conditioning cutoff circuit malfunction DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Is fault indicated? Is fault indicated? 0 1 -0 1 A -1 06...
  • Page 135 TROUBLESHOOTING [ENGINE CONTROL FS] P1464 Air conditioner (A/C) demand out of self-test range DESCRIPTION [Possible Cause] STEP INSPECTION ACTION • Was A/C switch off during KOEO and KOER self-tests? • Are any DTCs present? Are voltages correct? • Are voltages correct? Is resistance greater than 10,000 ohms? Is A/C amplifier okay? •...
  • Page 136 TROUBLESHOOTING [ENGINE CONTROL FS] KOEO, KOER P1474 Cooling fan control primary circuit malfunction P1479 Condenser fan control primary circuit malfunction DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Note Is voltage greater than 10.5 volts? Does test lamp turn on and off when cooling fan output is commanded on and off? •...
  • Page 137 TROUBLESHOOTING [ENGINE CONTROL FS] INSPECTION ACTION STEP is each resistance greater than 10,000 ohms? • Is resistance less than 5.0 ohms? 0 1 -0 1 A -1 09...
  • Page 138 TROUBLESHOOTING [ENGINE CONTROL FS] CONTINUOUS P1474 Cooling fan control circuit malfunction DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Is fault indicated? • Is fault indicated? 0 1 -0 1 A -1 10...
  • Page 139 TROUBLESHOOTING [ENGINE CONTROL FS] CONTINUOUS P1479 Condenser fan control circuit malfunction DESCRIPTION [Possible Cause] ACTION STEP INSPECTION Is fault indicated? 0 1 -0 1 A -1 11...
  • Page 140 TROUBLESHOOTING [ENGINE CONTROL FS] P1487 EGR boost solenoid valve circuit malfunction DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Is voltage greater than 10.5 volts? Is resistance less than 5.0 ohms? is voltage less than 1.0 volts? • Is resistance greater than 10,000 ohms? 0 1 -0 1 A -1 12...
  • Page 141 TROUBLESHOOTING [ENGINE CONTROL FS] Vehicle speed sensor (VSS) input signal out of self-test range P1501 Note DESCRIPTION [Possible Cause] ACTION INSPECTION STEP 2 ,0 0 0 Is reading on VSS PID less than 5 km/h (3 mph}? • Are any problems evident? Idle air control (IAC) system overpseed error P1506 DESCRIPTION...
  • Page 142 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION -5 .3 {-406 -1 6 Does the purge solenoid valve hold vacuum for 20 seconds? Does RPM drop or engine stall? For Fast Idle Symptom currently present: All others: Is each resistance greater than 10,000 ohms? For Idle quality, starting, or stalling symptoms currently present:...
  • Page 143 TROUBLESHOOTING [ENGINE CONTROL FS] P1602 Immobilizer unit (IU) PCM communication error DESCRIPTION [Possible Cause] INSPECTION ACTION STEP • Is same DTC present after cranking? • Does security light indicate DTC 01 • Does security light indicate DTC 03? Is other DTC present except P1624? Is there open circuit? Is there short circuit? •...
  • Page 144 TROUBLESHOOTING [ENGINE CONTROL FS] P1621 Code word does not match after engine cranking DESCRIPTION [Possible Cause] STEP INSPECTION ACTION • Is same DTC present after cranking? • Does P1602 present? • Does engine start after replacing IU and clearing DTC? P1622 Key ID number does not match DESCRIPTION...
  • Page 145 TROUBLESHOOTING [ENGINE CONTROL FS] Immobilizer system communication counter = 0 P1624 DESCRIPTION [Possible Cause] ACTION STEP INSPECTION • Is P1624 still present after cranking? • Is there another DTC. P1650 Power steering pressure (PSP) switch out of self-test range DESCRIPTION [Possible Cause] ACTION INSPECTION...
  • Page 146 TROUBLESHOOTING [ENGINE CONTROL FSJ STEP INSPECTION ACTION • Is resistance less than 5.0 ohms? P1652 IAC valve monitor disable by PSP switch failed on DESCRIPTION [Possible Cause] STEP INSPECTION ACTION • Does PSP PID indicate Low/High or High/Low? Does engine rpm decrease? Is resistance less than ohms? Is resistance less than...
  • Page 147 TROUBLESHOOTING [ENGINE CONTROL FS] KOER P1703 Brake switch out of self-test range DESCRIPTION [Possible Cause] STEP INSPECTION ACTION • Was brake pedal applied during KOEO self-test? • Do brake light operate normally? Note Does BOO PID cycle ON/OFF? Note Is voltage greater than volts? Is resistance less than 5.0 ohms? Are stoplamps still on?
  • Page 148 TROUBLESHOOTING [ENGINE CONTROL FS] INSPECTION ACTION STEP • Are stoplamps still on? KOEO P1703 Brake switch out of self-test range DESCRIPTION [Possible Cause] ACTION INSPECTION STEP • Was brake pedal applied and released during KOER self-test? • Do stoplamps operate normally? Note Does the BOO PID cycle ON/OFF? Note...
  • Page 149 TROUBLESHOOTING [ENGINE CONTROL FS] ACTION STEP INSPECTION • Is brake light still on? Is brake light still on? • Is brake light still on? 0 1 -0 1 A -1 21...
  • Page 150 TROUBLESHOOTING [ENGINE CONTROL FS] ENGINE SYMPTOM TROUBLESHOOTING [FS] W6U101W03 Diagnostic Index TROUBLESHOOTING ITEM DESCRIPTION TROUBLE 0 1 -0 1 A -1 22...
  • Page 151 TROUBLESHOOTING [ENGINE CONTROL FS] TROUBLESHOOTING ITEM DESCRIPTION TROUBLE 0 1 -0 1 A -1 23...
  • Page 152 > 5 ' Ù v> «n v> IA è Ì £ If ?» » £ ¡ 5 > > 3 > im p ro p er engine oil viscosity ___L. — ( im proper dipstick — 4 M alfunction of b ase en g in e >...
  • Page 153 ■ 0 r> 3 5 0 ¿ a » 2 1 1 ■É <o ¡ 2 u> ■ 0 e > U¡ < t> <a <o ñ...
  • Page 154 TROUBLESHOOTING [ENGINE CONTROL FS] Description of Drivability Problems ENGINE SPEED W 6 U 1 0 1 W A R Fuel Pressure Release and Servicing Fuel System Warning • Fuel vapor is hazardous. It can very easily ignite causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Page 155 TROUBLESHOOTING [ENGINE CONTROL FS] Symptom Troubleshooting MELTS MAIN OR OTHER FUSE [TROUBLESHOOTING HINTS] Damaged Fuse W 6 U 1 0 1 W A U 01-01A -1 27...
  • Page 156 TROUBLESHOOTING [ENGINE CONTROL FS] WILL NOT CRANK DESCRIPTION POSSIBLE CAUSE • INSPECTION ACTION STEP • • 0 1 -0 1 A - 1 28...
  • Page 157 TROUBLESHOOTING [ENGINE CONTROL FS] HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK • DESCRIPTION • • • • • • • • • • • • • POSSIBLE • CAUSE • Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: •...
  • Page 158 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION Zero or low: Fuel line pressure 260— 310 kPa {2.6— 3.2 kgf/cm2, 37—46 psi} Fuel line pressure More than 150 kPa {1.5 kgf/cm2, 21 psi} 01-01 A -1 30...
  • Page 159 TROUBLESHOOTING [ENGINE CONTROL FS] ENGINE STALLS -A FTER START, AT IDLE DESCRIPTION POSSIBLE CAUSE Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Page 160 TROUBLESHOOTING [ENGINE CONTROL FS] 01-01A -1 32...
  • Page 161 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION Specification 0.5— 1.5 mm {0.02— 0.05 in} Zero or low: High: Fuel line pressure 260— 310 kPa {2.6— 3.2 kgf/cm2, 37— 46 psi> Fuel line pressure More than 150 kPa {1.5 kgf/cm2, 21 psi> for 5 minutes 01-01A -1 33...
  • Page 162 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION Note < s r 01-01A -1 34...
  • Page 163 TROUBLESHOOTING [ENGINE CONTROL FS] CRANKS NORMALLY BUT WILL NOT START • • DESCRIPTION • • • • • • • • • • • • • • • • • • POSSIBLE • CAUSE • • • • Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: •...
  • Page 164 TROUBLESHOOTING [ENGINE CONTROL FS] 0 1 -0 1 A -1 36...
  • Page 165 TROUBLESHOOTING [ENGINE CONTROL FS] INSPECTION ACTION STEP Specification 0.5— 1.5 mm {0.02— 0.05 in} Specification 4.5— 5.5 V Zero or low: High: Fuel line pressure 260— 310kP a {2.6— 3.2 kgf/cm2, 37— 46 psi} Fuel line pressure More than 150 kPa {1.5 kgf/cm2, 21 psi} for 5 minutes 01-01 A -1 37...
  • Page 166 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION SLOW RETURN TO IDLE DESCRIPTION POSSIBLE CAUSE STEP INSPECTION No DTC Note 01-01 A -1 38...
  • Page 167 TROUBLESHOOTING [ENGINE CONTROL FS] ENGINE RUNS ROUGH/ROLLING IDLE • DESCRIPTION • • • • • • • • • • • • • • • • POSSIBLE • CAUSE • • • • Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: •...
  • Page 168 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION Note Note Specification 0.5— 1.5 mm {0.02— 0.05 in} Zero or low: Fuel line pressure High: 210— 260 kPa {2.1— 2.6 kgf/cm2, 30— 37 psi} Fuel line pressure More than 150 kPa {1.5 kgf/cm2, 21 psi} for 5 minutes 01 - 0 1 A -1 40...
  • Page 169 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION Less than specification (too rich): Greater than specification (too lean): FAST IDLE/RUNS ON DESCRIPTION POSSIBLE CAUSE INSPECTION ACTION STEP 01-01A-141...
  • Page 170 TROUBLESHOOTING [ENGINE CONTROL FS] LOW IDLE/STALLS DURING DECELERATION DESCRIPTION POSSIBLE CAUSE STEP INSPECTION ACTION 01-01A-142...
  • Page 171 TROUBLESHOOTING [ENGINE CONTROL FS] ENGINE STALLS/QUITS (ACCELERATION/CRUISE) ENGINE RUNS ROUGH (ACCELERATION/CRUISE) MISSES (ACCELERATION/CRUISE) BUCK/JERK (ACCELERATION/CRUISE/DECELERATION) HESITATION/STUMBLE (ACCELERATION) SURGES (ACCELERATION/CRUISE) DESCRIPTION POSSIBLE CAUSE Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor Is hazardous.
  • Page 172 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION Specification 0.5— 1.5 mm {0.02— 0.05 in} Zero or low: Fuel line pressure 260— 310kP a {2.6— 3.2 kgf/cm2, 37— 46 psi> Fuel line pressure More than 150 kPa {1.5 kgf/cm2, 21 psi} for 5 minutes 0 1 -0 1 A -1 44...
  • Page 173 TROUBLESHOOTING [ENGINE CONTROL FS] ACTION STEP INSPECTION Note Note 0 1 -0 1 A -1 45...
  • Page 174 TROUBLESHOOTING [ENGINE CONTROL FS] LACK/LOSS OF POWER ACCELERATION/CRUISE DESCRIPTION POSSIBLE CAUSE Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Page 175 TROUBLESHOOTING [ENGINE CONTROL FS] INSPECTION ACTION STEP 0 1-4 0 A MASS AIR FLOW SENSOR INSPECTION [FS] Specification 0.5— 1.5 mm {0.02— 0.05 in} Zero or low: High: Fuel line pressure 260— 310 kPa {2.6— 3.2 kgf/cm2, 37—46 psi} Note 01-01A -1 47...
  • Page 176 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION 0 1 -10A COMPRESSION INSPECTION [FS] 0 1 -0 1 A -1 48...
  • Page 177 TROUBLESHOOTING [ENGINE CONTROL FS] KNOCKING/PINGING ACCELERATION/CRUISE DESCRIPTION Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: POSSIBLE • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep CAUSE sparks and flames away from fuel.
  • Page 178 TROUBLESHOOTING [ENGINE CONTROL FS] POOR FUEL ECONOMY DESCRIPTION • • • • • • • • • • • • • POSSIBLE • CAUSE • Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: •...
  • Page 179 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION Zero or low: Fuel line pressure High: 210— 260 kPa {2.1— 2.6 kgf/cm2, 30— 37 psi} 0 1 -0 1 A -1 51...
  • Page 180 TROUBLESHOOTING [ENGINE CONTROL FS] EMISSION COMPLIANCE DESCRIPTION • • • • • • • • • • POSSIBLE • CAUSE • Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: •...
  • Page 181 TROUBLESHOOTING [ENGINE CONTROL FS] ACTION STEP INSPECTION Fuel line pressure High: 210— 260 kPa {2.1— 2.6 kgf/cm2, 30— 37 psi} Fuel line pressure 210— 260 kPa {2.1— 2.6 kgf/cm2, 30— 37 psi} 01-01A -1 53...
  • Page 182 TROUBLESHOOTING [ENGINE CONTROL FS] MIL NEVER ON DESCRIPTION POSSIBLE CAUSE INSPECTION ACTION STEP Specification More than 10.5 V Specification More than 10.5 V HIGH OIL CONSUMPTION/LEAKS DESCRIPTION POSSIBLE CAUSE ACTION INSPECTION STEP 01-01A -1 54...
  • Page 183 TROUBLESHOOTING [ENGINE CONTROL FS] COOLING SYSTEM CONCERNS OVERHEATING DESCRIPTION POSSIBLE CAUSE INSPECTION ACTION STEP Note Thermostat operating voltage Approx. 0.6 0.9 V 0 1 -0 1 A -1 55...
  • Page 184 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION If condenser fan does not operate, check following: If cooling fan motor does not operate, check following: COOLING SYSTEM CONCERNS RUNS COLD DESCRIPTION POSSIBLE CAUSE STEP INSPECTION ACTION Note Thermostat operating voltage Approx. 0.6— 0.9 V 01-01 A -1 56...
