ENGINE LUBRICATION

SECTION Lu
CONTENTS
OIL PUMP ........................................................... LU-2 Disassembly and Assembly ............................LU-2
Component Parts Location ............................LU-2 Inspection ........................................................LU-3
 OIL PUMP

(1) Component Parts Location

Outer rotor

rn Inner rotor
\ \

Oil pump housing (front cover)

-8 Regulator spring
rn : Engine oil g
: Not reusable Regulator plug
: N-rn {kgf-rn) (n) 39 - 69(4.0 - 7.01
LUMOOOI

CAUTION:
Apply new engine oil to the parts marked in the figure prior
to installation.

(2) Disassembly and Assembly

1. PREPARATION
Front cover (Refer to "TIMING CHAIN" in EM section.)
NOTE:
Oil pump is integrated in front cover.

2. INSTALLATION OF INNER ROTOR AND OUTER

ROTOR
Install inner rotor with its mark facing rearward (cover side).
Install outer rotor with its mark facing frontward (housing side).

\
Oil pump cover
LUM0002
 OIL PUMP

(3) Inspection
1. OIL PUMP COMPONENTS INSPECTION
Measure each clearance using a feeler gauge.
Outer rotor to housing clearance (1 in the figure)
Standard:
- -
0.114 0.260 mm (0.0045 0.0102 in)
Outer rotor to inner rotor tip clearance (2 in the figure)
Standard:
0.180 mm (0.0071 in) or less

Measure each clearance using a feeler gauge and straightedge.

Inner rotor to housing side clearance (3 in the figure)
Standard:
-
0.030 0.070 mm (0.0012 - 0.0028 in)
Outer rotor to housing side clearance (4 in the figure)
Standard:
- -
0.030 0.190 mm (0.0012 0.0075 in)

Feeler gauge
LUM0004

2. INNER ROTOR TO HOUSING SOCKET

CLEARANCE
Measure the inner diameter of oil pump housing socket using
an inside micrometer. (5 in the figure)

I Measuring point 6 / . - Measure the outer diameter of inner rotor socket using a
micrometer. (6 in the figure)
(Clearance) = (Inner diameter of front cover socket) -
(outer diameter of inner rotor socket)
Standard:
- -
0.045 0.091 mm (0.0018 0.0914 in)
 OIL PUMP

Inspection (Cont'd)
3. REGULATOR VALVE CLEARANCE
Measure inner diameter of regulator valve cylinder using an
inside micrometer.
Measure regulator valve outer diameter using a micrometer.
(Clearance) = (Cylinder bore inner diameter) - (Valve outer
diameter)
Standard:

Inner diameter
- -
0.040 0.097 mm (0.0016 0.0965 in)
CAUTION:
Apply engine oil to regulator valve. Make sure that the
I Outer diameter LUM0007 I valve moves smoothly.

4. REGULATOR VALVE SPRING

Check spring for sagging.
Free length:
Approx. 63 mm (2.48 in)
 ENGINE COOLING SYSTEM

SECTION co
CONTENTS
:HANGING ENGINE COOLANT .......................CO-2 Removal and Installation ................................ CO-3
Draining Engine Coolant ...............................CO-2 Water Pump Inspection ..................................CO-3
Refilling Engine Coolant .................................CO-2 THERMOSTAT ................................................... C 0 4
WATER PUMP .................................................... CO-3 Component Parts Location ............................CO-4
Component Parts Location ............................ CO-3 Removal and Installation ................................ CO-4
CHANGING ENGINE COOLANT

(1) Draining Engine Coolant

WARNING:
Do not drain coolant when engine is still hot. It may cause
burns.

Remove exhaust manifold side drain plug of cylinder block and

drain the coolant in cylinder block.

(2) Refilling Engine Coolant

Refer to the following for the coolant level and LLC density.

Engine coolant level [including the reservoir tank (MAX level) volume]
Unit: I (Imp qt.)

Engine type TB45E

Without rear heater Approx. 11.2 (9-718)
With rear heater Approx. 12.3 (10-718)

LLC density (%):

30 (Standard)
50 (Cold area)
Install cylinder block drain plug.
Apply sealant (Three Bond 12158 or equivalent) to the threads
of cylinder block drain plug.
- - -
Pl: 34 44 N*m (3.5 4.5 kgf-m, 26 32 ft-lb.)
Make sure that each clamp and drain plug is securely tightened.
 WATER PUMP

(1) Component Parts Location

n:N-rn {kgf-m) Fan spacer

(2) Removal and Installation

1. PREPARATION
WARNING:
Do not drain coolant when engine is still hot. It may cause
burns.

Engine drive belts

CAUTION:
Handle water pump vane so that it does not contact with
other parts.

