<SUPPLEMENT-II>
ENGINE CONTROL SYSTEM
SECTION EC
EC
CONTENTS
ENGINE AND EMISSION CONTROL OVERALL Wiring Diagram ................................................ 2025
SYSTEM............................................................... 2003 DTC 0707 P7zF/INJ TIMG FB.............................. 2026
Circuit Diagram ................................................ 2003 Wiring Diagram ................................................ 2026
TROUBLE DIAGNOSIS FOR POWER DTC 0807 ECM 14............................................... 2027
SUPPLY ............................................................... 2004 Wiring Diagram ................................................ 2027
Main Power Supply and Ground Circuit .......... 2004 DTC 0902 ECM RLY ........................................... 2028
DTC 0102 MASS AIR FLOW SEN...................... 2006 Wiring Diagram ................................................ 2028
Wiring Diagram ................................................ 2006 DTC 0905 TURBO PRESSURE .......................... 2029
DTC 0103 COOLANT TEMP SEN ...................... 2007 Wiring Diagram ................................................ 2029
Wiring Diagram ................................................ 2007 DTC 1003 EGR VOLUME CONT/V..................... 2030
DTC 0104 VEHICLE SPEED SEN ...................... 2008 Wiring Diagram ................................................ 2030
Wiring Diagram ................................................ 2008 DTC 1004 FUEL CUT SYSTEM1........................ 2031
DTC 0203 ACCEL POS SW (F/C) ...................... 2009 Wiring Diagram ................................................ 2031
Wiring Diagram ................................................ 2009 GLOW CONTROL SYSTEM ............................... 2032
DTC 0208 OVER HEAT....................................... 2010 Wiring Diagram ................................................ 2032
Wiring Diagram ................................................ 2010 START SIGNAL................................................... 2033
Diagnostic Procedure....................................... 2011 Wiring Diagram ................................................ 2033
Component Inspection ..................................... 2016 PARK/NEUTRAL POSITION (PNP) SWITCH .... 2034
Main 12 Causes of Overheating...................... 2017 Wiring Diagram ................................................ 2034
DTC 0402 P9zFUEL TEMP SEN ......................... 2018 HEAT UP SWITCH .............................................. 2035
Wiring Diagram ................................................ 2018 Wiring Diagram ................................................ 2035
DTC 0403 ACCEL POS SENSOR ...................... 2019 SWIRL CONTROL VALVE CONTROL
Wiring Diagram ................................................ 2019 SOLENOID VALVE.............................................. 2036
DTC 0504 A/T COMM LINE ................................ 2021 Wiring Diagram ................................................ 2036
Wiring Diagram ................................................ 2021 INTAKE AIR CONTROL VALVE CONTROL
DTC 0701 P1zCAM POS SEN ............................. 2022 SOLENOID VALVE.............................................. 2037
Wiring Diagram ................................................ 2022 Wiring Diagram ................................................ 2037
DTC 0702 P2zTDC PULSE SIG........................... 2023 AIR CONDITIONER CONTROL .......................... 2038
Wiring Diagram ................................................ 2023 Wiring Diagram ................................................ 2038
DTC 0703 P3zPUMP COMM LINE ...................... 2024 MI (MIL) & DATA LINK CONNECTORS ............ 2039
Wiring Diagram ................................................ 2024 Wiring Diagram ................................................ 2039
DTC 0704 P4zSPILL/V CIRC, DTC 0706
P6zSPILL VALVE ................................................. 2025
When you read wiring diagrams:
+ Read GI section, “HOW TO READ WIRING DIAGRAMS”.
+ See EL section, “POWER SUPPLY ROUTING” for power distribution circuit.
When you perform trouble diagnoses, read GI section, “HOW TO FOLLOW FLOW CHART IN
TROUBLE DIAGNOSES” and “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL
INCIDENT”.
EC-2002
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
Circuit Diagram
SMA for models without fuel filter switch
TEC095M
EC-2003
TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
WIRING DIAGRAM
TEC181M
EC-2004
TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
(Cont’d)
TEC097M
EC-2005
DTC 0102 MASS AIR FLOW SEN
Wiring Diagram
TEC182M
EC-2006
DTC 0103 COOLANT TEMP SEN
Wiring Diagram
TEC183M
EC-2007
DTC 0104 VEHICLE SPEED SEN
Wiring Diagram
TEC184M
EC-2008
DTC 0203 ACCEL POS SW (F/C)
Wiring Diagram
TEC185M
EC-2009
DTC 0208 OVER HEAT
Wiring Diagram
TEC186M
EC-2010
DTC 0208 OVER HEAT
Diagnostic Procedure
1 INSPECTION START
Do you have CONSULT-II?
Yes or No
Yes c GO TO 2.
No c GO TO 3.
2 CHECK COOLING FAN OPERATION
With CONSULT-II
1. Turn ignition switch “ON”.
2. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II.
SEF646X
3. Make sure that cooling fan-1 operates.
OK or NG
OK c GO TO 12.
NG c GO TO 4.