  • Page 185 TROUBLESHOOTING [ENGINE CONTROL FS] EXHAUST SMOKE DESCRIPTION • • • • • POSSIBLE • CAUSE • Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Page 186 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION Zero or low: Fuel line pressure High: 210—260 kPa {2.1— 2.6 kgf/cm2, 30— 37 psi} Fuel line pressure 210— 260 kPa {2.1— 2.6 kgf/cm2, 30— 37 psi} 0 1 -0 1 A -1 58...
  • Page 187 TROUBLESHOOTING [ENGINE CONTROL FS] FUEL ODOR (IN ENGINE COMPARTMENT) DESCRIPTION Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: POSSIBLE • Fuel vapor is hazardous, it can easily ignite, causing serious injury and damage. Always keep CAUSE sparks and flames away from fuel.
  • Page 188 TROUBLESHOOTING [ENGINE CONTROL FS] ENGINE NOISE DESCRIPTION POSSIBLE CAUSE STEP INSPECTION ACTION 0 1 -0 1 A -1 60...
  • Page 189 TROUBLESHOOTING [ENGINE CONTROL FS] VIBRATION CONCERNS (ENGINE) DESCRIPTION POSSIBLE CAUSE INSPECTION ACTION STEP A/C DOES NOT WORK DESCRIPTION POSSIBLE CAUSE INSPECTION ACTION STEP Specification More than 01 -01 A -1 61...
  • Page 190 TROUBLESHOOTING [ENGINE CONTROL FS] A/C ALWAYS ON/A/C COMPRESSOR RUNS CONTINUOUSLY DESCRIPTION POSSIBLE CAUSE STEP INSPECTION ACTION Note Note Note 0 1 -0 1 A -1 62...
  • Page 191 TROUBLESHOOTING [ENGINE CONTROL FS] A/C DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONS DESCRIPTION POSSIBLE CAUSE INSPECTION ACTION STEP 0 1 -0 1 A -1 63...
  • Page 192 TROUBLESHOOTING [ENGINE CONTROL FS] EXHAUST SULPHUR SMELL Note DESCRIPTION Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: POSSIBLE • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep CAUSE sparks and flames away from fuel.
  • Page 193 TROUBLESHOOTING [ENGINE CONTROL FS] INTERMITTENT CONCERNS DESCRIPTION ACTION STEP INSPECTION 0 1 -0 1 A -1 65...
  • Page 194 TROUBLESHOOTING [ENGINE CONTROL FS] FUEL FILL ISSUES DESCRIPTION Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read POSSIBLE following warnings before performing fuel system service: CAUSE • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Page 195 TROUBLESHOOTING [ENGINE CONTROL FS] CONSTANT VOLTAGE DESCRIPTION POSSIBLE CAUSE INSPECTION ACTION STEP Note Note 01-01A -1 67...
  • Page 196 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION Sensors connected to ground: 0 1 -0 1 A -1 68...
  • Page 197 TROUBLESHOOTING [ENGINE CONTROL FS] E N G IN E D IA G N O S T IC IN S P E C T IO N [FS] P ro c ed u re S p a rk Plug C o n d itio n C h e c k P u rp o s e Troubleshooting chart Spark plug condition...
  • Page 198 TROUBLESHOOTING [ENGINE CONTROL FS] STEP INSPECTION ACTION Specification Grayish white with specific plug [TROUBLESHOOTING HINTS] Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily Ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Page 199 TROUBLESHOOTING [ENGINE CONTROL FS] Wet/carbon stuck on all plugs [TROUBLESHOOTING HINTS] © Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Page 200 TROUBLESHOOTING [ENGINE CONTROL FS] Grayish white with all plugs n-ROUBLESHOOTING HINTS] Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous, it can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Page 201 TROUBLESHOOTING [ENGINE CONTROL FS] Fuel Pressure Hold Inspection Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “BEFORE REPAIR PROCEDURE”...
  • Page 202 TROUBLESHOOTING [ENGINE CONTROL FS] Caution • Before connecting the negative battery cable be sure all fuel connections, clamps and fittings are secure. Fuel pump will operate at full pressure anytime the cable is connected to the battery. When the cable makes contact, it is sure to arc and create a danger of ignition or explosion.
  • Page 203 TROUBLESHOOTING [ENGINE CONTROL FS] Pressure Regulator Control Inspection Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate FS].) skin and eyes. To prevent this, always complete the “BEFORE REPAIR PROCEDURE”...
  • Page 204 TROUBLESHOOTING [ENGINE CONTROL FS] A/C Cut Off Control Inspection Purge Control Inspection W 6 U 1 0 1 W B 2 Main Relay Operation Inspection Ignition Timing Control Inspection Specification B T D C 6— 18° (12 ± 6°) 0 1 -0 1 A -1 76...
  • Page 205 TROUBLESHOOTING [ENGINE CONTROL FS] Spark Test Warning • High voltage in the ignition system can cause strong electrical shock which can result in serious injury. Avoid direct contact to the vehicle body during the following spark test. STEP INSPECTION ACTION Specification 16 kQ/m Specification...
  • Page 206 TROUBLESHOOTING [ENGINE CONTROL FS] Condenser fan relay S S T s 0 1 -0 1 A -1 78...
  • Page 207 TROUBLESHOOTING [ENGINE CONTROL KL] 01-01B TROUBLESHOOTING [ENGINE CONTROL KL] ENGINE SYMPTOM TROUBLESHOOTING FOREWORD ........... 01-01 B-1 [ K L ] ............0 1 -0 1 B -1 28 ENGINE ON-BOARD DIAGNOSIS [KL] 01-01 B-1 01-01 B -1 28 0 1 -0 1 B -1 30 0 1 -0 1 B-1 0 1 -0 1 B -1 32 01-01 B-1...
  • Page 208 TROUBLESHOOTING [ENGINE CONTROL KL] Key On Engine Off (KOEO) Self-Test On-Board Diagnostic Test New generation star (NGS) tester hook-up procedure Note Key On Engine Running (KOER) Self-Test MUST W 6 U 1 0 1 W K G Read/Clear Continuous Memory DTC Access Self-Test laòùòùòòa/ ^ W 6 U 1 0 1 W H O...
  • Page 209 TROUBLESHOOTING [ENGINE CONTROL KL] Reading DTCs procedure Note SELEC T ITEM AND PRESS TRIGGER TO START W 6 U 1 0 1 W K 3 DIAGNOSTIC DATA LINK VEHICLE AND ENGINE SELECTION. V F H I C L E A N D E N G I N E S E I F C T I O N PCM.
  • Page 210 TROUBLESHOOTING [ENGINE CONTROL KL] SELECT ITEM ANO PRESS TRIGGER TO START SELECT I TEH AND PRESS TRIGGER TO START Read/clear continuous DTC self-test procedure CANCEL. Note Key ON engine running self-test procedure Note READ/CLEAR CONTINUOUS DTCs. KOER ON-DEMAND SELF-TEST. SELECT ITE« ANO PRESS TRIGGER TO START START.
  • Page 211 TROUBLESHOOTING [ENGINE CONTROL KL] After Repair Procedure Playback of Stored PIDs Procedure GENERIC OBD II Note FUNCTIONS VIEW RECORDER AREAS. PID/DATA Monitor and Record Procedure PID/DATA MONITOR AND RECORD. SELECT ITEM ANO PRESS TRIGGER TO START AIRM P C M 0 2 ACCS *CPP/PNP ARCF...
  • Page 212 TROUBLESHOOTING [ENGINE CONTROL KL] GENERIC OBD II FUNCTIONS. OXYGEN SENSOR TESTS. MANUFACTURING SPECIFIC TEST ID. (41H) SELECT ITEM ANO PRESS TRIGGER TO START OBD II Drive Mode W 6 U 1 0 1 W K F OUTPUT TEST MODE. Caution •...
  • Page 213 TROUBLESHOOTING [ENGINE CONTROL KL] Diagnostic Trouble Code Table Diagnosed Circuit Condition DC*1 OBD Monitor*2 DTC No. 0 1 -0 1 B -7...
  • Page 214 TROUBLESHOOTING [ENGINE CONTROL KL] < c r 0 1 -0 1 B -8...
  • Page 215 TROUBLESHOOTING [ENGINE CONTROL KL] Diagnosed Circuit Condition DC*1 OBD Monitor*2 DTC No. P1124 0 1 -0 1 B -9...
  • Page 216 TROUBLESHOOTING [ENGINE CONTROL KL] DTC No. Diagnosed Circuit Condition DC*1 OBD Monitor*2 0 1 -0 1 B -1 0...
  • Page 217 TROUBLESHOOTING [ENGINE CONTROL KL] Diagnosed Circuit Condition DC*1 OBD Monitor*2 DTC No. P0102 MAF sensor circuit low input DESCRIPTION [Possible Cause] ACTION STEP INSPECTION Note For Key on engine running (KOER) reading between 0.60 and 1.00 volt: All others: • Is MAF PID less than specified value? •...
  • Page 218 TROUBLESHOOTING [ENGINE CONTROL KL] INSPECTION ACTION Is each resistance greater than 10,000 ohms? < s r Is resistance less than 5.0 ohms? Is voltage greater than 10.5 volts? Is resistance less than 10 ohms? Is resistance less than 5.0 ohms? Is each resistance greater than 10,000 ohms? 0 1 -0 1 B -1 2...
  • Page 219 TROUBLESHOOTING [ENGINE CONTROL KL] INSPECTION ACTION STEP Note Is voltage at idle between 0.34 and 1.96 volts? • Is voltage between 0.34 and 1.96 volts? within specified value? Note Is voltage greater than 0.20 volts? 01-01B-13...
  • Page 220 TROUBLESHOOTING [ENGINE CONTROL KL] P0103 MAF sensor circuit high Input DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Note Did MAF PID drop from previous reading less than specified value? Is voltage greater than 10.5 volts? Is resistance greater than 10,000 ohms? N o te 0 1 -0 1 B -1 4...
  • Page 221 TROUBLESHOOTING [ENGINE CONTROL KL] EGR boost sensor circuit input signal out of self-test range P0106 DESCRIPTION [Possible Cause] INSPECTION STEP Is voltage between 4.0 and 6.0 volts? Is each resistance less than 5 ohms? Is resistance greater than 10,000 ohms? Do vacuum lines have any blockage or damage? 0 1 -0 1 B -1 5...
  • Page 222 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION Is voltage response between 0.8 and 1.5 volts? • Is EGR boost solenoid valve power voltage greater than 10.5 volts? Is resistance less than 5.0 ohms? Is each resistance greater than 10,000 ohms? 0 1 -0 1 B -1 6...
  • Page 223 TROUBLESHOOTING [ENGINE CONTROL KL] ACTION STEP INSPECTION • Was vacuum signal of 0 kPa {0 -2 5 mmHg, 0 1 InHg} Indicated by vacuum gauge before Test Pins 98 and 51 were shorted and -27 (-2 0 3 254 mmHg, - 8 10 inHg} after Pins were shorted? 0 1 -0 1 B -1 7...
  • Page 224 TROUBLESHOOTING [ENGINE CONTROL KL] P0107 EGR boost sensor circuit input signal out of self-test range minimum DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Is voltage between 4.0 and 6.0 volts? Is resistance less than 5 ohms? • Is resistance greater than 10,000 ohms? •...
  • Page 225 TROUBLESHOOTING [ENGINE CONTROL KL] EGR boost sensor circuit input signal out of self-test range maximum P0108 DESCRIPTION [Possible Cause] INSPECTION ACTION STEP Is voltage between 4.0 and 6.0 volts? is resistance less than 5.0 ohms? • Is resistance greater than 10,000 ohms? Is voltage response between 0.8 and 1.5 volts? 01-01B-19...
  • Page 226 TROUBLESHOOTING [ENGINE CONTROL KL] KOEO, KOER P0112 IAT sensor circuit low input P0117 ECT sensor circuit low input DESCRIPTION [Possible Cause] ACTION STEP INSPECTION • Is ECT or IAT PID more than 4.2 volts (less than -4 0 ”C { -4 0 ”F})? Is voltage between 4.5 volts and 5.5 volts? •...
  • Page 227 TROUBLESHOOTING [ENGINE CONTROL KL] IAT sensor circuit low input CONTINUOUS P0112 P0113 IAT sensor circuit high input IAT sensor intermittent P1112 ECT sensor circuit low input P0117 ECT sensor circuit high input P0118 P1117 ECT sensor intermittent DESCRIPTION [Possible Cause] ACTION STEP INSPECTION...
  • Page 228 TROUBLESHOOTING [ENGINE CONTROL KL] KOEO, KOER P0113 IAT sensor circuit high input P0118 ECT sensor circuit high input DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Note Is ECT or IAT PID less than 0.2 volts (greater than 120 ‘ C {248 ’ F})? Is each resistance less than 5.0 ohms? •...
  • Page 229 TROUBLESHOOTING [ENGINE CONTROL KL] TP sensor circuit low input P0122 DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Note Is DTC P0123 present (ignore all other DTC’s)? • Is voltage between 4.0 and 6.0 volts? Is resistance less than 5.0 ohms? • Is each resistance greater than 10,000 ohms? 01-01B-23...
  • Page 230 TROUBLESHOOTING [ENGINE CONTROL KL] Note P0123 TP sensor circuit high input DESCRIPTION [Possible Cause] STEP INSPECTION ACTION • Is TPV PID less than 0.17 volts? • Is voltage between 4.0 and 6.0 volts? • Is each resistance greater than 10,000 ohms? Note 0 1 -0 1 B -2 4...
  • Page 231 TROUBLESHOOTING [ENGINE CONTROL KL] Insufficient engine coolant temperature to enter a closed loop fuel control P0125 DESCRIPTION [Possible Cause] STEP INSPECTION ACTION • Is coolant level correct? Heated oxygen sensor (Front RH) (H 02S 11) circuit low response P0133 P0153 Heated oxygen sensor (Front LH) (H 02S 21) circuit low response DESCRIPTION [Possible Cause]...
  • Page 232 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION • Are there any air leaks? Note Is voltage greater than 1.50 volts? • Is resistance less than 5.0 ohms? 0 1 -0 1 B -2 6...