(3) Water Pump Inspection

Check water pump body and vanes for severe corrosion and
dirt.
Make sure that water pump shaft turns smoothly without
roughness.
 THERMOSTAT

(1) Component Parts Location

@ Engine coolant temperature sensor

Connector
0 Copper washer
Bolt (2)
m I 5.7 - 23.7
11.8 - 2.41

Bolt (3)
15.7 - 23.7
(1.8 - 2.4) 0 O-ring
Thermostat housing
I
ate; outlet 0 Gasket

: Liquid gasket Crankshaft pulley side

0 : Not reusable
: N-rn {kgf-m)
COM0013

(2) Removal and Installation

WARNING:
Do not touch thermostat or container and hot water until
they get cold. They may cause burns.

Icross section I INSTALLATION OF THERMOSTAT

Install thermostat with jiggle valve facing upward.
Make sure that thermostat flange is securely inserted to seal
ring.
THERMOSTAT

Removal and Installation (Cont'd)

2. THERMOSTAT INSPECTION
WARNING:
Do not touch thermostat or container and hot water until
they get cold. They may cause burns.

Put a thread through thermostat valve and submerge it in a

water-filled container, then heat it up while stirring the water.
Read the water temperature when thermostat drops. This is the
valve opening temperature.
Valve opening temperature standard:
82°C (180°F) (Standard)
Maximum valve lift standard:
8 mm or morel95"C (0.31 in or moreI203"F)
(Standard)
 TB45 ENGINE CONTROL