3 CHECK COOLING FAN OPERATION
Without CONSULT-II
1. Turn ignition switch “OFF”.
2. Disconnect engine coolant temperature sensor harness connector.
3. Connect 150Ω resistor to engine coolant temperature sensor harness connector.
4. Restart engine and make sure that cooling fan operates.
MEC475B
OK or NG
OK c GO TO 12.
NG c GO TO 4.
EC-2011
DTC 0208 OVER HEAT
Diagnostic Procedure (Cont’d)
4 CHECK COOLING FAN POWER SUPPLY CIRCUIT
1. Turn ignition switch “OFF”.
2. Disconnect cooling fan relay-1.
SEF690V
3. Turn ignition switch “ON”.
4. Check voltage between cooling fan relay-1 terminals 1, 5 and ground with CONSULT-II or tester.
SEF607X
OK or NG
OK c GO TO 6.
NG c GO TO 5.
5 DETECT MALFUNCTIONING PART
Check the following.
+ Fuse block (J/B) connector E112
+ 10A fuse or 20A fuse
+ 30A fusible links
+ Harness for open or short between cooling fan relay-1 and fuse
+ Harness for open or short between cooling fan relay-1 and battery
c Repair open circuit or short to ground or short to power in harness or connectors.
EC-2012
DTC 0208 OVER HEAT
Diagnostic Procedure (Cont’d)
6 CHECK COOLING FAN GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch “OFF”.
2. Disconnect cooling fan motor-1 harness connector.
SEF691V
3. Check harness continuity between cooling fan relay-1 terminal 3 and cooling fan motor-1 terminals 1, 3, cooling fan motor-1 ter-
minals 2, 4 and body ground. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK c GO TO 7.
NG c Repair open circuit or short to ground or short to power in harness or connectors.
7 CHECK COOLING FAN OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminal 14 and cooling fan relay-1 terminal 1. Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK c GO TO 9.
NG c GO TO 8.
8 DETECT MALFUNCTIONING PART
Check the following.
+ Harness connectors E127, M21
+ Harness connectors M52, F7
+ Harness for open or short between cooling fan relay-1 and ECM
c Repair open circuit or short to ground or short to power in harness or connectors.
9 CHECK COOLING FAN RELAY-1
Refer to “Component Inspection”, EC-2016.
OK or NG
OK c GO TO 10.
NG c Replace cooling fan relay.
EC-2013
DTC 0208 OVER HEAT
Diagnostic Procedure (Cont’d)
10 CHECK COOLING FAN MOTOR-1
Supply battery voltage between the following terminals and check operation.
SEF292Z
OK or NG
OK c GO TO 11.
NG c Replace cooling fan motor.
11 CHECK INTERMITTENT INCIDENT
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END
12 CHECK COOLING SYSTEM FOR LEAK
Apply pressure to the cooling system with a tester, and check if the pressure drops.
Testing pressure: 157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
CAUTION:
Higher than the specified pressure may cause radiator damage.
SLC754A
Pressure should not drop.
OK or NG
OK c GO TO 14.
NG c GO TO 13.
13 DETECT MALFUNCTIONING PART
Check the following for leak.
+ Hose
+ Radiator
+ Water pump (Refer to LC section, “Water Pump”.)
c Repair or replace.
EC-2014
DTC 0208 OVER HEAT
Diagnostic Procedure (Cont’d)
14 CHECK RADIATOR CAP
Apply pressure to cap with a tester and check radiator cap relief pressure.
SLC755A
Radiator cap relief pressure:
79 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi)
OK or NG
OK c GO TO 15.
NG c Replace radiator cap.
15 CHECK THERMOSTAT
1. Remove thermostat.
2. Check valve seating condition at normal room temperatures.
It should seat tightly.
3. Check valve opening temperature and valve lift.
SLC343
Valve opening temperature:
82°C (180°F) [standard] (Models for cold areas)
76.5°C (170°F) [standard] (Models for except cold areas)
Valve lift:
More than 10 mm/95°C (0.394 in/203°F)
4. Check if valve is closed at 5°C (9°F) below valve opening temperature. For details, refer to LC section, “Thermostat”.
OK or NG
OK c GO TO 16.
NG c Replace thermostat.
EC-2015
DTC 0208 OVER HEAT
Diagnostic Procedure (Cont’d)
16 CHECK ENGINE COOLANT TEMPERATURE SENSOR
1. Remove engine coolant temperature sensor.
2. Check resistance between engine coolant temperature sensor terminals 1 and 2 as shown in the figure.
SEF304X
OK or NG
OK c GO TO 17.
NG c Replace engine coolant temperature sensor.
17 CHECK MAIN 12 CAUSES
If the cause cannot be isolated, go to “MAIN 12 CAUSES OF OVERHEATING”, EC-2017.
c INSPECTION END
Component Inspection
FUEL PUMP RELAY
Check continuity between terminals 3 and 5.
Conditions Continuity
12V direct current supply between
Yes
terminals 1 and 2
No current supply No
If NG, replace relay.