  • Page 233 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION • Is resistance greater than 10,000 ohms? P0135 Heated oxygen sensor heater (Front RH) (HTR 11) circuit malfunction P0141 Heated oxygen sensor heater (Middle) (HTR 12) circuit malfunction P0147 Heated oxygen sensor heater (Rear) (HTR 13) circuit malfunction Heated oxygen sensor heater (Front LH) (HTR 21) circuit malfunction P0155 DESCRIPTION...
  • Page 234 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION • Is voltage greater than 10.5 volts? Is resistance between 4.0 ohms? • • Is resistance between and 30 ohms? • • • • • is resistance greater than 10,000 ohms? 0 1 -0 1 B -2 8...
  • Page 235 TROUBLESHOOTING [ENGINE CONTROL KL] INSPECTION ACTION STEP Is resistance greater than 10,000 ohms? &• Is resistance less than 4.0 ohms? 01-01B-29...
  • Page 236 TROUBLESHOOTING [ENGINE CONTROL KL] P0136 Heated oxygen sensor (Middle) (H 02S 12) circuit malfunction P1137 Lack of heated oxygen sensor (Middle) (H 02S 12) switch sensor indicates lean P1138 Lack of heated oxygen sensor (Middle) (H 02S 12) switch sensor indicates rich DESCRIPTION [Possible Cause] STEP...
  • Page 237 TROUBLESHOOTING [ENGINE CONTROL KL] INSPECTION ACTION STEP Is resistance greater than 10,000 ohms? Is resistance reading less than 5.0 ohms? 01-01B-31...
  • Page 238 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION Note Is voltage greater than 1.5 volts? Is resistance reading less than 5.0 ohms? • Is PID voltage greater than 1.5 volts? Are voltage readings greater than 1.5 volts? 0 1 -0 1 B -3 2...
  • Page 239 TROUBLESHOOTING [ENGINE CONTROL KL] Heated oxygen sensor (Rear) (H 02S 13) circuit malfunction P0142 P1143 Lack of heated oxygen sensor (Rear) (H 02S 13) switch sensor indicates lean P1144 Lack of heated oxygen sensor (Rear) (H 02S 13) switch sensor indicates rich DESCRIPTION [Possible Cause] ACTION...
  • Page 240 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION Is resistance greater than 10,000 ohms? Is resistance reading less than 5.0 ohms? 0 1 -0 1 B -3 4...
  • Page 241 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION Note Is voltage greater than 1.5 volts? • Is resistance reading less than 5.0 ohms? Is PID voltage greater than 1.5 volts? Are voltage readings greater than 1.5 volts? 0 1 -0 1 B -3 5...
  • Page 242 TROUBLESHOOTING [ENGINE CONTROL KL] P0171 Adaptive fuel control system (RH) too lean P0172 Adaptive fuel control system (RH) too rich P0174 Adaptive fuel control system (LH) too lean P0175 Adaptive fuel control system (LH) too rich P1130 Lack of heated oxygen sensor (Front RH) (H 02S 11) switch adaptive fuel at limit P1131 Lack of heated oxygen sensor (Front RH) (H 02S 11) switch sensor indicates too lean P1132...
  • Page 243 TROUBLESHOOTING [ENGINE CONTROL KL] INSPECTION ACTION STEP If DTC P1127 is present: DTCs P1131, P1130 or P1151, P1150: DTCs P1132, P1130 or P1152, P1150: For Continuous DTCs Only P1130, P1150, P0171, P0174, P0172 and P0175: • Are any heated oxygen sensor DTCs present? All others: Note...
  • Page 244 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION Is resistance reading less than 5.0 ohms? Is each resistance greater than 10,000 ohms? Is resistance greater than 10,000 ohms? Is reading 0.2 volt or less? 0 1 -0 1 B -3 8...
  • Page 245 TROUBLESHOOTING [ENGINE CONTROL KL] INSPECTION ACTION STEP Is resistance greater than 10,000 ohms? Note Is heated oxygen sensor voltage greater than 0.45 volt? • If engine will start: No start: • Is fuel pressure between 207 301 kPa kgf/cm2, 30 45 psi} for all others? 0 1 -0 1 B -3 9...
  • Page 246 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION Is voltage greater than 10.5 volts? Is resistance less than 5.0 ohms? Is resistance greater than 10,000 ohms? Is vacuum line free of damage? • Was vacuum signal present? 0 1 -0 1 B -4 0...
  • Page 247 TROUBLESHOOTING [ENGINE CONTROL KL] INSPECTION ACTION STEP • Is vacuum line free of damage? Note Is vacuum signal indicated vacuum gauge? Note Did vacuum gauge reading drop from -2 7 33 kPa {-203 247 mmHg, - 8 — -1 0 InHg} to 0 3.3 kPa {0 mmHg, 0 1 InHg} when Pin 19 was...
  • Page 248 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION Note Is voltage reading between Pin V during engine crank and V during other conditions? For Continuous DTCs P1130, P1150, P0171, P0172, P0174 and P0175: For No Starts: For Fuel Control DTCs displayed with misfire DTCs: Does fuel pressure remain within kgf/cm2, psi} of highest reading...
  • Page 249 TROUBLESHOOTING [ENGINE CONTROL KL] ACTION STEP INSPECTION Does fuel pressure reading hold steady within 21 kPa {0.21 kgf/cm2, 3 psi} during test? Does fuel pressure gauge reading increase as vacuum gauge reading decreases, or decrease as vacuum gauge reading increases? Does fuel pressure change as vacuum changes? •...
  • Page 250 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION • Does air flow freely through supply line? For Continuous DTCs P1130, P1150, P0171 and P0174: For DTCs P0172 and P0175: • Does fuel pressure remain within 34 kPa {0.35 kgf/cm2, 5 psi} of highest reading after 10 seconds? •...
  • Page 251 TROUBLESHOOTING [ENGINE CONTROL KL] ACTION STEP INSPECTION • Is each resistance less than 5.0 ohms? • Is each resistance greater than ohms? Note Note • Does test lamp have dim glow while cranking or running engine?___________ 0 1 -0 1 B -4 5...
  • Page 252 TROUBLESHOOTING [ENGINE CONTROL KL] INSPECTION ACTION STEP DTCs P0171, P0174, P1130, P1131, P1150and P1151: • Is leakage and flow within specification? DTCs P0172 and P0175: For DTCs P1132and P1152: CONTINUOUS DTCs P0171, P0174, P1130 or P1150: DTCs P1131 and P1130 or P1151 and P1150: •...
  • Page 253 TROUBLESHOOTING [ENGINE CONTROL KL] INSPECTION ACTION STEP Note Possible causes: Is voltage greater than 0.5 volt during or at end of Self-Test? Are DTCs P1131 or P1151 present? • Does voltage reading indicate less than volt within seconds? 0 1 -0 1 B -4 7...
  • Page 254 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION Note Did heated oxygen sensor voltage stay high (greater than 0.45 volt) or low (less than 0.45 volt)? Note Does heated oxygen sensor appear to switch properly? 0 1 -0 1 B -4 8...
  • Page 255 TROUBLESHOOTING [ENGINE CONTROL KL] Fuel pump circuit malfunction KOEO P0230 DESCRIPTION [Possible Cause] INSPECTION ACTION STEP • Is voltage greater than 10.5 volts? • Is fuel pump relay okay? Is voltage less than .0 volt? Is resistance greater than 10,000 ohms? •...
  • Page 256 TROUBLESHOOTING [ENGINE CONTROL KL] P0300 Random misfire detected P0301 Cylinder No. 1 misfire detected P0302 Cylinder No. 2 misfire detected P0303 Cylinder No. 3 misfire detected P0304 Cylinder No. 4 misfire detected P0305 Cylinder No. 5 misfire detected Cylinder No. 6 misfire detected P0306 •...
  • Page 257 TROUBLESHOOTING [ENGINE CONTROL KL] ACTION INSPECTION STEP • Is resistance between 12.0— 16.0 ohms? Note • Does test lamp emit dim glow while engine is running? • Is fuel pressure between 210— 310 kPa {2.1— 3.1 kgf/cm2, 31—46 psi}? • Does fuel pressure remain at specification within 16.5 kPa {0.16 kgf/cm2, 5 psi} for 60 seconds?________...
  • Page 258 TROUBLESHOOTING [ENGINE CONTROL KL] 0 1 -0 1 B -5 2...
  • Page 259 TROUBLESHOOTING [ENGINE CONTROL KL] Ignition engine speed input circuit malfunction P0320 DESCRIPTION [Possible Cause] ACTION INSPECTION STEP For No starts: For Intermittent faults: * Are any of above present? Verify all 2-way radio installation instructions All others: regarding routing of antenna and power lead.
  • Page 260 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION Is resistance less than 5.0 ohms? Is resistance greater than 10,000 ohms? Is voltage less than 0.5 volts? Is resistance greater than 5.11 megaohm? 0 1 -0 1 B -5 4...
  • Page 261 TROUBLESHOOTING [ENGINE CONTROL KL] Camshaft position (CMP) sensor circuit malfunction P0340 DESCRIPTION [Possible Cause] ACTION INSPECTION STEP • Will engine start? t p r Is DTC P0340 present? Is voltage greater than 0.5 volts? Is resistance less than 5.0 ohms? Are resistance measurements less than 5.0 ohms? Is voltage less than 1.0 volt?
  • Page 262 TROUBLESHOOTING [ENGINE CONTROL KL] 0 1 -0 1 B -5 6...
  • Page 263 TROUBLESHOOTING [ENGINE CONTROL KL] P0400 EGR flow malfunction DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Are any other DTCs displayed on NGS tester? Are there any air leaks? • • Are cylinder compression readings within specification? Note • Does EGR valve initialization noise heard? •...
  • Page 264 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION • Is each resistance approximately 22 ohms? Is each resistance less than ohms? Is each resistance greater than 10,000 ohms? • Is EGR boost solenoid valve power circuit voltage greater than 10.5 volts? Is resistance between 30 and 70 ohms? Is resistance less than 5.0 ohms? 0 1 -0 1 B -5 8...
  • Page 265 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION Is each resistance greater than 10,000 ohms? Was vacuum signal indicated at any time by vacuum gauge? 0 1 -0 1 B -5 9...
  • Page 266 TROUBLESHOOTING [ENGINE CONTROL KL] P0420 Catalyst efficiency below threshold DESCRIPTION [Possible Cause] Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Page 267 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION Note Note • Were any of following heated oxygen sensor monitor DTCs recorded in step 1: P0156? Note • Were any of following ECT sensor DTCs recorded: P0117, P0118, P0125 and P1117? Were any other DTCs recorded In step Note •...
  • Page 268 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION Is ratio of 0 2 S 1 2 and 0 2 S 1 3 greater than 2.0? Note Is fuel pressure between 210 310 kPa {2.2 3.1 kgf/cm2, 31 psi>? Are above components free of cracks and punctures, etc.? Are above components free of dents and areas of collapsed material or...
  • Page 269 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION Note • Did manifold vacuum rise above 54 kPa {407 mmHg, 16 inHg} with engine rpm at 2,000? Note Note Is rate of speed that vacuum gauge needle rises back to normal range (above 54 kPa {407 mmHg, 16 inHg}) much slower than that of non-restricted system?
  • Page 270 TROUBLESHOOTING [ENGINE CONTROL KL] INSPECTION STEP ACTION • • Did vacuum needle quickly rise above 54 kPa {407 mmHg, 16 inHg} with engine Note rpm at 2,000? • Note • • Did vacuum needle quickly rise above 54 kPa {407 mmHg, 16 inHg} with engine rpm at 2,000? t r r 0 1 -0 1 B -6 4...
  • Page 271 TROUBLESHOOTING [ENGINE CONTROL KL] P0442 Evaporative emission control system leak detected (Small leak) DESCRIPTION [Possible Cause] Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Page 272 TROUBLESHOOTING [ENGINE CONTROL KL] • • • • 1 3 . • • • • • • • • • • • • • 0 1 -0 1 B -6 6...
  • Page 273 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION • Is constant voltage between 4.0 and 6.0 volts? Is each resistance greater than 10,000 ohms? Did FTP V PID value maintain negative pressure? Is fault detected? • Is fault detected? 0 1 -0 1 B -6 7...
  • Page 274 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION • Is fault detected? ¡y Is fault detected? • Is fault detected? P0443 Evaporative emission control system purge solenoid valve circuit malfunction DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Note • Is voltage greater than 10.5 volts? •...
  • Page 275 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION • Is resistance less than 5.0 ohms? Is each resistance greater than 10,000 ohms? • Was DTC P0443 generated in either KOEO or KOER self test? Is fault detected? 0 1 -0 1 B -6 9...
  • Page 276 TROUBLESHOOTING [ENGINE CONTROL KL] P0446 Evaporative emission control system vent control malfunction • DESCRIPTION [Possible Cause] • • • • • • Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: •...
  • Page 277 TROUBLESHOOTING [ENGINE CONTROL KL] ACTION STEP INSPECTION • Is an obstruction indicated? Does air flow? Is the fault detected? • Is fault detected? Does CDCV hold for one 01-01B-71...
  • Page 278 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION • Is resistance less than 45 ohms? Is each resistance greater than 10,000 ohms? • Is fault detected? P0452 Evaporative emission control system fuel tank pressure sensor circuit low input DESCRIPTION [Possible Cause] STEP INSPECTION ACTION...
  • Page 279 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION • Is constant voltage between 4.0 and 6.0 volts? • Is constant voltage between 4.0 and 6.0 volts? Is each resistance greater than 10,000 ohms? Is MIL ON? 01-01B-73...
  • Page 280 TROUBLESHOOTING [ENGINE CONTROL KL] P0453 Evaporative emission control system fuel tank pressure sensor circuit high input DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Note Is FTP PID voltage greater than 4.50 volts? Is voltage greater than 10.5 volts? Is voltage greater than 10.5 volts? Is FTP PID voltage less than 0.10 volt? •...
  • Page 281 TROUBLESHOOTING [ENGINE CONTROL KL] ACTION STEP INSPECTION • Is resistance greater that 10,000 ohms? • Is MIL illuminated? 0 1 -0 1 B -7 5...