SECTION EC
CONTENTS
PRECAUTIONS ..................................................EC-3 CRANKSHAFT POSITION SENSOR 120" (REF)
General Precautions for Service Operations .. EC-3 SIGNAL CIRCUIT ........................................EC-59
PREPARATION ................................................... EC-4 Control Unit InputlOutput Signal Specifications
Special tool ...................................................... EC-4 EC-59
ENGINE CONTROL SYSTEM ............................EC-5 Circuit Diagram ............................................EC-59
Description ..................................................... EC-5 Component Parts Inspection ........................EC-59
System Diagram ............................................. EC-6 MASS AIR FLOW SENSOR SYSTEM .............EC-60
Sensors and Actuators Control Items .............EC-9 Service Tool Data Monitor Display ...............EC-60
BASIC INSPECTION ........................................EC-10 Control Unit InpuUOutput Signal Specifications
lnspection of ldle Speed. Ignition Timing. and EC-60
Air-Fuel Ratio ........................................... EC-10 Circuit Diagram ........................................... EC-60
Throttle Valve Closed Position Learning and Component Parts Inspection ........................EC-60
Idle Air Volume Learning .............................. EC-12 ENGINE COOLANT TEMPERATURE SENSOR
Fuel Pressure Inspection ..............................EC-13 SYSTEM ............................................................EC-61
TROUBLE SHOOTING .....................................EC-16 Service Tool data monitor display ................ EC-61
How to Proceed with Trouble Diagnosis ...... EC-16 Control Unit InputlOutput Signal Specifications
Diagnosis Chart by Symptom .......................EC-20 EC-61
Component Parts Location ........................... EC-28 Circuit Diagram ............................................ EC-61
Circuit Diagram ............................................. EC-33 Component Parts Inspection ........................ EC-61
ECCS Terminal Layout .................................EC-36 HEATED OXYGEN SENSOR SYSTEM ...........EC-62
ECCS InpuUOutput Signal Specifications ....EC-39 Service Tool Data Monitor Display ............... EC-62
Service Tool ................................................. EC-45 Control Unit InpuUOutput Signal Specifications
Self-diagnosis Function (without service tool) EC-62
...................................................................... EC-50 Circuit Diagram ............................................. EC-62
Service Tool Reference Value in Data Monitor VEHICLE SPEED SENSOR SYSTEM ..............EC-63
......................................................................EC-54 Service Tool Data Monitor Display ............... EC-63
Fail-safe Function ........................................EC-56 Control Unit InpuUOutput Signal Specifications
POWER SUPPLY AND GROUND SYSTEM ....EC-57 EC-63
Control Unit InpuVOutput Signal Specifications THROTTLE POSITION SENSOR SYSTEM .....EC-64
...................................................................... EC-57 Service Tool Data Monitor Display ............... EC-64
Circuit Diagram .............................................EC-57 Control Unit InpuUOutput Signal Specifications
CRANKSHAFT POSITION SENSOR I"(POS) EC-58 EC-64
Control Unit InpuUOutput Signal Specifications Circuit Diagram ........................................... EC-64
EC-58 Component Parts Inspection ........................EC-64
Circuit Diagram ............................................. EC-58 ACCELERATOR PEDAL POSITION SENSOR
Component Parts Inspection ........................ EC-58 SYSTEM ............................................................
EC-65
 Service Tool Data Monitor Display ...............EC-65 Circuit Diagram ........................................... EC-76
Control Unit InpuUOutput Signal Specifications Component Parts Inspection ........................EC-76
EC-65 LPG INJECTOR SYSTEM ................................ EC-77
Circuit Diagram ............................................ EC-65 Control Unit InpuffOutput Signal Specifications
Component Parts Inspection ........................EC-66 EC-77
INTAKE AIR TEMPERATURE SENSOR ..........EC-66 Circuit Diagram ............................................ EC-78
Service Tool Data Monitor Display ............... EC-66 LPG ASSISTANCE INJECTOR SYSTEM ........ EC-79
Control Unit InpuUOutput Signal Specifications Control Unit InpuffOutput Signal Specifications
EC-66 EC-79
Circuit Diagram ............................................ EC-66 Circuit Diagram ...........................................EC-79
PNP SWITCH SYSTEM ....................................EC-67 Component Parts Inspection......................... EC-79
Service Tool Data Monitor Display ............... EC-67 LPG FUEL PRESSURE SENSOR SYSTEM .....EC-80
Control Unit InpuffOutput Signal Specifications Control Unit InpuUOutput Signal References EC-80
EC-67 Circuit Diagram ............................................EC-80
Circuit Diagram ......................................... EC-67 BLOWBY GAS RESTORATION DEVICE ........EC-81
Component Parts Inspection ........................ EC-67 System Diagram .........................................EC-81
STOP LAMP SWITCH SYSTEM ......................EC-68 Removal and Installation of PCV Valve ....... EC-81
Service Tool Data Monitor Display ...............EC-68 PCV Valve Inspection ..................................EC-81
Control Unit InpuUOutput Signal Specifications FUEL CUT FUNCTION .....................................EC-82
EC-68 Inspection Procedure ................................... EC-82
Circuit Diagram ............................................ EC-68 REMOVAL AND INSTALLATION OF ECM
Component Parts Inspection ........................ EC-68 COMPONENTS .................................................EC-83
ELECTRIC LOAD SWITCH SYSTEM ..............EC-69 Removal and Installation of ECM ................. EC-83
Service Tool Data Monitor Display ...............EC-69 Removal and lnstallation of Crankshaft Position
ECM InpuffOutput Signal Specifications ......EC-69 Sensor (Integrated Into the Distributor) ........ EC-83
Circuit Diagram ............................................ EC-69 Removal and lnstallation of Mass Air Flow
IGNITION SYSTEM ........................................ EC-70 Sensor ..........................................................EC-83
Service Tool Data Monitor Display ...............EC-70 Removal and lnstallation of Engine Coolant
Control Unit InpuUOutput Signal Specifications Temperature Sensor .................................... EC-83
EC-70 Removal and lnstallation of Heated Oxygen
Circuit Diagram ....................................... EC-70 Sensor (With Heated Oxygen Sensor
Component Parts Inspection ........................ EC-70 Heater) .................................................... EC-84
FUEL INJECTOR SYSTEM ..............................EC-72 Removal and lnstallation of Throttle Position
Service Tool Data Monitor Display ............... EC-72 Sensor (Electric Throttle Control Actuator
Control Unit InpuUOutput Signal Specifications Assembly) ....................................................EC-84
EC-72 Removal and lnstallation of Accelerator Pedal
Circuit Diagram .......................................... EC-72 Position Sensor
Component Parts Inspection ........................ EC-72 (Accelerator Pedal Assembly) ......................EC-85
FUEL PUMP SYSTEM ...................................... EC-73 Removal and lnstallation of Intake Air
Service Tool Data Monitor Display ............... EC-73 Temperature Sensor
Control Unit InpuffOutput Signal Specifications (With Mass Air Flow Sensor) ........................ EC-85
EC-73 Removal and lnstallation of Ignition Coil
Circuit Diagram ............................................ EC-73 (Integrated in Distributor) ............................. EC-85
Component Parts Inspection ........................ EC-73 Removal and Installation of Fuel Injector ..... EC-85
THROTTLE CONTROL MOTOR SYSTEM ......EC-74 Removal and Installation of Fuel Pump ....... EC-85
Control Unit InpuUOutput Signal Specifications Removal and lnstallation of Throttle Control
EC-74 Motor (Electric Throttle Control Actuator
Circuit Diagram ............................................ EC-74 Assembly) .................................................... EC-85
Component Parts Inspection ........................EC-74 Removal and lnstallation of LPG lnjector
ENGINE WARNING LIGHT SYSTEM ..............EC-75 Holder ...................................................... EC-86
Control Unit InpuUOutput Signal Specifications LPG Injector Drive Unit ................................ EC-86
EC-75 SERVICE DATA AND SPECIFICATIONS
Circuit Diagram ............................................ EC-75 (SDS) ................................................................EC-87
HEATEDOXYGENSENSORHEATER Standard. Repair Limit ................................. EC-87
SYSTEM ............................................................
EC-76
Service Tool Data Monitor Display ...............EC-76
Control Unit InpuUOutput Signal Specifications
EC-76
 PRECAUTIONS

(1) General Precautions for Service

Operations
Even when ignition switch is OFF, battery voltage may damage
the control unit. Turn ignition switch OFF and disconnect battery
ground cable before removing and installing control unit
harness.