SEF145X
EC-2016
DTC 0208 OVER HEAT
Main 12 Causes of Overheating
Engine Step Inspection item Equipment Standard Reference page
OFF 1 + Blocked radiator + Visual No blocking —
+ Blocked condenser
+ Blocked radiator grille
+ Blocked bumper
2 + Coolant mixture + Coolant tester 30 - 50% coolant mixture See “RECOMMENDED
FLUIDS AND LUBRI-
CANTS” in MA section.
3 + Coolant level + Visual Coolant up to MAX level See “Changing Engine
in reservoir tank and Coolant”, “ENGINE MAIN-
radiator filler neck TENANCE” in MA sec-
tion.
4 + Radiator cap + Pressure tester 78 - 98 kPa See “System Check”,
(0.78 - 0.98 bar, 0.8 - 1.0 “ENGINE COOLING SYS-
kg/cm2, 11 - 14 psi) TEM” in LC section.
59 - 98 kPa (0.59 - 0.98
bar, 0.6 - 1.0 kg/cm2,
9 - 14 psi) (Limit)
ON*2 5 + Coolant leaks + Visual No leaks See “System Check”,
“ENGINE COOLING SYS-
TEM” in LC section.
ON*2 6 + Thermostat + Touch the upper and Both hoses should be hot. See “Thermostat” and
lower radiator hoses “Radiator”, “ENGINE
COOLING SYSTEM” in
LC section.
ON*1 7 + Cooling fan + Visual Operating See “DTC 0208 OVER
HEAT”.
OFF 8 + Combustion gas leak + Color checker chemical Negative —
tester 4 gas analyzer
ON*3 9 + Coolant temperature + Visual Gauge less than 3/4 —
gauge when driving
+ Coolant overflow to res- + Visual No overflow during driving See “Changing Engine
ervoir tank and idling Coolant”, “ENGINE MAIN-
TENANCE” in MA sec-
tion.
OFF*4 10 + Coolant return from res- + Visual Should be initial level in See “ENGINE MAINTE-
ervoir tank to radiator reservoir tank NANCE” in MA section.
OFF 11 + Cylinder head + Straight gauge feeler 0.1 mm (0.004 in) Maxi- See “Inspection”, “CYLIN-
gauge mum distortion (warping) DER HEAD” in EM sec-
tion.
12 + Cylinder block and pis- + Visual No scuffing on cylinder See “Inspection”, “CYLIN-
tons walls or piston DER BLOCK” in EM sec-
tion.
*1: Engine running at idle.
*2: Engine running at 3,000 rpm for 10 minutes.
*3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes.
*4: After 60 minutes of cool down time.
For more information, refer to “OVERHEATING CAUSE ANALYSIS” in LC section.
EC-2017
DTC 0402 P9zFUEL TEMP SEN
Wiring Diagram
TEC187M
EC-2018
DTC 0403 ACCEL POS SENSOR
Wiring Diagram
TEC188M
EC-2019
DTC 0403 ACCEL POS SENSOR
Wiring Diagram (Cont’d)
TEC189M
EC-2020
DTC 0504 A/T COMM LINE
Wiring Diagram
TEC190M
EC-2021
DTC 0701 P1zCAM POS SEN
Wiring Diagram
TEC187M
EC-2022
DTC 0702 P2zTDC PULSE SIG
Wiring Diagram
TEC187M
EC-2023
DTC 0703 P3zPUMP COMM LINE
Wiring Diagram
TEC187M
EC-2024
DTC 0704 P4zSPILL/V CIRC, DTC 0706 P6zSPILL VALVE
Wiring Diagram
TEC187M
EC-2025
DTC 0707 P7zF/INJ TIMG FB
Wiring Diagram
TEC187M
EC-2026
DTC 0807 ECM 14
Wiring Diagram
TEC191M
EC-2027
DTC 0902 ECM RLY
Wiring Diagram
TEC451
EC-2028
DTC 0905 TURBO PRESSURE
Wiring Diagram
TEC193M
EC-2029
DTC 1003 EGR VOLUME CONT/V
Wiring Diagram
TEC194M
EC-2030
DTC 1004 FUEL CUT SYSTEM1
Wiring Diagram
TEC187M
EC-2031
GLOW CONTROL SYSTEM
Wiring Diagram
TEC195M
EC-2032
START SIGNAL
Wiring Diagram
TEC196M
EC-2033
PARK/NEUTRAL POSITION (PNP) SWITCH
Wiring Diagram
TEC197M
EC-2034
HEAT UP SWITCH
Wiring Diagram
TEC198M
EC-2035
SWIRL CONTROL VALVE CONTROL SOLENOID VALVE
Wiring Diagram
TEC199M
EC-2036
INTAKE AIR CONTROL VALVE CONTROL SOLENOID VALVE
Wiring Diagram
TEC200M
EC-2037
AIR CONDITIONER CONTROL
Wiring Diagram
TEC201M
EC-2038
MI (MIL) & DATA LINK CONNECTORS
SMA for models without
Wiring Diagram fuel filter switch
TEC202M
EC-2039
MI (MIL) & DATA LINK CONNECTORS
EC-2040