  • Page 282 TROUBLESHOOTING [ENGINE CONTROL KL] P0455 Evaporative emission control system leak detected (Gross leak) DESCRIPTION [Possible Cause] Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Page 283 TROUBLESHOOTING [ENGINE CONTROL KL] ACTION STEP INSPECTION Note • Is fault detected? Is fault detected? • Is fault detected? • Is fault detected? Did manifold vacuum rise above 54 kPa {407 mmHg, 16 InHg}. • Is fault detected? 0 1 -0 1 B -7 7...
  • Page 284 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION • Are FTP V PID values same as atmospheric pressure (approx. 2.5 V)? • Is FTP V PID value between 4.0 and 6.0 volts? • Is constant voltage between 4.0 and 6.0 volts? Is each resistance greater than 10,000 ohms? •...
  • Page 285 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION Is fault detected? Is fault detected? Is fault detected? Is fault detected? Does FTP PID values maintained negative pressure? 01-01B-79...
  • Page 286 TROUBLESHOOTING [ENGINE CONTROL KL] INSPECTION STEP ACTION Is fault detected? Is fault detected? Is fault detected? • Is fault detected? 01-01B-80...
  • Page 287 TROUBLESHOOTING [ENGINE CONTROL KL] P0460 Fuel gauge sender unit circuit malfunction (Open/short and functional) DESCRIPTION [Possible Cause] Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Page 288 TROUBLESHOOTING [ENGINE CONTROL KL] P0500 Vehicle speed sensor (VSS) malfunction DESCRIPTION [Possible Cause] INSPECTION ACTION STEP Is each resistance less than 5.0 ohms? Is each resistance greater than 500 ohms? Is resistance between 190 and 250 ohms? 01-01B-82...
  • Page 289 TROUBLESHOOTING [ENGINE CONTROL KL] P0505 Idle air control (IAC) system malfunction P1504 Idle air control (IAC) valve circuit malfunction Idle air control (IAC) system underspeed error P1507 DESCRIPTION [Possible Cause] ACTION STEP INSPECTION Is voltage greater than 10.5 volts? Note •...
  • Page 290 TROUBLESHOOTING [ENGINE CONTROL KLj STEP INSPECTION ACTION • Is resistance less than 5.0 ohms? Is voltage less than 1.0 volt? • Is each resistance greater than 10,000 ohms? Is voltage between 3.0 and 11.5 volts? 0 1 -0 1 B -8 4...
  • Page 291 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION For idle quality, starting, or stalling symptoms currently present: All others: • Do IAC or RPM PIDs suddenly change in value indicating fault? 0 1 -0 1 B -8 5...
  • Page 292 TROUBLESHOOTING [ENGINE CONTROL KL] P0603 PCM Keep alive memory (KAM) test error P0605 PCM Read only memory (ROM) test error DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Note • Are battery terminal connections In good condition? Is wiring too close to ignition components or wires? Is voltage less than 10.5 volts? •...
  • Page 293 TROUBLESHOOTING [ENGINE CONTROL KL] P0703 Brake switch input malfunction DESCRIPTION [Possible Cause] STEP INSPECTION ACTION • Does brake light operate normally? Note Does BOO PID cycle ON/OFF? Note Is voltage greater than 10.5 volts? • Is resistance less than 5.0 ohms? Is brake light still on? •...
  • Page 294 TROUBLESHOOTING [ENGINE CONTROL KL] INSPECTION STEP ACTION • Is brake light still on? 01-01B-88...
  • Page 295 TROUBLESHOOTING [ENGINE CONTROL KL] P0704 Clutch switch input circuit malfunction DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Note • Does reading change from ON to OFF for both switches? Is resistance less than 5.0 ohms for both switches? Is each resistance less than 5.0 ohms? •...
  • Page 296 TROUBLESHOOTING [ENGINE CONTROL KL] P1001 Active self-test standard protocol communication error DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Was correct self test activation method used? Was voltage between 4.0 and 6.0 volts? • Could Continuous Memory DTCs be accessed before this OBD Test was entered? •...
  • Page 297 TROUBLESHOOTING [ENGINE CONTROL KL] INSPECTION ACTION STEP Note Note Were any Continuous Memory DTCs present. Is voltage greater 10.5 volts? • Is resistance less than 5.0 ohms? Is resistance less than 5.0 ohms? Is resistance less than 5 ohms? 0 1 -0 1 B-91...
  • Page 298 TROUBLESHOOTING [ENGINE CONTROL KL] • Is resistance greater than 10,000 ohms? • Was voltage greater than 1.0 volt? 01-01B-92...
  • Page 299 TROUBLESHOOTING [ENGINE CONTROL KL] MAF sensor intermittent P1100 DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Note Is MAF PID within specified value? 01-40B MASS AIR FLOW SENSOR INSPECTION [KL] Does voltage go below minimum 0.39 volts or above maximum 3.90 volts? 0 1 -0 1 B -9 3...
  • Page 300 TROUBLESHOOTING [ENGINE CONTROL KL] P1101 MAF sensor out of self-test range DESCRIPTION [Possible Cause] STEP INSPECTION ACTION For Continuous Memory DTC P0102: For Continuous Memory DTC P0103: For all other Continuous Memory DTCs: Is Continuous Memory DTC present with KOER DTC P I I 01? Note •...
  • Page 301 TROUBLESHOOTING [ENGINE CONTROL KL] INSPECTION STEP ACTION • Is each resistance greater than 10,000 ohms? • Is resistance greater than 10,000 ohms? Note Is voltage between 0.34 and 1.96 volts at idle? Is voltage between 0.34 and 1.96 volts? • Is within specified value? 01-01B-95...
  • Page 302 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION ¡y • Is resistance less than 5.0 ohms? Is each resistance greater than 10,000 ohms? Is each resistance greater than 10,000 ohms? Is resistance less than 5.0 ohms? • Is voltage greater than 10.5 volts? 01-01B-96...
  • Page 303 TROUBLESHOOTING [ENGINE CONTROL KL] P1116 ECT sensor input signal out of self-test range DESCRIPTION [Possible Cause] INSPECTION ACTION STEP For symptom of cooling system concern: All others: 6 present? Is voltage between volts and volts? For ECT sensor with NO START: All others: Is resistance within specification? Note...
  • Page 304 TROUBLESHOOTING [ENGINE CONTROL KL] P1120 TP sensor out of range low DESCRIPTION [Possible Cause] INSPECTION ACTION STEP • Is fault present? While opening throttle, TP PID 0.49 volts? Is voltage between 4.0 and 6.0 volts? Is resistance less than 5.0 ohms? Is voltage between volts? 01-01B-98...
  • Page 305 TROUBLESHOOTING [ENGINE CONTROL KL] P1121 TP sensor input signal inconsistent with MAF sensor DESCRIPTION [Possible Cause] INSPECTION ACTION STEP • Does engine run? While opening and closing throttle, is there sudden drop in TP V PID below 0.66 volts or sudden jump in TP V PID 1.20 volts? Is TP V PID greater than 2.44 volts and LOAD PID reading less than 25%?
  • Page 306 TROUBLESHOOTING [ENGINE CONTROL KL] P1124 TP sensor input signal out of self-test range DESCRIPTION [Possible Cause] STEP INSPECTION ACTION • Is KOEO or KOER DTC • Does throttle move freely and return to closed throttle position? P1125 TP sensor circuit intermittent DESCRIPTION [Possible Cause] STEP...
  • Page 307 TROUBLESHOOTING [ENGINE CONTROL KL] Exhaust system too cool P1127 DESCRIPTION [Possible Cause] ACTION INSPECTION STEP • Do all PID indicate on? 01-01B -101...
  • Page 308 TROUBLESHOOTING [ENGINE CONTROL KL] P1250 Pressure regulator control (PRC) solenoid valve circuit malfunction DESCRIPTION [Possible Cause] ACTION INSPECTION STEP Is voltage greater than 10.5 volts? Is resistance less than 5.0 ohms? Is voltage less than 1.0 volt? Is resistance greater than 10,000 ohms? Is resistance less than 5.0 ohms? 01-01B -102...
  • Page 309 TROUBLESHOOTING [ENGINE CONTROL KL] P1409 EGR valve (Stepper motor) malfunction DESCRIPTION [Possible Cause] STEP INSPECTION ACTION • Is connection okay? Is each voltage greater than 10.5 volts? Is each resistance greater than 10,000 ohms? Is each resistance less than 5.0 ohms? 01-01B -103...
  • Page 310 TROUBLESHOOTING [ENGINE CONTROL KL] P1410 EGR boost solenoid valve stuck DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Are any of above concerns present? Are any continuous memory DTCs displayed? Are any KOEO DTCs displayed? Are any KOER DTCs displayed? Is voltage greater than 10.5 volts? •...
  • Page 311 TROUBLESHOOTING [ENGINE CONTROL KL] INSPECTION ACTION STEP Is voltage less than 1.0 volts? Is resistance greater than 10,000 ohms? Is resistance less than 5.0 ohms? Is voltage between 4.0 and 6.0 volts? Is each resistance less than 5.0 ohms? 0 1 -0 1 B -1 05...
  • Page 312 TROUBLESHOOTING [ENGINE CONTROL KL] INSPECTION ACTION STEP is resistance greater than 10,000 ohms? Is each voltage greater than 10.5 volts? ¡ n r Is each resistance greater than 10,000 ohms? Is each resistance less than 5.0 ohms? 0 1 -0 1 B -1 06...
  • Page 313 TROUBLESHOOTING [ENGINE CONTROL KL] Evaporative emission control system unable to bleed up fuel tank vacuum P1450 • DESCRIPTION [Possible Cause] • ACTION STEP INSPECTION • • Does vacuum to solenoid on purge solenoid valve release rapidly? • • • Is resistance between 30 and 36 ohms? •...
  • Page 314 TROUBLESHOOTING [ENGINE CONTROL KL] Canister drain cut valve (CDCV) malfunction DESCRIPTION [Possible Cause] ACTION STEP INSPECTION Is voltage greater than volts? Is resistance between ohms? • • • • • Is resistance less than 5.0 ohms? • • • • •...
  • Page 315 TROUBLESHOOTING [ENGINE CONTROL KL] INSPECTION ACTION STEP Is voltage between volts? Is MIL illuminated? Wide open throttle air conditioning cutoff circuit malfunction P1460 DESCRIPTION [Possible Cause] ACTION STEP INSPECTION Note Is voltage greater than 10.5 volts? Are all resistance checks okay? 01-01B -109...
  • Page 316 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION • Is voltage less than 1.0 volt? • Is resistance greater than 10,000 ohms? • Is resistance less than 5.0 ohms? 01-01B-110...
  • Page 317 TROUBLESHOOTING [ENGINE CONTROL KL] CONTINUOUS P1460 Wide open throttle air conditioning cutoff circuit malfunction DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Is fault indicated? Is fault indicated? 01-01B -111...
  • Page 318 TROUBLESHOOTING [ENGINE CONTROL KL] P1464 Air conditioner (A/C) demand out of self-test range DESCRIPTION [Possible Cause] STEP INSPECTION ACTION • Was A/C switch off during KOEO and KOER self-tests? • Are any DTCs present? Are voltages correct? • Are voltages correct? Is resistance greater than 0,000 ohms? Is A/C amplifier okay? •...
  • Page 319 TROUBLESHOOTING [ENGINE CONTROL KL] KOEO, KOER P1474 Cooling fan control primary circuit malfunction P1479 Condenser fan control primary circuit malfunction DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Note Is voltage greater than 10.5 volts? Does test lamp turn on and off when cooling fan output is commanded on and off? •...
  • Page 320 TROUBLESHOOTING [ENGINE CONTROL KL] ACTION INSPECTION STEP Is each resistance greater than 0,000 ohms? Is resistance less than 5.0 ohms? 01-01B-114...
  • Page 321 TROUBLESHOOTING [ENGINE CONTROL KL] CONTINUOUS P1474 Cooling fan control primary circuit malfunction DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Is fault indicated? • Is fault indicated? 0 1 -0 1 B -1 1 5...
  • Page 322 TROUBLESHOOTING [ENGINE CONTROL KL] Condenser fan control primary circuit malfunction CONTINUOUS P1479 DESCRIPTION [Possible Cause] ACTION STEP INSPECTION • Is fault indicated? Is fault indicated? 0 1 -0 1 B -1 1 6...
  • Page 323 TROUBLESHOOTING [ENGINE CONTROL KL] EGR boost solenoid valve circuit malfunction P1487 DESCRIPTION [Possible Cause] STEP INSPECTION ACTION Is constant voltage between 4.0 and 6.0 volts? Is resistance less than 5.0 ohms? Is voltage less than 1.0 volts? Is resistance greater than 10,000 ohms? Is resistance less than 5.0 ohms? 01-01B -117...
  • Page 324 TROUBLESHOOTING [ENGINE CONTROL KL] P1501 Vehicle speed sensor input signal out of self-test range Note DESCRIPTION [Possible Cause] ACTION STEP INSPECTION Is reading on VSS PID less than 5 km/h {3 mph}? • Are any problems evident? Idle air control (IAC) system overspeed error P1506 DESCRIPTION [Possible Cause]...
  • Page 325 TROUBLESHOOTING [ENGINE CONTROL KL] For Fast Idle Symptom currently present: For idle quality, starting, or stalling symptoms currently present: Others: Do IAC or RPM PIDs suddenly change in valve indicating fault? 0 1 -0 1 B -1 1 9...
  • Page 326 TROUBLESHOOTING [ENGINE CONTROL KL] P1602 Immobilizer unit (IU) PCM communication error DESCRIPTION [Possible Cause] STEP INSPECTION ACTION • Is same DTC present after cranking? • Does security light indicate DTC 01 • Does security light indicate DTC 03? Is other DTC present except P1624? Is there open circuit? Is there short circuit? •...
  • Page 327 TROUBLESHOOTING [ENGINE CONTROL KL] P1621 Code word does not match after engine cranking DESCRIPTION [Possible Cause] STEP INSPECTION ACTION • Is same DTC present after cranking? • Does P1602 present? • Does engine start after replacing IU and clearing DTC? P1622 Key ID number does not match DESCRIPTION...