Be careful not to damage connector terminals when connecting

Bend and disconnecting. Check the terminals for bend or breakage
before connecting.
Check the inpuffoutput signal of terminal before replacing
control unit. Confirm that it operates normally.
Refer to EC section, "ECCS control unit
InpuffOutput Signal Specifications".

Ensure the appropriate distance between test probes when

using a circuit tester. A longer distance is recommended,
because if the distance is too short, it may cause contact of test
probes, resulting in a short circuit. A short circuit allows battery
voltage to be applied directly to the control unit, resulting in
damage to its internal power transistors.

Circuit tester
EGM0063

EC-3 TB45 ENGINE

--
 PREPARATION

(1) Special Tools

Description Application
EGI fuel pressure indicator For measuring fuel pressure
ST1959 0000 gauge

Heated oxygen sensor wrench Removing and installing heated

KV101 13700 oxygensensor

Maintenance tool For system inspection and

diagnosis

For molding coil Checking engine speed

Adapter harness
EGlOl 17500

EC-4 TB45 ENGINE

 ENGINE CONTROL SYSTEM

(1) Description
Adopts Electronic Concentrated Engine Control System
(ECCS). Fuel injection control, ignition timing control, idle speed
control, and electronically controlled governor control etc. are all
performed by a single control unit.
Adopts electric throttle control actuator system to control
electronically controlled governor.

Item Description
-

Electric throttle control Adopts electronic throttle control actuator with integrated throttle control motor to adjust throttle valviipening
optimally according to driving conditions or to improve safety and operability by electronically controlled governor.
Fuel injection control With SOFlS control, amounts of injected fuel are optimized to improve exhaust performance and response.
Using feedback control through learning of air-fuel ratio compensation, the system corrects the ratio during
transitional conditions, such as sudden sharp changes in the ratio, in order to improve drivability.
Ignition timing control Uses Hall IC crankshaft position sensor (POS) and camshaft position sensor (PHASE) to perform controls so that
optimum ignition timing is obtained for every operating condition. Optimum ignition timing setup according to each
fuel is also enabled at the time of a combined use formula.
Adopts electronic distribution system (NDIS) in which each cylinder is equipped with an ignition coil incorporating
a power transistor for better ignition performance.
Idle speed control Adopts electronic throttle control actuator that continuously regulates intake air amount required for idling.
Governor speed control I .Performs maximum regulation of engine speed for oil pressure pump protection by engine speed signal
Maximum speed regulation
control
I. Performs maximum speed regulation by vehicle speed sensor signal. Also, performs variable control of maximum
speed by changeover switch as an option.
Idling area torque upcontrol I Performs torque up control in idling area by engine speed signal in order to also enable cargo work at idling.
Overheat prevention control . Reduces engine heat generation by reducing maximum engine speed and regulating maximum throttle opening
when engine coolant temperature reaches approximately 110°C (230°F).
Prevents resulting in engine breakage by overheat by performing fuel cut at 1,000 rpm or more when engine
coolant temperature reaches approximately 135°C (275°F).
son mode control Changes throttle opening characteristic of throttle position by soft mode switch, and then minute operation of
engine speed is enabled.
Fuel pump control Turns fuel pump relay ONlOFF depending on engine speed signal.
(gasoltne)

LPG interceptionvalvecontrol I .Turns interception valve relay ONlOFF depending on engine speed signal and fuel pressure sensor signal.
Fail-safe function

Diagnostic system
II . Ensures vehicle's safe operation and enables vehicle to be driven in an emergency when any of the major system
components (mass air flow sensor, engine coolant temperature sensor, etc.) have malfunctioned.
Adopts self-diagnosis system for easier trouble diagnosis.

EC-5 TB45 ENGINE

ENGINE CONTROL SYSTEM

(1) System Diagram

1. GASOLINE

EC-6 TB45 ENGINE

ENGINE CONTROL SYSTEM

System Diagram (Cont'd)

2. LPG

ECM0219

EC-7 TB45 ENGINE

ENGINE CONTROL SYSTEM

System Diagram (Cont'd)

3. COMBINED

EC-8 TB45 ENGINE

 ENGINE CONTROL SYSTEM

(3) Sensors and Actuators Control Items

Main sensors and actuators related to the ECCS are listed below.