  • Page 328 TROUBLESHOOTING [ENGINE CONTROL KL] P1624 Immobilizer system communication counter = 0 DESCRIPTION [Possible Cause] INSPECTION ACTION STEP • Is P1624 still present after cranking? • Is there another DTC.? 01-01B -122...
  • Page 329 TROUBLESHOOTING [ENGINE CONTROL KL] P1650 Power steering pressure (PSP) switch out of self-test range DESCRIPTION [Possible Cause] ACTION INSPECTION STEP Does PSP PID Indicate voltage Low/High Does engine rpm increase? Is each resistance less than 5.0 ohms? Is either resistance less than ohms? •...
  • Page 330 TROUBLESHOOTING [ENGINE CONTROL KL] P1652 IAC valve monitor disable by PSP switch failed on DESCRIPTION [Possible Cause] STEP INSPECTION ACTION • Does PSP PID indicate Low/High or High/Low? Does engine rpm decrease? Is resistance less than 5.0 ohms? • Is resistance less than 5.0 ohms? •...
  • Page 331 TROUBLESHOOTING [ENGINE CONTROL KL] Brake switch out of self-test range KOEO P1703 DESCRIPTION [Possible Cause] INSPECTION ACTION STEP • Was brake pedal applied during KOEO self-test? • Does brake light operate normally? Note • Does BOO PID cycle ON/OFF? Note Is voltage greater than 10 volts? Is resistance less than 5.0 ohms? •...
  • Page 332 TROUBLESHOOTING [ENGINE CONTROL KL] KOER P1703 Brake switch out of self-test range DESCRIPTION [Possible Cause] STEP INSPECTION ACTION • Was brake pedal applied and released during KOER self-test? • Does brake light operate normally? Note • Does BOO PID cycle ON/OFF? Note Is voltage greater than 10 volts? Is resistance less than 5.0 ohms?
  • Page 333 TROUBLESHOOTING [ENGINE CONTROL KL] INSPECTION ACTION STEP • Is brake light still on? Is brake light still on? IS brake light still on? 0 1 -0 1 B -1 27...
  • Page 334 TROUBLESHOOTING [ENGINE CONTROL KL] ENGINE SYMPTOM TROUBLESHOOTING [KL] Diagnostic Index TROUBLESHOOTING ITEM DESCRIPTION TROUBLE 0 1 -0 1 B -1 28...
  • Page 335 TROUBLESHOOTING [ENGINE CONTROL KL] TROUBLESHOOTING ITEM DESCRIPTION TROUBLE 0 1 -0 1 B -1 2 9...
  • Page 336 TROUBLESHOOTING [ENGINE CONTROL KL] Quick Diagnostic Chart >■ Í £ ■ -J < A C T . £ Ì 1 Ï £ • ■ J £3 Ï ■ = r > ■ji A-E L ] T IC )T 1 01-01B -130...
  • Page 337 < u <o v > u > <* <0 f> ’ a § g 8 3 ro to < £ > a> rs»...
  • Page 338 TROUBLESHOOTING [ENGINE CONTROL KL] Description of Drivability Problems Fuel Pressure Release and Servicing Fuel System Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Warning •...
  • Page 339 TROUBLESHOOTING [ENGINE CONTROL KL] Symptom Troubleshooting MELTS MAIN OR OTHER FUSE [TROUBLESHOOTING HINTS] Related Wiring Harness 0 1 -0 1 B -1 33...
  • Page 340 TROUBLESHOOTING [ENGINE CONTROL KL] WILL NOT CRANK DESCRIPTION POSSIBLE CAUSE STEP INSPECTION ACTION 0 1 -0 1 B -1 3 4...
  • Page 341 TROUBLESHOOTING [ENGINE CONTROL KL] HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK • DESCRIPTION • • • • • • • • • • • • • POSSIBLE • CAUSE • Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: •...
  • Page 342 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION Zero or low: High: Fuel line pressure 260— 310kP a {2.6— 3.2 kgf/cm2, 37— 46 psi} Fuel line pressure More than 150 kPa {1.5 kgf/cm2, 21 psi} 0 1 -0 1 B -1 36...
  • Page 343 TROUBLESHOOTING [ENGINE CONTROL KL] ENGINE STALLS -A FTER START, AT IDLE DESCRIPTION • POSSIBLE • CAUSE • • • • • • • • • • STEP INSPECTION ACTION Note 0 1 -0 1 B -1 37...
  • Page 344 TROUBLESHOOTING [ENGINE CONTROL KL] 0 1 -0 1 B -1 3 8...
  • Page 345 TROUBLESHOOTING [ENGINE CONTROL KL] INSPECTION ACTION STEP Specification 0.5— 1.5 mm {0.02— 0.05 in} Zero or low: High: Fuel line pressure 260— 310kP a {2.6— 3.2 kgf/cm2, 37— 46 psi} Fuel line pressure More than 150 kPa {1.5 kgf/cm2, 21 psi} for 5 minutes Note 0 1 -0 1 B -1 39...
  • Page 346 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION CRANKS NORMALLY BUT WILL NOT START DESCRIPTION POSSIBLE CAUSE STEP INSPECTION ACTION 0 1 -0 1 B -1 4 0...
  • Page 347 TROUBLESHOOTING [ENGINE CONTROL KL] 01-01B-141...
  • Page 348 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION Specification 0.5— 1.5 mm {0.02— 0.05 In} Specification 4.5— 5.5 V Zero or low: High: Fuel line pressure 260— 310kP a {2.6— 3.2 kgf/cm2, 37—46 psi} Fuel line pressure More than 150 kPa {1.5 kgf/cm2, 21 psi} for 5 minutes 0 1 -0 1 B -1 42...
  • Page 349 TROUBLESHOOTING [ENGINE CONTROL KL] ACTION STEP INSPECTION SLOW RETURN TO IDLE DESCRIPTION POSSIBLE CAUSE STEP INSPECTION ACTION Note 01-01B -143...
  • Page 350 TROUBLESHOOTING [ENGINE CONTROL KL] ENGINE RUNS ROUGH/ROLLING IDLE • DESCRIPTION • • • • • • • • • • • • • • • • POSSIBLE • CAUSE • • • • Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: •...
  • Page 351 TROUBLESHOOTING [ENGINE CONTROL KL] ACTION STEP INSPECTION Note Note Specification 0.5— 1.5 mm {0.02— 0.05 in} Zero or low: Fuel line pressure High: 210— 260 kPa {2.1— 2.6 kgf/cm2, 30— 37 psi} Fuel line pressure More than 150 kPa {1.5 kgf/cm2, 21 psi} for 5 minutes 0 1 -0 1 B -1 45...
  • Page 352 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION FAST IDLE/RUNS ON DESCRIPTION POSSIBLE CAUSE INSPECTION ACTION STEP ’C 0 1 -0 1 B -1 46...
  • Page 353 TROUBLESHOOTING [ENGINE CONTROL KL] LOW IDLE/STALLS DURING DECELERATION DESCRIPTION POSSIBLE CAUSE INSPECTION ACTION STEP 01-01B -147...
  • Page 354 TROUBLESHOOTING [ENGINE CONTROL KL] ENGINE STALLS/QUITS (ACCELERATION/CRUISE) ENGINE RUNS ROUGH (ACCELERATION/CRUISE) MISSES (ACCELERATION/CRUISE) BUCK/JERK (ACCELERATION/CRUISE/DECELERATION) HESITATION/STUMBLE (ACCELERATION) SURGES (ACCELERATION/CRUISE) DESCRIPTION POSSIBLE CAUSE Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous.
  • Page 355 TROUBLESHOOTING [ENGINE CONTROL KL] ACTION INSPECTION STEP Specification 0.5— 1.5 mm {0.02— 0.05 in} Zero or low: High: Fuel line pressure 260— 310kP a {2.6— 3.2 kgf/cm2, 37—46 psi} 01-01B -149...
  • Page 356 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION Fuel line pressure More than 150 kPa {1.5 kgf/cm2, 21 psi} for 5 minutes Note - 0 7 -10 REFRIGERANT PRESSURE CHECK Note 01-01B -150...
  • Page 357 TROUBLESHOOTING [ENGINE CONTROL KL] LACK/LOSS OF POWER ACCELERATION/CRUISE DESCRIPTION POSSIBLE CAUSE Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Page 358 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION Specification 0.5— 1.5 mm {0.02— 0.05 In} Zero or low: High: Fuel line pressure 260— 310kP a {2.6— 3.2 kgf/cm2, 37— 46 psi> Note - 07-10 REFIGERANT PRESSURE CHECK 01-01 B -1 52...
  • Page 359 TROUBLESHOOTING [ENGINE CONTROL KL] ACTION STEP INSPECTION 0 1 -0 1 B -1 5 3...
  • Page 360 TROUBLESHOOTING [ENGINE CONTROL KL] KNOCKING/PINGING - ACCELERATION/CRUISE DESCRIPTION Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: POSSIBLE • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep CAUSE sparks and flames away from fuel.
  • Page 361 TROUBLESHOOTING [ENGINE CONTROL KL] POOR FUEL ECONOMY DESCRIPTION • • • • • • • • • • • • • POSSIBLE • CAUSE • Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: •...
  • Page 362 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION Zero or low: Fuel line pressure High: 210— 260 kPa {2.1— 2.6 kgf/cm2, 30— 37 psi} EMISSION COMPLIANCE DESCRIPTION POSSIBLE CAUSE Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous.
  • Page 363 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION ¡y High: 210— 260 kPa {2.1— 2.6 kgf/cm2, 30— 37 psi> Fuel line pressure 210— 260 kPa (2.1— 2.6 kgf/cm2, 30— 37 psi} 01-01B -157...
  • Page 364 TROUBLESHOOTING [ENGINE CONTROL KL] MIL NEVER ON DESCRIPTION POSSIBLE CAUSE STEP INSPECTION ACTION Specification More than 10.5 V Specification More than 10.5 V HIGH OIL CONSUMPTION/LEAKS DESCRIPTION POSSIBLE CAUSE STEP INSPECTION ACTION 01-01B -158...
  • Page 365 TROUBLESHOOTING [ENGINE CONTROL KL] COOLING SYSTEM CONCERNS OVERHEATING DESCRIPTION POSSIBLE CAUSE STEP INSPECTION ACTION Note Thermostat opening voltage Approx. 0.6— 0.9 V 01-01B-159...
  • Page 366 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION If condenser fan does not operate, check following: If cooling fan motor does not operate, check following: COOLING SYSTEM CONCERNS RUNS COLD DESCRIPTION POSSIBLE CAUSE STEP INSPECTION ACTION Note Thermostat opening voltage Approx. 01-01B -160...
  • Page 367 TROUBLESHOOTING [ENGINE CONTROL KL] EXHAUST SMOKE DESCRIPTION • • • • • POSSIBLE • CAUSE • Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Page 368 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION Zero or low: Fuel line pressure High: 210— 260 kPa {2.1— 2.6 kgf/cm2, 30— 37 psi} Fuel line pressure 210— 260 kPa {2.1— 2.6 kgf/cm2, 30—37 psi} 0 1 -0 1 B -1 62...
  • Page 369 TROUBLESHOOTING [ENGINE CONTROL KL] FUEL ODOR (IN ENGINE COMPARTMENT) DESCRIPTION Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: POSSIBLE • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep CAUSE sparks and flames away from fuel.
  • Page 370 TROUBLESHOOTING [ENGINE CONTROL KL] ENGINE NOISE DESCRIPTION © POSSIBLE CAUSE © STEP INSPECTION ACTION VIBRATION CONCERNS (ENGINE) DESCRIPTION POSSIBLE CAUSE STEP INSPECTION ACTION 0 1 -0 1 B -1 64...
  • Page 371 TROUBLESHOOTING [ENGINE CONTROL KL] A/C DOES NOT WORK DESCRIPTION POSSIBLE CAUSE ACTION STEP INSPECTION Specification More than 10.5 V 0 1 -0 1 B -1 65...
  • Page 372 TROUBLESHOOTING [ENGINE CONTROL KL] A/C ALWAYS ON/A/C COMPRESSOR RUNS CONTINUOUSLY DESCRIPTION POSSIBLE CAUSE STEP INSPECTION ACTION Note Note Note 0 1 -0 1 B -1 66...
  • Page 373 TROUBLESHOOTING [ENGINE CONTROL KL] A/C DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONS DESCRIPTION POSSIBLE CAUSE INSPECTION ACTION STEP 0 1 -0 1 B -1 67...
  • Page 374 TROUBLESHOOTING [ENGINE CONTROL KL] EXHAUST SULPHUR SMELL Note DESCRIPTION Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: POSSIBLE • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep CAUSE sparks and flames away from fuel.
  • Page 375 TROUBLESHOOTING [ENGINE CONTROL KL] INTERMITTENT CONCERNS DESCRIPTION STEP INSPECTION ACTION 0 1 -0 1 B -1 69...
  • Page 376 TROUBLESHOOTING [ENGINE CONTROL KL] FUEL REFILL ISSUES DESCRIPTION Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read POSSIBLE following warnings before performing fuel system service: CAUSE • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Page 377 TROUBLESHOOTING [ENGINE CONTROL KL] CONSTANT VOLTAGE DESCRIPTION POSSIBLE CAUSE INSPECTION ACTION STEP Note 01-01 B -1 71...
  • Page 378 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION Note Sensors connected to ground circuit: 0 1 -0 1 B -1 7 2...
  • Page 379 TROUBLESHOOTING [ENGINE CONTROL KL] ENGINE DIAGNOSTIC INSPECTION [KL] Spark Plug Condition Check Procedure Purpose Spark plug condition Troubleshooting chart Wet/carbon stuck on specific plug [TROUBLESHOOTING HINTS] Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: •...
  • Page 380 TROUBLESHOOTING [ENGINE CONTROL KL] STEP INSPECTION ACTION Specification Grayish white with specific plug [TROUBLESHOOTING HINTS] Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Page 381 TROUBLESHOOTING [ENGINE CONTROL KL] Wet/carbon stuck on all plugs [TROUBLESHOOTING HINTS] ® Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Page 382 TROUBLESHOOTING [ENGINE CONTROL KL] Grayish white with all plugs [TROUBLESHOOTING HINTS] Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous, it can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Page 383 TROUBLESHOOTING [ENGINE CONTROL KL] Fuel Pressure Hold Inspection Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “BEFORE REPAIR PROCEDURE”...
  • Page 384 TROUBLESHOOTING [ENGINE CONTROL KL] Caution • Before connecting the negative battery cable be sure all fuel connections, clamps and fittings are secure. Fuel pump will operate at full pressure anytime the cable is connected to the battery. When the cable makes contact, it is sure to arc and create a danger of ignition or explosion.
  • Page 385 TROUBLESHOOTING [ENGINE CONTROL KL] Pressure Regulator Control Inspection Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “BEFORE REPAIR PROCEDURE”...
  • Page 386 TROUBLESHOOTING [ENGINE CONTROL KL] Purge Control Inspection A/C Cut Off Control Inspection Main Relay Operation Inspection Ignition Timing Control Inspection Specification B TD C 4— 16° (10 ± 6°) 0 1 -0 1 B -1 80...
  • Page 387 TROUBLESHOOTING [ENGINE CONTROL KL] Spark Test Warning • High voltage in the ignition system can cause strong electrical shock which can result in serious injury. Avoid direct contact to the vehicle body during the following spark test. STEP INSPECTION ACTION Specification 16 kil/m Specification...
  • Page 388 TROUBLESHOOTING [ENGINE CONTROL KL] Condenser fan relay 0 1 -0 1 B -1 82...
  • Page 389 TROUBLESHOOTING [CRUISE CONTROL SYSTEM] 01-01C TROUBLESHOOTING [CRUISE CONTROL SYSTEM] FOREWORD ..........01— 01C-1 01-01C -1 CRUISE CONTROL SYSTEM SYMPTOM 0 1 -0 1 C -2 TROUBLESHOOTING......01-01C -1 FOREWORD W 6 U 1 0 1 W 4 A CRUISE CONTROL SYSTEM SYMPTOM TROUBLESHOOTING W 6 U 1 0 1 W 4 B Diagnostic Index Malfunction symptom...
  • Page 390 TROUBLESHOOTING [CRUISE CONTROL SYSTEM] Symptom Troubleshooting Set speed is not kept even when SET switch is depressed. STEP INSPECTION ACTION 0 1 -0 1 C -2...
  • Page 391 TROUBLESHOOTING [CRUISE CONTROL SYSTEM] INSPECTION ACTION STEP 0 1 -0 1 C -3...
  • Page 392 TROUBLESHOOTING [CRUISE CONTROL SYSTEM] STEP INSPECTION ACTION W6U101WP1 (l/-l I M I l' I I I il W6U101WP2 W6U101WP3 0 1 -0 1 C -4...
  • Page 393 TROUBLESHOOTING [CRUISE CONTROL SYSTEM] ACTION STEP INSPECTION W 6 U 1 0 1 W P 5 0 1 -0 1 C -5...
  • Page 394 TROUBLESHOOTING [CRUISE CONTROL SYSTEM] STEP INSPECTION ACTION W 6 U 1 0 1 W P 7 0 1 -0 1 C -6...
  • Page 395 TROUBLESHOOTING [CRUISE CONTROL SYSTEM] INSPECTION ACTION STEP W 6 U 1 0 1 W P C 0 1 -0 1 C -7...
  • Page 396 TROUBLESHOOTING [CRUISE CONTROL SYSTEM] STEP INSPECTION ACTION W 6 U 1 0 1 W P G L T J J L J W 6 U 1 0 1 W P H 0 1 -0 1 C -8...
  • Page 397 TROUBLESHOOTING [CRUISE CONTROL SYSTEM] ACTION STEP INSPECTION is ^ ä f = ^ | 0 1 -0 1 C -9...
  • Page 398 TROUBLESHOOTING [CRUISE CONTROL SYSTEM] While driving at a set speed, cruise control indicator light does not illuminate, or sometimes goes off. TROUBLESHOOTING HINTS STEP INSPECTION ACTION 0 1 -0 1 C -1 0...
  • Page 399 TROUBLESHOOTING [CRUISE CONTROL SYSTEM] INSPECTION ACTION STEP 1111 f r m I I I l W 3 U 1 0 1 W P N W 6 U 1 0 1 W P P 01-01C -11...
  • Page 400 TROUBLESHOOTING [CRUISE CONTROL SYSTEM] Although set mode is set by pressing the SET switch, and the cruise control indicator light illuminates, the cruising speed is not stable. TROUBLESHOOTING HINTS STEP INSPECTION ACTION While driving at the set speed, the speed can not be canceled although the cancel operation has been executed.
  • Page 401 TROUBLESHOOTING [CRUISE CONTROL SYSTEM] STEP INSPECTION ACTION 0 1 -0 1 C -1 3...
  • Page 402 TROUBLESHOOTING [CRUISE CONTROL SYSTEM] STEP INSPECTION ACTION 0 1 -0 1 C -1 4...
  • Page 403 TROUBLESHOOTING [CRUISE CONTROL SYSTEM] While driving at the set speed, the vehicle does not accelerate even when ACCEL switch is depressed. It does not return to the previous set speed, even while driving faster than 40 km/h {25 MPH} and RESUME switch is depressed after the set speed is canceled.
  • Page 404 MECHANICAL [FS] 01-10A MECHANICAL [FS] DRIVE BELT INSPECTION [ F S ] .0 1 -1 OA-1 01-1 OA-1 01-10A-1 DRIVE BELT ADJUSTMENT [F S ]..0 1 -1 OA-2 VALVE CLEARANCE INSPECTION [ F S ] ............01-1 OA-2 VALVE CLEARANCE ADJUSTMENT [ F S ] ............
  • Page 405 MECHANICAL [FS] Tension DRIVE BELT ADJUSTMENT [FS] {4.4— 6 .2 , 32— 44} B 38— 51 A 19— 25 {3 .8 — 5 .3 , 2 8 — 38} {1.9— 2 .6 , N m { k g f m , f t l b f } W 6 U 1 1 0 W A 4 3 8 —...
  • Page 406 MECHANICAL [FS] Standard [Engine cold] 0.225—0.295 mm {0.0089— 0.0116 in} W 6 U 1 1 0 W A 6 VALVE CLEARANCE ADJUSTMENT [FS] W 6 U 1 1 0 W 0 4 W 6 U 1 1 0 W A 9 SSTs W 6 U 1 1 0 W A A Note...
  • Page 407 MECHANICAL [FS] W 6 U 1 1 0 W A E S S T S S T N ew a d ju s tm e n t sh im C a u tio n = R e m o v e d s h im th ic k n e s s + M e a s u re d •...
  • Page 408 MECHANICAL [FS] Tightening torque 15—22 N-m {1.5— 2.3 kgf-m, 11— 16 ftlb f} TIMING BELT REMOVAL/INSTALLATION [FS] W 6 U 1 1 0 W 0 6 6.9 — 9.8 N m 7 .9 — 1 0 .7 N m {70— 100 k g f c m , 6 0 .8 — 8 6 .8 in lb f) 3 8 —...
  • Page 409 MECHANICAL [FS] Crankshaft Pulley Removal Note Caution • The crankshaft position sensor rotor is on the rear of the crankshaft pulley, and can be damaged easily. Caution • The following will damage the belt and shorten its life; forcefully twisting it, turning it inside out, or allowing oil or grease on it.
  • Page 410 MECHANICAL [FS] Timing Belt Installation Note Caution • Be sure not to apply tension other than that of the tensioner spring. 01 — 1 OA— 7...
  • Page 411 MECHANICAL [FS] Cylinder Head Cover Installation Note Crankshaft Pulley Installation Note SST. ,© © -<gy — < P > - — © © W 6 U 1 1 0 W A W CYLINDER HEAD GASKET REPLACEMENT [FS] W 6 U 1 1 0 W 0 7 Warning •...
  • Page 412 MECHANICAL [FS] W 6 U 1 1 0 W A Y Camshaft Removal Note Camshaft Pulley Removal Note W 6 U 1 1 0 W A Z 0 1 -1 0 A -9...
  • Page 413 MECHANICAL [FS] Cylinder Head Removal Note Camshaft Installation Note W 6 U 1 1 0 W B ! Caution • Because there is little camshaft thrust Cylinder Head Installation Note clearance, the camshaft must be held horizontally while it is installed. Otherwise, excessive force will be applied to the thrust area, causing burr on the thrust Standard length...
  • Page 414 MECHANICAL [FS] Camshaft Pulley Installation Note Tightening torque 11.3— 14.2 N m {115— 145 kgf cm, 100— 125 in lbf} W 6 U 1 1 0 W B 9 W 6 U 1 1 0 W B 7 Tightening torque 50—60 N m {5.0—...
  • Page 415 MECHANICAL [FS] FRONT OIL SEAL REPLACEMENT [FS] W 6 U 1 1 0 W 0 8 Front Oil Seal Removal Note Front Oil Seal Installation Note 0— 0 .5 m m {0— 0 .0 1 9 in} t e r W 6 U 1 1 0 W B D REAR OIL SEAL REPLACEMENT [FS] W 6 U 1 1 0 W 0 9...
  • Page 416 MECHANICAL [FS] Rear Oil Seal Installation Note Rear Oil Seal Removal Note ENGINE REMOVAL/INSTALLATION [FS] W 6 U 1 1 0 W 1 0 W arn in g • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Page 417 MECHANICAL [FS] N m {k g f-m , ft lb t) W 6 U 1 1 0 W B H No.4 Engine Mount Bracket Installation Note 0 1 -1 OA-14...
  • Page 418 MECHANICAL [FS] ENGINE DISASSEMBLY/ASSEMBLY [FS] W 6 U 1 1 0 W 1 1 W 6 U 1 1 0 W 8 K 0 1 -1 OA-15...
  • Page 419 MECHANICAL [FS] ENGINE TUNE-UP [FS] Engine Tune-up Preparation Idle Speed Adjustment SSTs d i a g n o s t ic t e s t m o d e s SSTs SELECT ITEM ANO PRESS TRIGGER TO START Ignition Timing Inspection Specification MTX: ATX:...
  • Page 420 MECHANICAL [FS] SELECT ITEM AND PRESS TRIGGER TO START SELECT ITEM AND PRESS TRIGGER TO START W 6 U 1 1 0 W Z 2 Specifications MTX: 550— 850 (700 ± 150) rpm ATX: 500— 800 (650 ± 150) rpm Caution •...
  • Page 421 MECHANICAL [FS] ldle-up Speed Inspection Idle Mixture Inspection Idle-up speed (rpm)*1 Load condition D range N, P position 0 1 -1 OA-18...
  • Page 422 MECHANICAL [KL] 01-10B MECHANICAL [KL] DRIVE BELT INSPECTION [ K L ] 01-10B -1 01-1 OB-1 01-1 OB-2 DRIVE BELT ADJUSTMENT [KL] ..0 1-10B -2 VALVE CLEARANCE INSPECTION [K L ] ............0 1 -1 0B-2 VALVE CLEARANCE ADJUSTMENT [ K L ] ............01-1 OB-3 COMPRESSION INSPECTION [KL] .
  • Page 423 MECHANICAL [KL] Drive Belt Tension Check Tension Drive belt ‘ New Used SST, DRIVE BELT ADJUSTMENT [KL] W 6 U 1 1 0 W 1 3 GENERATOR, GENERATOR+A/C W 6 U 1 1 0 W B Q VALVE CLEARANCE INSPECTION [KL] W 6 U 1 1 0 W 1 4 Standard [Engine cold] IN: 0.245—0.315 mm {0.0097—...
  • Page 424 MECHANICAL [KL] Standard [Engine cold] IN: 0.245— 0.315 mm {0.0097— 0.0124 in} EX: 0.265— 0.335 mm {0.0105— 0.0131 in} W 6 U 1 1 0 W B T Standard [Engine cold] IN: 0.245— 0.315 mm {0.0097— 0.0124 in) EX: 0.265— 0.335 mm {0.0105— 0.0131 in} VALVE CLEARANCE ADJUSTMENT [KL] W 6 U 1 1 0 W 1 5 W 6 U 1 1 0 W B W...
  • Page 425 MECHANICAL [KL] SSTs W 6 U 1 1 0 W B Y W 6 U 1 1 0 W C 1 W 6 U 1 1 0 W C 2 W 6 U 1 1 0 W B Z New adjustment shim = Removed shim thickness + Measured valve clearance - Standard valve clearance (0.28 mm {0.011 in} (IN),...
  • Page 426 MECHANICAL [KL] COMPRESSION INSPECTION [KL] W 6 U 1 1 0 W 1 6 Compression SST. Tightening torque 15—22 N m {1.5—2.3 kg fm , 11— 16 ft lbf} 0 1 -1 OB-5...
  • Page 427 MECHANICAL [KL] TIMING BELT REMOVAL/INSTALLATION [KL] W 6 U 1 1 0 W 1 7 W 6 U 1 1 0 W C 6 0 1 -1 OB-6...
  • Page 428 MECHANICAL [KL] Timing Belt Removal Note Crankshaft Pulley Removal Note Caution • When removing the bolt, hold the Caution tensioner so that the bolt holes are • The crankshaft position sensor rotor is on aligned, otherwise the threads can be the rear of the crankshaft pulley, and can damaged.
  • Page 429 MECHANICAL [KL] W 6 U 1 1 0 W C C W 6 U 1 1 0 W C F Timing Belt Installation Note Note Note W 6 U 1 1 0 W C G Caution • Applying pressure of more than 9.8 kN {1,000 kgf, 2,200 Ibf} can damage the auto tensioner.
  • Page 430 MECHANICAL [KL] Timing Belt Auto Tensioner Installation Note. W 6 U 1 1 0 W C K Caution • Verify that the belt has no looseness at the tension side. • Do not damage the bolt threads when installing. W 6 U 1 1 0 W C P Crankshaft Pulley Installation Note SST.
  • Page 431 MECHANICAL [KL] CYLINDER HEAD GASKET REPLACEMENT [KL] W 6 U 1 1 0 W 1 8 Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. •...