Gasoline std std std

-std Combined std std
Fuel -
LPG std std std std Combined
I
Control Item Fuel injection control
-e
-

Crankshaft position sensor (POS, REF) Q 8

Mass air flow sensor 8 8
Intake air temperature sensor +
Engine coolant temperature sensor 8
Heated oxygen sensor 8
Vehicle speed sensor 8 sensor unit + +
Throttle position sensor + +
R
cr, Accelerator pedal position sensor +
Ignition switch IGN Q 8
C
PNP switch +
Stop lamp switch
Headlamp (electrical load) switch
Battery voltage +
LPG fuel pressure sensor + 8
LPG injector drive unit check signal
Fuel changing switch 8 8

LPG assistance injector 8 8

LPG interception valve relay Q
LPG interception valve Q

EC-9 TB45 ENGINE

BASIC INSPECTION

(1) Inspection of ldle Speed, Ignition Timing,

and Air-Fuel Ratio

1. STANDARD AT IDLE
Idle speed [N position] (rpm) 1 675 * 50
Ignition timing (BTDClrpm) 1 10 i 21675
CO density (%) 0.1 or less
HC density (ppm)) 50 or less

CAUTION:
Perform "TAS Learning" (EC section) when idle speed or
ignition timing is outside the standard.

Turn ignition switch ON, and then make sure that no

malfunction is detected by self-diagnosis.
Make sure that engine is free of oil pressure pump loads and
any electrical loads. Perform the inspection with the shift lever in
the N position.
Warm up engine and transaxle to the normal operating
temperature.

2. IDLE SPEED

@ WITH SERVICE TOOL

1. Connect Service too to vehicle side data link connector.
2. Select "ENG SPEED" in "DATA display monitor". Make sure that
the idle speed is 675 k 50 rpm.
CAUTION:
Perform "ldle Air Volume Learning" (EC section) when idle
speed is outside the standard.

@ WITHOUT SPECIAL TOOL

1. Connect an adapter harness for molded coils (Special tool)
between the distributor harness connectors, and install a
tachometer.
2. Make sure that idle speed is 675 i 50 rpm.
CAUTION:
Perform "TAS Learning" (EC section) when idle speed is
outside the standard.

3. COIHC DENSITY INSPECTION

The vehicle uses an air-fuel ratio feedback system with a self-
learning function. Because a wide compensation range is available,
no additional COlHC density adjustment is necessary.
Warm up engine to normal operating temperature. Confirm idle
speed and ignition timing are within the standards. Then, check
COlHC density with a COlHC measuring device.
Check condition of air-fuel ratio feedback with the following
steps when measured values are outside the standard:

EC-10 TB45 ENGINE

-- - -
 BASIC INSPECTION

Inspection of Idle Speed, Ignition Timing, and

Air-Fuel Ratio (Cont'd)

@ WITH SERVICE TOOL

1. Select "Oxygen Sensor Monitor Bankl" in "Data display menu".
2. Keep engine speed at approximately 2,000 rpm, and make sure
that "RICH" and "LEAN" are alternately displayed.

@) WITHOUT SERVICE TOOL

1. Inspect using heated oxygen sensor monitor mode. (Refer to
EC section, "DIAGNOSTIC TEST MODE II HEATED OXYGEN
SENSOR MONITOR for operation procedure.)
2. Keep engine speed at approximately 2,000 rpm, and make sure
that engine warning light blinks at least 5 times within 10
seconds.
NOTE:
Increase engine speed when inspecting while air-fuel ratio
feedback control is activated during idle.

4. INSPECTION AND ADJUSTMENT OF IGNITION

(To tachometer or super tuner) TIMING
Connect a timing light (super tuner, etc.) to receive a signal from
the ignition primary system using an adapter harness for
molded coils (Service tool).
(Attach pickup to the 1 high-tension cable for general timing
lights.)

+
Make sure that ignition timing and base idle speed is BTDC 10"
k 2O1675 rpm.

EC-11 TB45 ENGINE

 BASIC INSPECTION

Inspection of ldle Speed, Ignition Timing, and

Air-Fuel Ratio (Cont'd)
Perform adjustment following the procedures described below if
ignition timing is outside the standard.
Loosen distributor bolts, and rotate the distributor so that the
ignition timing meets BTDC 10" k 2"/675 rpm.
Clockwise rotation of the distributor advances the ignition Make
I sure that ignition timing advances synchronously when racing
the engine.

(2) Throttle Valve Closed Position Learning

and ldle Air Volume Learning
1. DESCRIPTION
When electric throttle control actuator or ECCS CIU connector is
removed, it is necessary for ECs to learn throttle valve closed
position (throttle position sensor output with throttle valve fully
closed) after reinstallation. Thus, throttle valve closed position
learning is performed.
When electric throttle control actuator or ECM is replaced, the
minimum required idle air volume needs to be learned. Thus, throttle
valve closed position learning and idle air volume learning are
performed.
ldle air volume learning is necessary even when idle speed or
ignition timing is outside the standard. Note that idle air volume
learning is equivalent to the base idle speed adjustment by
conventional throttle adjusting screw of carburetor or LPG mixer.