  • Page 432 MECHANICAL [KL] W 6 U 1 1 0 W C U Caution • Remove the thrust caps only after removing all camshaft caps. Otherwise, the thrust caps can be damaged. Camshaft Pulley Removal Note W 6 U 1 1 0 W C T Camshaft Removal Note Caution •...
  • Page 433 MECHANICAL [KL] Cylinder Head Removal Note Tightening torque 23.1—25.9 N m {2.35— 2.65 kgf-m, 17.0— 19.1 ft lbf} W 6 U 1 1 0 W C X Cylinder Head Gasket Installation Note 85°— 95° 85°— 95° W 6 U 1 1 0 W C Y Cylinder Head installation Note Camshaft Installation Note Standard length...
  • Page 434 MECHANICAL [KL] t — W 6 U 1 1 0 W D 6 Caution • Install the thrust caps (RH is 4 mark, LH is B mark) first. Otherwise, camshaft can be broken or damaged. Note Tightening torque 11.3— 14.2 N m {115—...
  • Page 435 MECHANICAL [KL] Tightening torque 123— 140 N m {12.5— 14.3 kgf-m, 91— 103 ft lbf} W 6 U 1 1 0 W D 9 W 6 U 1 1 0 W D D Cylinder Head Cover Installation Note W 6 U 1 1 0 W D A Camshaft Pulley Installation Note Thickness 01.5—...
  • Page 436 MECHANICAL [KL] FRONT OIL SEAL REPLACEMENT [KL] W6U110W 19 Front Oil Seal Removal Note W 6 U 1 1 0 W D L Front Oil Seal Installation Note W6U110WDM 0 1 -1 0 B -1 5...
  • Page 437 MECHANICAL [KL] REAR OIL SEAL REPLACEMENT [KL] Rear Oil Seal Removal Note W6U110WDP Rear Oil Seal Installation Note W6U110WDN 0 1 -1 O B-16...
  • Page 438 MECHANICAL [KL] ENGINE REMOVAL/INSTALLATION [KL] W6U110W21 Warning • Fuel vapor is hazardous, it can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage.
  • Page 439 MECHANICAL [KL] No.4 Engine Mount Bracket Installation Note ENGINE DISASSEMBLY/ASSEMBLY [KL] W6U110W22 W6U110WDT 01-1 O B-18...
  • Page 440 MECHANICAL [KL] ENGINE TUNE-UP [KL] W6U110W23 Engine Tune-up Preparation Specification BTDC — ± SSTs Idle Speed Adjustment SELECT ITEM ANO PRESS TRIGGER TO START SSTs W6U110WDU ignition Timing Inspection Specification W6U110WY0 SELECT ITEM AND PRESS TRIGGER TO START W6U110WDV 0 1 -1 0 B -1 9...
  • Page 441 MECHANICAL [KL] W 6 U 1 1 0 W Y 2 Specification Caution 550— 750(650 ± 100) rpm • The throttle adjusting screw is set at the factory and must not be adjusted. Any adjustment may affect engine performance. Caution •...
  • Page 442 MECHANICAL [KL] Idle Mixture Inspection ldle-up Speed Inspection Idle-up speed (rpm)*1 D range N, P position 0 1 -1 OB-21...
  • Page 443 LUBRICATION SYSTEM 01-11 LUBRICATION SYSTEM ENGINE OIL LEVEL IN SPECTIO N 01-11-1 OIL PAN REMOVAL/INSTALLATION . . . 0 1 -11-3 ENGINE OIL REPLACEM ENT....01-11-1 ......0 1 -1 1 -3 OIL FILTER REPLACEMENT ....01-11-1 ......0 1 -1 1 -3 OIL PRESSURE INSPECTION ....01-11-2 ENGINE OIL LEVEL INSPECTION W 6 U 1 1 1 W 0 1...
  • Page 444 LUBRICATION SYSTEM OIL PRESSURE INSPECTION W 6 U 1 1 1 W 0 4 Warning • Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with Note soap and water immediately after this work.
  • Page 445 LUBRICATION SYSTEM OIL PAN REMOVAL/INSTALLATION W 6 U 1 1 1 W 0 5 Oil Pan Removal Note C au tio n • Pry tools can easily scratch the oil pan mounting surfaces. Prying off the oil pan can also easily bend the oil pan flange. Refer to the following instructions before removing the oil pan.
  • Page 446 LUBRICATION SYSTEM Thickness 02.0— 3.0 mm {0.079— 0.118 in} W 6 U 1 1 1 W A B 0 1 -1 1 -4...
  • Page 447 COOLING SYSTEM 01-12 COOLING SYSTEM THERMOSTAT COOLING SYSTEM SERVICE REMOVAL/INSTALLATION....0 1 -1 2 -5 W A R N IN G S ..........01-12-1 ....0 1 -1 2 -5 ENGINE COOLANT LEVEL IN SPEC TIO N ..........01-12-1 THERMOSTAT INSPECTIO N....0 1 -1 2 -6 ENGINE COOLANT REPLACEMENT .
  • Page 448 COOLING SYSTEM ENGINE COOLANT REPLACEMENT Caution • The engine has aluminum parts that can be damaged by alcohol or methanol antifreeze. Do not use alcohol or methanol Antifreeze solution mixture percentage in the cooling system. Use only Volume ethylene-glycol-based coolant. Gravity percentage Coolant protection...
  • Page 449 COOLING SYSTEM ENGINE COOLANT LEAKAGE INSPECTION W 6 U 1 1 2 W 0 4 Caution • Applying more than 123 kPa {1.25 kgf/cm2, 17.8 psi} can damage the hoses, fittings, and other components, and cause leaks. Pressure 123 kPa {1.25 kgf/cm2, 17.8 psi} W 6 U 1 1 2 W A 2 RADIATOR CAP INSPECTION W 6 U 1 1 2 W 0 5...
  • Page 450 COOLING SYSTEM RADIATOR REMOVAL/INSTALLATION W 6 U 1 1 2 W 0 6 Cooling Fan Component Installation Note W 6 U 1 1 2 W A 4 W 6 U 1 1 2 W A 5 0 1 -1 2 -4...
  • Page 451 COOLING SYSTEM THERMOSTAT REMOVAL/INSTALLATION W 6 U 1 1 2 W 0 7 Thermostat Installation Note W 6 U 1 1 2 W A L W 6 U 1 1 2 W A 7 W 6 U 1 1 2 W A 9 0 1 -1 2 -5...
  • Page 452 COOLING SYSTEM THERMOSTAT INSPECTION W 6 U 1 1 2 W 0 8 W 6 U 1 1 2 W A H WATER PUMP REMOVAL/INSTALLATION W 6 U 1 1 2 W A A 0 1 -1 2 -6...
  • Page 453 COOLING SYSTEM COOLING FAN MOTOR INSPECTION W 6 U 1 1 2 W 1 0 W 6 U 1 1 2 W A C COOLING FAN MOTOR REMOVAL/INSTALLATION W 6 U 1 1 2 W 1 1 W 6 U 1 1 2 W A D 0 1 -1 2 -7...
  • Page 454 COOLING SYSTEM COOLING FAN RELAY INSPECTION W 6 U 1 1 2 W 1 2 W 6 U 1 1 2 W A E W 6 U 1 1 2 W A K 0 1 -1 2 -8...
  • Page 455 INTAKE-AIR SYSTEM [FS] 01-13A INTAKE-AIR SYSTEM [FS] VACUUM HOSE ROUTING ACCELERATOR PEDAL DIAGRAM [ F S ] ........0 1 -1 3A-1 REMOVAL/INSTALLATION [F S ] 0 1 -1 3A -3 INTAKE-AIR SYSTEM . . . 0 1 -1 3A -3 REMOVAMNSTALLATION [F S ] 0 1 -1 3A -2 ACCELERATOR CABLE...
  • Page 456 INTAKE-AIR SYSTEM [FS] INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [FS] W 6 U 1 1 3 W 0 2 Warning • When the engine and intake-air system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing or installing the intake-air system. 0 1 -1 3 A -2...
  • Page 457 INTAKE-AIR SYSTEM [FS] Intake Manifold installation Note Intake Manifold Removal Note Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage.
  • Page 458 INTAKE-AIR SYSTEM [FS] ACCELERATOR CABLE INSPECTION/ADJUSTMENT [FS1 W 6 U 1 1 3 W 0 5 Note Note Free play 1.5— 4.0 mm {0.06— 0.15 in} W 6 U 1 1 3 W A 6 0 1 -1 3 A -4...
  • Page 459 INTAKE-AIR SYSTEM [KL] 01-13B INTAKE-AIR SYSTEM [KL] VACUUM HOSE ROUTING VARIABLE RESONANCE INDUCTION DIAGRAM [K L ] ........0 1 -1 3B-1 SYSTEM (VRIS) SHUTTER VALVE ACTUATOR No.2 INSPECTION [KL] .. 0 1 -1 3B -4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [KL] ..0 1 -1 3B -2 VARIABLE RESONANCE INDUCTION SYSTEM (VRIS) CHECK VALVE 0 1 -1 3B -3...
  • Page 460 INTAKE-AIR SYSTEM [KL] INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [KL] W 6 U 1 1 3 W 5 2 Warning • When the engine and intake-air system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing or installing the intake-air system. 0 1 -1 3 B -2...
  • Page 461 INTAKE-AIR SYSTEM [KL] Intake Manifold Removal Note Intake Manifold Installation Note Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage.
  • Page 462 INTAKE-AIR SYSTEM [KL] VARIABLE RESONANCE INDUCTION SYSTEM (VRIS) SHUTTER VALVE ACTUATOR No.1 INSPECTION [KL] W 6 U 1 1 3 W 5 4 Vacuum kPa {mmHg, inHg} Rod movement Note VARIABLE RESONANCE INDUCTION SYSTEM (VRIS) SHUTTER VALVE ACTUATOR No.2 INSPECTION [KL] W 6 U 1 1 3 W 5 5 Vacuum kPa {mmHg, inHg} Rod movement...
  • Page 463 INTAKE-AIR SYSTEM [KL] VARIABLE RESONANCE INDUCTION SYSTEM (VRIS) SOLENOID VALVE No.1 No.2 INSPECTION [KL] W 6 U 1 1 3 W 5 8 Port Terminal Step W 6 U 1 1 3 W B 9 ACCELERATOR PEDAL REMOVAL/INSTALLATION [KL] W 6 U 1 1 3 W 5 9 Accelerator Cable installation Note W 6 U 1 1 3 W C 1 0 1 -1 3 B -5...
  • Page 464 INTAKE-AIR SYSTEM [KL] ACCELERATOR CABLE INSPECTION/ADJUSTMENT [KL] W 6 U 1 1 3 W 6 0 Note Note Free play 1.5—4.0 mm {0.06— 0.15 in} W 6 U 1 1 3 W C 2 0 1 -1 3 B -6...
  • Page 465 FUEL SYSTEM 01-14 FUEL SYSTEM FUEL INJECTOR BEFORE REPAIR PROCEDURE .... 01-14-1 REMOVAL/INSTALLATION [F S ] 0 1 -1 4 -9 AFTER REPAIR P R O C E D U R E ....01-14-1 ....0 1 -1 4 -1 0 FUEL INJECTOR REMOVAL/INSTALLATION [KL] ..
  • Page 466 FUEL SYSTEM TZZZZZZZZZSOlZ Ì W 6 U 1 1 4 W A 1 Caution • Connecting the wrong fuel pump relay socket terminals may possibly cause a malfunction. Carefully connect the specified terminals only. W 6 U 1 1 4 W A 2 more than 45°...
  • Page 467 FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION W 6 U 1 1 4 W 0 3 Warning • Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it. 0 1 -1 4 -3...
  • Page 468 FUEL SYSTEM Fuel Drawing Note Note Specification W 6 U 1 1 4 W A 8 Outer diameter: 13 mm {0.51 in} Length: 2160 mm {85.0 in} or longer W 6 U 1 1 4 W A 9 Joint Hose Installation Note Caution over 35 mm {1.38 •...
  • Page 469 FUEL SYSTEM Fuel Pipe Assembly Note W 6 U 1 1 4 W A C Nonreturn Valve Installation Note W 6 U 1 1 4 W A B Note W 6 U 1 1 4 W A 7 FUEL TANK INSPECTION +0.98 kPa {+7.4 mmHg, +0.29 inHg} SST.
  • Page 470 FUEL SYSTEM +0.98 kPa {+7.4 mmHg, +0.29 inHg} W 6 U 1 1 4 W B 6 +0.98 kPa {+7.4 mmHg, +0.29 inHg} +0.98 kPa {+7.4 mmHg, +0.29 inHg} FUEL SHUT-OFF VALVE INSPECTION Note NONRETURN VALVE INSPECTION W 6 U 1 1 4 W 0 4 W 6 U 1 1 4 W B 7 W 6 U 1 1 4 W B 8 0 1 -1 4 -6...
  • Page 471 FUEL SYSTEM FUEL PUMP REMOVAL/INSTALLATION W 6 U 1 1 4 W 0 5 • Fuel Pipe Disassembly/Assembly Note FUEL PUMP INSPECTION W 6 U 1 1 4 W 0 6 Fuel Pump Continuity Fuel Pump Maximum Pressure Inspection Warning •...
  • Page 472 FUEL SYSTEM Fuel Line Hold Pressure Inspection Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped. W 6 U 1 1 4 W Q ! Caution •...
  • Page 473 FUEL SYSTEM Caution Caution • Connecting the wrong fuel pump relay • Before connecting the negative battery socket terminals may possibly cause a cable be sure all fuel connections, clamps malfunction. Carefully connect the and fittings are secure. Fuel pump will operate at full pressure anytime the cable specified terminals only.
  • Page 474 FUEL SYSTEM Fuel Injector Installation Note W 6 U 1 1 4 W A N W 6 U 1 1 4 W A P FUEL INJECTOR REMOVAL/INSTALLATION [KL] 0 1 -1 4 -1 0...
  • Page 475 FUEL SYSTEM Fuel Distributor Installation Note Fuel Injector Installation Note FUEL INJECTOR INSPECTION On-vehicle Note W 6 U 1 1 4 W N R Fuel Injector Resistance Inspection [FS] 0 1 -14 -11...
  • Page 476 FUEL SYSTEM W 6 U 1 1 4 W A M Resistance 12— 16 Q (at 20 ‘ C {68 °F}) Fuel Injector Resistance Inspection [KL] W 6 U 1 1 4 W A R W 6 U 1 1 4 W Q 3 W 6 U 1 1 4 W N M Caution •...
  • Page 477 FUEL SYSTEM cable makes contact, it is sure to arc and create a danger of ignition or explosion. approx. degrees W 6 U 1 1 4 W N S W 6 U 1 1 4 W A T Fuel leakage Less than 1 drop/2 minutes Caution •...
  • Page 478 FUEL SYSTEM Fuel leakage Less than 1 drop/2 min. Volume Test [FS] Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped.
  • Page 479 FUEL SYSTEM W 6 U 1 1 4 W Q 7 C a u tio n • B efo re c o n n e c tin g th e n e g a tiv e b a tte ry C au tio n c a b le be s u re all fu e l c o n n e c tio n s , c la m p s •...
  • Page 480 FUEL SYSTEM PRESSURE REGULATOR REMOVAL/INSTALLATION W 6 U 1 I 4 W 1 2 W6U114WQ0 W6U114WAW PRESSURE REGULATOR INSPECTION W 6U114W 13 Fuel line pressure 210—260 kPa {2.1— 2.7 kgf/cm2, 30— 38 psi> 210—250 kPa {2.1— 2.6 kgf/cm2, 30— 36 psi} W6U114WAY W6U114WAX w 6 u m w N X...
  • Page 481 FUEL SYSTEM PRC SOLENOID VALVE REMOVAL/INSTALLATION W 6 U U 4 W 0 N W 6 U 1 1 4 W N Y W 6 U 1 1 4 W B 9 PRC SOLENOID VALVE INSPECTION W 6 U 1 1 4 W 1 S W 6 U 1 1 4 W B 0 W 6 U 1 1 4 W A Z FUEL PUMP RELAY INSPECTION...
  • Page 482 EXHAUST SYSTEM 01-15 EXHAUST SYSTEM EXHAUST SYSTEM IN S P E C T IO N 01-15-1 EXHAUST SYSTEM EXHAUST SYSTEM REMOVAL/INSTALLATION [KL] 0 1 -1 5 -2 REMOVAL/INSTALLATION [F S ] 01-15-1 EXHAUST SYSTEM INSPECTION W 6 U 1 1 5 W 0 1 EXHAUST SYSTEM REMOVAL/INSTALLATION [FS] W 6 U 1 1 5 W 0 2 Warning...
  • Page 483 EXHAUST SYSTEM EXHAUST SYSTEM REMOVAL/INSTALLATION [KL] W 6 U 1 1 5 W 5 2 Warning • When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing or installing the exhaust system. 0 1 -1 5 -2...
  • Page 484 EMISSION SYSTEM 01-16 EMISSION SYSTEM EMISSION SYSTEM (ENGINE CATCH TANK INSPECTION ....0 1 -1 6 -6 COMPARTMENT SIDE) COMPONENT ROLLOVER VALVE INSPECTION ..0 1 -1 6 -6 LOCATION [FS] ........01-16-1 PURGE SOLENOID VALVE EMISSION SYSTEM (ENGINE INSPECTION..........0 1 -1 6 -6 COMPARTMENT SIDE) COMPONENT EGR VALVE REMOVAL/INSTALLATION LOCATION [ K L ] ........
  • Page 485 EMISSION SYSTEM EMISSION SYSTEM (ENGINE COMPARTMENT SIDE) COMPONENT LOCATION [KL] W 6 U 1 1 6 W 0 A W 6 U 1 1 6 W N 0 0 1 -1 6 -2...
  • Page 486 EMISSION SYSTEM EMISSION SYSTEM (FUEL TANK SIDE) COMPONENT REMOVAL/INSTALLATION W 6 U 1 1 6 W 0 2 W 6 U 1 1 6 W A 1 EVAPORATIVE GAS CHECK VALVE (TWO-WAY) INSPECTION W 6 U 1 1 6 W 0 3 SST.
  • Page 487 EMISSION SYSTEM AIR FILTER INSPECTION W 6 U 1 1 6 W 0 4 PRESSURE CONTROL VALVE INSPECTION W 6 U 1 1 6 W 0 5 SST. W 6 U 1 1 6 W A 4 +0.98 kPa {+7.4 mmHg, +0.29 inHg} +0.98 kPa {+7.4 mmHg, +0.29 inHg} W 6 U 1 1 6 W A 5 +0.98 kPa {+7.4 mmHg, +0.29 inHg}...
  • Page 488 EMISSION SYSTEM +0.98 kPa {+7.4 mmHg, +0.29 inHg} Note W 6 U 1 1 6 W A 8 CHARCOAL CANISTER INSPECTION W 6 U 1 1 6 W 0 6 W 6 U 1 1 6 W A 9 CANISTER DRAIN CUT VALVE (CDCV) INSPECTION W 6 U 1 1 6 W 0 7 W 6 U 1 1 6 W A A &...
  • Page 489 EMISSION SYSTEM CATCH TANK INSPECTION ROLLOVER VALVE INSPECTION Note PURGE SOLENOID VALVE INSPECTION EGR VALVE REMOVAL/INSTALLATION [FS] W 6 U 1 1 6 W 1 0 0 1 -1 6 -6...
  • Page 490 EMISSION SYSTEM EGR VALVE REMOVAL/INSTALLATION [KL] Warning • Do not remove the EGR valve with the engine hot. Engine coolant in the EGR valve may badly burn or injure. Always remove and install the EGR valve when the engine is cold. Engine Coolant Hose Removal Note W 6 U 1 1 6 W N F EGR VALVE INSPECTION...
  • Page 491 EMISSION SYSTEM EGR BOOST SOLENOID VALVE INSPECTION W 6 U 1 1 6 W 1 2 Terminal Port Step i r j W 6 U 1 1 6 W A K PCV VALVE INSPECTION W 6 U 1 1 6 W 1 3 Specification Condition Airflow...
  • Page 492 CHARGING SYSTEM 01-17 CHARGING SYSTEM BATTERY REMOVAUINSTALLATION . 01-17-1 GENERATOR REMOVAL/INSTALLATION 0 1 -1 7 -3 BATTERY IN S P E C T IO N ......01-17-1 .. 0 1 -1 7 -3 Battery .............01-17-1 GENERATOR INSPECTIO N......0 1 -1 7 -4 Dark Current ...........
  • Page 493 CHARGING SYSTEM Dark Current Dark current 20 mA max. Caution • Operating electrical loads while measuring the dark current can damage the circuit tester. BATTERY RECHARGING Warning • Hydrogen gas is produced during normal battery operation. A battery-related explosion can cause serious injury. Keep all flames (including cigarettes), heat, and sparks away from the top and surrounding area of open battery cells.
  • Page 494 CHARGING SYSTEM GENERATOR REMOVAL/INSTALLATION W 6 U 1 1 7 W 0 4 Warning • When the battery cables are connected, touching the vehicle body with generator terminal B will generate sparks. This can cause personal injury, fire, and damage to the electrical components.
  • Page 495 CHARGING SYSTEM GENERATOR INSPECTION W 6 U 1 1 7 W 0 5 Generator Warning Light Standard voltage Ignition switch ON Idle (V) [20 "C {68 ”F}] Terminal 14.1— 14.7 13.2— 13.8 14.1— 14.7 Current H s I I L I) W 6 U 1 1 7 W A 4 Generator Voltage...
  • Page 496 IGNITION SYSTEM 01-18 IGNITION SYSTEM 0 1 -1 8 -2 IGNITION COIL HIGH-TENSION LEAD REMOVAL/INSTALLATION ....01-18-1 IGNITION COIL IN S P E C T IO N ....01-18-1 REMOVAL/INSTALLATION....0 1 -1 8 -3 01-18-1 SPARK PLUG INSPECTION [K L ] 0 1 -1 8 -3 0 1 -1 8 -2 IGNITION COIL REMOVAL/INSTALLATION...
  • Page 497 IGNITION SYSTEM Insulation Resistance of Case Specification Above 10 Mft W 6 U 1 1 8 W A 3 Secondary Coil Winding Specification 11.5— 15.5 ki2 [20 'C {68 °F}] W 6 U 1 1 8 W A 6 W 6 U 1 1 8 W A 4 W 6 U 1 1 8 W A 5 0 1 -1 8 -2...
  • Page 498 IGNITION SYSTEM HIGH-TENSION LEAD REMOVAL/INSTALLATION W 6 U 1 1 8 W 0 3 Caution • The high-tension leads must be reinstalled to their original positions. Incorrect installation can damage the leads and cause power loss, and negatively effect the electronic components. SPARK PLUG INSPECTION [KL] W 6 U 1 1 8 W 0 4 Caution...
  • Page 499 STARTING SYSTEM 01-19 STARTING SYSTEM STARTER REMOVAL/INSTALLATION . 01-19-1 0 1 -1 9 -2 0 1 -1 9 -2 STARTER INTERLOCK SWITCH STARTER IN S P E C T IO N ......0 1 -1 9 -2 INSPECTION (M T X )........0 1 -1 9 -2 0 1 -1 9 -2 STARTER REMOVAL/INSTALLATION W 6 U 1 1 9 W 0 1...
  • Page 500 STARTING SYSTEM Starter Installation Note (FS) STARTER INSPECTION W 6 U 1 1 9 W 0 2 On-vehicle Inspection Specification Above 8 V W 6 U 1 1 9 W A 4 Specification No Load Test STARTER INTERLOCK SWITCH INSPECTION (MTX) W 6 U 1 1 9 W 0 3 W 6 U 1 1 9 W A 6 0 1 -1 9 -2...
  • Page 501 STARTING SYSTEM 0 1 -1 9 -3...
  • Page 502 CRUISE CONTROL SYSTEM 01-20 CRUISE CONTROL SYSTEM CRUISE ACTUATOR ACTUATOR CABLE 01 20-1 REMOVAL/INSTALLATION REMOVAL/INSTALLATION.... 0 1 -2 0 -3 20-1 CRUISE CONTROL SWITCH 20-2 CRUISE ACTUATOR INSPECTION . REMOVAL/INSTALLATION 0 1 -2 0 -4 20-2 CRUISE CONTROL SWITCH 0 1 -2 0 -3 INSPECTIO N......
  • Page 503 CRUISE CONTROL SYSTEM CRUISE ACTUATOR INSPECTION W 6 U 1 2 0 W 0 2 Terminal Voltage List (Reference) W 6 U 1 2 0 W A 4 Voltage (V)/ Terminal Signal Connection Test condition Inspection area Continuity 0 1 -2 0 -2...
  • Page 504 CRUISE CONTROL SYSTEM ACTUATOR CABLE ADJUSTMENT W 6 U 1 2 0 W 0 3 approximately 3 mm {0.12 in) W 6 U 1 2 0 W A 6 W 6 U 1 2 0 W A 5 ACTUATOR CABLE REMOVAL/INSTALLATION W 6 U 1 2 0 W 0 4 W 6 U 1 2 0 W A 9 W 6 U 1 2 0 W A 7...
  • Page 505 CRUISE CONTROL SYSTEM CRUISE CONTROL SWITCH REMOVAL/INSTALLATION W 6 U 1 2 0 W 0 5 CRUISE CONTROL SWITCH INSPECTION W 6 U 1 2 0 W 0 6 C O N T R O L S W IT C H M A IN S W IT C H i R E S U M E /A C C E L ~ j C R U IS E...
  • Page 506 CONTROL SYSTEM [FS] 01-40A CONTROL SYSTEM [FS] CONTROL SYSTEM COMPONENT LOCATION [FS] ........01-40A -2 POWERTRAIN CONTROL MODULE (PCM) REMOVAL/INSTALLATION [F S ] 01-40A -3 ....... 01-40A -3 POWERTRAIN CONTROL MODULE (PCM) INSPECTION [FS] ........01-40A -3 01-40A -3 ....01-40A -9 MASS AIR FLOW SENSOR INSPECTION [FS] ............01-40A -15 (104...
  • Page 507 CONTROL SYSTEM [FS] W 6 U 1 4 0 W 0 1 0 1 -4 0 A -2...
  • Page 508 CONTROL SYSTEM [FS] POWERTRAIN CONTROL MODULE (PCM) REMOVAL/INSTALLATION [FS] W 6 U 1 4 0 W 0 2 Caution • PCM is sensitive to static electrical charges. If exposed to these charges, damage may result, if service of PCM is required, use the following safeguards to avoid damage to components.
  • Page 509 CONTROL SYSTEM [FS] T e rm in a l v o lta g e (R e fe re n c e ) Terminal Signal Connect to Test condition Voltage (V) Possible malfunction 0 1 -4 0 A -4...
  • Page 510 CONTROL SYSTEM [FS] Terminal Signal Connect to Test condition Voltage (V) Possible malfunction O/D OFF switch O/D OFF switch 0 1 -4 0 A -5...
  • Page 511 CONTROL SYSTEM [FS] Test condition Voltage (V) Possible malfunction Connect to 0 1 -4 0 A -6...
  • Page 512 CONTROL SYSTEM [FS] Terminal Signal Connect to Test condition Voltage (V) Possible malfunction — 0 1 -4 0 A -7...
  • Page 513 CONTROL SYSTEM [FS] Terminal Signal Connect to Test condition Possible malfunction 0 1 -4 0 A -8...
  • Page 514 CONTROL SYSTEM [FS] Terminal Signal Connect to Test condition Voltage (V) Possible malfunction Using the SST (NGS Tester) SSTs W 6 U 1 4 0 W A 3 Note [F S ].) 0 1 -4 0 A -9...
  • Page 515 CONTROL SYSTEM [FS] PID/DATA MONITOR item table Note 0 1 -4 0 A -1 0...
  • Page 516 CONTROL SYSTEM [FS] Application Monitor item Full name Unit/Condition 01-40A -11...
  • Page 517 CONTROL SYSTEM [FS] Application Monitor item Full name Unit/Condition PID/DATA MONITOR table (Reference) Reference Value/Condition Monitor item 01- 4 0 A -1 2...