2. OPERATION PROCEDURE FOR THROTTLE

VALVE CLOSED POSITION LEARNING
1. Turn ignition switch ON / OFF. (And hold it for approximately 5
seconds after turning it OFF.)
2. Make sure that throttle valve operates. (Check for operating
sound.)
3. Upon completion of above, learning is complete.
CAUTION:
Throttle valve closed position learning cannot be
performed with Service tool.

EC-12 TB45 ENGINE

BASIC INSPECTION

Throttle Valve Closed Position Learning and

Idle Air Volume Learning (Cont'd)
3. OPERATION PROCEDURE FOR IDLE AIR
VOLUME (TAS) LEARNING
1. Perform throttle valve closed position learning.
2. Fully warm up engine and transaxle. [Engine coolant
temperature: 70 - 99°C (158 - 194OF)l
3. Make sure that engine is free of oil pressure load and any
electrical loads with the shift lever in the N position.
4. Execute the following contents while idling using Service tool.
1) Touch "YES" on "TAS LEARN (CLEAR)" in WORK
SUPPORT.
CAUTION:
"TAS LEARN CLEAR (PLANT)" is the original setting on the
vehicle. Do not use it.
2) When learning is completed, "CMPLT" is displayed. '
CAUTION:
It will take approximately 20 seconds to complete the idle
air volume learning. Do not turn OFF the ignition switch
until completion.

3) Make sure that the learning has been completed by

checking the "TAS LEARN History" in Data Display Menu.
Learning completed : CMPLT
Learning not yet completed : Not CMPLT
4) Make sure that idle speed and ignition timing are within the
standard.
5) Perform "TAS Learning" again if values are outside the
standard.

4. ACCELERATOR PEDAL RELEASED POSITION

LEARNING

1) DESCRIPTION
When the accelerator pedal assembly has been replaced or the
accelerator pedal position sensor connector has been disconnected,
the accelerator pedal released position needs to be learned after
being repaired, so learn accelerator pedal in fully-released position.

2) OPERATION PROCEDURE
1) Turn ignition switch ON and wait at least 2 seconds.
2) Turn ignition switch OFF and wait at least 10 seconds.
3) Then turn ignition switch ON again and wait at least 2 seconds
(learning completed).

(3) Fuel Pressure Inspection

QUICK INSPECTION

1. FUEL PRESSURE RELEASE

CAUTION:
Relieve fuel pressure before removing fuel piping to secure
safety.

EC-13 TB45 ENGINE

BASIC INSPECTION
@ WITH SERVICE TOOL
1. Start engine.
2. Select "FUEL PRESSURE RELEASE" of Work support menu,
and touch "YES".
3. Crank engine 2 or 3 times to consume the fuel in the fuel line
after it stalls.
4. Turn ignition switch OFF.

@ WITHOUT SERVICE TOOL

1. Disconnect fuel pump fuse.
2. Start engine.
3. Crank engine 2 or 3 times to consume the fuel in the fuel line
after it stalls.
4. Turn OFF the ignition switch, and install the fuel pump fuse.

2. FUEL PRESSURE INSPECTION

CAUTION:
Safely and securely remove and install fuel hose.
Use the fuel pressure gauge for fuel pressure inspection.
Do not inspect fuel pressure while other systems are
operating. Malfunctions may occur in fuel pressure value.

EC-I4 TB45 ENGINE

BASIC INSPECTION

Fuel Pressure Inspection (Cont'd)

1. Release the fuel pressure.
2. Install fuel pressure gauge using fuel hose for fuel pressure
inspection.
3. Remove fuel hose, and then install fuel hose for fuel pressure
inspection.
CAUTION:
Usable period of fuel hose for fuel pressure inspection is
30 times or less. (Fuel hoses that are damaged and allow
fuel leakage are not contained above.)

4. Turn ignition switch ON, and then make sure that there is no
fuel leakage.
5. Start engine, and check for fuel leakage.
6. Make sure that fuel pressure is within the standard.
At idle:
0.35 MPa (3.6 kglcm2, 51 psi)

If the vehicle shows poor starting, check fuel pressure with fuel
pump operating for approximately Isecond after ignition switch
is turned ON, and during cranking.
For 1 second after ignition switch is turned ON and
during cranking:
0.35 MPa (3.6 kglcm2, 51 psi)

Check the following items if a malfunction is detected.

CAUTION:
Also check fuel pressure at increased engine speed.
Malfunctioning pressure regulator (integrated with fuel
pump)
Clogged fuel piping
Clogged fuel filter
Poor fuel pump discharge

EC-15 TB45 ENGINE

 TROUBLE SHOOTING

(I)
How to Proceed with Trouble Shooting
1. The most important point in performing trouble diagnosis of
Sensor
malfunctions is to thoroughly understand the vehicle systems
(both control and mechanical).
An ECCS-based engine controls actuators such as injectors
and the ignition coil according to information from sensors.
Then through actuator operation, the engine (mechanical
system) runs. Sensors transmit information on the running
condition, which changes constantly, to ECCS. It is important to
understand these cycles.

ECM0233

2. It is also important to clarify customer concerns before starting

the inspection. First of all, reproduce the symptom, and
understand it fully. Ask the customer about hislher complaints
carefully. In some cases, it will be necessary to check the
symptoms by driving the vehicle with the customer.
CAUTION:
Customers are not professionals. Do not assume "maybe
the customer means ..." or "maybe the customer
mentioned this symptom".

3. It is essential to confirm symptoms right from the beginning in

order to ensure all malfunctions are completely repaired.
For an intermittent malfunction, it is important to reproduce the
symptom based on an interview with the customer and past
examples. Do not perform an inspection on an ad hoc basis.
Most intermittent malfunctions are caused by poor contacts. In
this case, it will be effective to shake the suspected harness or
connector by hand. When repairs are performed without any
symptom check, no one can judge if the malfunction has
actually been eliminated.
4. The next important thing is to find which system among the
following is causing the malfunction: ECCS control signal
system, or a mechanical system (such as the engine main body
and auxiliary component). It is important to inspect the system
using SST or by checking the ECCS inpuffoutput signals.
When checking the ECCS inpuffoutput signals, connect a check
adapter (Special tool) to ECCS in order to prevent misdiagnosis.
Special Service Tools (Service tool):
Check adapter V (EG1755 0000)
(for SMJ 150-pin connector)
Harness adapter (EG1755 0200)
(150-pin / 121-pin conversion adapter)

EC-16 TB45 ENGINE

 TROUBLE SHOOTING

How to Proceed with Trouble Shooting (Cont'd)

5. Use the reference value of inpuffoutput data (guideline) in this
manual in order to judge the ECCS inputloutput signals.
Measure the data of another vehicle of the same model under
the same conditions when it is difficult to judge, and compare
the data. It is advisable to collect sufficient data of a normally
operating vehicle.

1. TROUBLE SHOOTING FLOW CHART

There are many different malfunction symptoms. So there is no
perfect trouble diagnosis technique applicable to all malfunctions.
Experience is also important to achieving an accurate trouble
shooting.
Nonetheless, an accurate trouble diagnosis can be performed by
applying similar procedures, regardless of the malfunction symptom.
perform trouble diagnosis following the flow chart shown below.

I Diagnosis I
Use the diagnosis sheet.
NOmalfunclion symptoms
Malfunction symptoms

No malfunction

CONFIRMATIONOF DRIVING CONDITION

BY FREEZE FRAME DATA
CONFIRMATIONOF DRIVING CON-
DITION BY FREEZE FRAME DATA
CHECK MALFUNCTION INDICATION
SYSTEM
CHECK MALFUNCTION INDICATION
SYSTEM

REPAIRIREPIACE ESTIMATION OF POSSIBLE CAUSE

REPAIFUREPIACE

REPAlRlREPIACE

-' BASIC INSPECTION :

I
rase the seltdiagnostic resul~.):
~ _ _ _ _ _ _ _ _ _ _ r _ _ _ _ _ _ _ - - d
SELF-DIAGNOSIS
(Erase the self-diagnostic results.)
Inspection of idle speed, ignition timing, and air-fuel ratio : ,----------L----------
. Check inpuUoutput signal (Data monltor or check the voltage.) .' EXPLAINCUSTOMER : I
- - ...- - - ....- -... :
I-: REPAIWREPLACEPROCESS. EXPLAINCUSTOMER
8- REPAIWREPLACE PROCESS. (END)

EC-17 TB45 ENGINE

 TROUBLE SHOOTING

How to Proceed with Trouble Shooting (Cont'd)

2. DIAGNOSTIC WORK SHEET
1. DESCRIPTION
-
In order to clarify the malfunction symptom, it is important to ask
Question point
the customer and collect information about their concerns.
.WHAT ........... Vehide8enginemodel Ask the customer about what symptoms are present under what
.WHEN ................ Date,Frequencies
conditions. Use the information to clarify the symptom.
.WHERE.. .............. Road conditions Use the trouble diagnosis sheet to be certain not to miss any
vital information.
.HOW . . . . Operatingconditions,Weather conditions
. WHAT BECAME ...............Symptom

EC-18 TB45 ENGINE

 TROUBLE SHOOTING

How to Proceed with Trouble Shooting (Cont'd)

Trouble Shooting lnformation Memo

Trouble Diagnosis Information Memo

...
r--0
3 Aner bmuphl back lor senicing Appmx. date:
---.
1

-C
9
6
VI

5 Operating
g mndition, etc.
5

Other:
Enter comments.
etc.

ECM0037

EC-19 TB45 ENGINE

 TROUBLE SHOOTING

(2) Diagnosis Chart by Symptom

TB45 ENGINE RELATIONSHIP BETWEEN MALFUNCTIONING
SYMPTOMS AND THE SENSOR CIRCUIT

The table below shows the possible symptoms caused by the

malfunction of each sensor circuit.
-
Symptoms 1 Poor idle Poor driving control Engine stall Other

Description/notable characteristicsof
the symptom

Actuator rnalfunction
Q : Highly possible
r : Possible

Crankshaft position sensor OPEN An open circuit in either POS or

(POS. REF) PHASE signal makes it impossible
for the vehicle to start.
Control signals for fuel system and
ignition system are not output.

. The symptom depends on the

durationof momentarily open circuit
and the operating conditions. Slight
shocksand surgesmaybe sensed
during driving, while engine stall
may be caused during idle.

.
- -

Mass airflow 1 OPEN It will be fail-safe mndilion, and

sensor
I I
High
Output
Signal

Low output . The air-fuel ratio becomes lean.

air may be suspected.

Ground OPEN 1. It will be over-rich.

OPEN It will be fail-safe mndition, and

Power
vehicle runs at an engine speed of
supply

Intake air temperature OPEN1

sensor SHORT

Engine coolant temperature OPEN1 It will be fail-safe mndition, and

sensor SHORT then Engine warning light turns with
overheat step #I ON. This
malfunctiontends to occur when
engine is mld or when the engine
coolant temperature is high.

Heated oxygen sensor

Vehicle speed sensor

t
Resistanc
e is large.

Resistance
is small.

OPEN/
IsHoRT

OPEN/
1sHo.T
-

1.
.
The engine coolant temperature is
judged as low. This malfunction

judged as high. This rnalfunction

tends to occur when engine is mld.

It will be base air-fuel ratio.

Ourat~onof fuel cut becomes

shorter or fuel may not be cut.

EC-20 TB45 ENGINE

 TROUBLE SHOOTING

Poor idle Poor driving control

7
Engine stall Other

Descriptionhotablecharacteristicsof
the symptom

Actuator malfunction
d : Highly possible
* : Possible

Thronle position sensor OPENl Idle will be base rpm. No addition

SHORT for acceleration.

output Possible interruptionby

fluctuation unnecessaryfuel injection. Poor
around or control unit connection
may be the cause.

lollng 6 paged as OFF dunng ~dle

adjustment T~rnlng~gnltlonswltcn repeatedly
to ON and OFF vvlll set the system
to normal.

sensor SHORT

output
fluctuation

Ignition switch (IGN) Impossibleto start without outputs

for fuel and ignition systems.
I I

Neutral switch OPEN PNP switch is judged as OFF, and

H
the target w l d engine speed in NIP
position is lowered

SHORT PNP switch is judged as ON, and

fast idle is effective for w l d engine
in positionsother than NIP position.
making the creep larger.

Stop tamp switch

IZEETT 1
Headlamp (electrical load)
switch

Power supply for CU

I PpEN 1 ~3 Impossibleto start without outputs
for fuel and ignition systems.

Sensor ground (wolant ~OPENI

temperature sensor, thronle SHORT
I The same as the open circuit in the
applicable sensor.
position sensor) I 1
A slightly raised wnnector often
Control unit and wnnector Poor
results in w o r connection. Entrv of
wnnection.
water causes engine stall and
water entry
t afterwards it is momentarilv
~mposs~ble to restart englne In some
cases, restartng a poss~bleaRer a
short wait.

LPG fuel pressure sensor

I Upon shortcircuit. LPG cutoff valve
OFF. Starting not possible.

drive unit signal

Fuel changing switch OPEN

LPG fuel pressure sensor ]OPEN I

EC-21 TB45 ENGINE

 TROUBLE SHOOTING

Diagnosis Chart by Symptom (Cont'd)

TB45 ENGINE RELATIONSHIPS BETWEEN MALFUNCTIONING
SYMPTOMS AND ACTUATOR CIRCUITS
The table below shows the possible symptoms caused by the
malfunction of each actuator circuit.

Symptoms Poor idle Poor driving control Engine stall

Descriptionhotable characteristicsof
the symptm

Actuator malfunction
b : Highly possible
: Possible

No fuel injection to cylinder with open

circuit, resulting in LEAN output of
heated oxygen sensors.
Starting engine is impossiblewhen

I"'F
the circuits for all the cylinders are
open.
Momentarily

circuit (CI

Continuous fuel injection to cylinder

wlth short circuit, resulting in OVER-
RICH and misfiring.
Startmg engine is impossiblewhen
the circuits for all the cylinders are
open.

The cylinder with foreign material will

keep injecting.
intrusion
Clogging The symptom depends on clogging
status. The mnection factor of air-
fuel ratio becomes larger.

circuit (CI

Ignition signal circuit OPEN OPEN

Immediatelyengine stalls during
Momentarily
engine running, and then does not
o w restart.
Ignition mil Power OPEN Injects fuel toward spark plug during
supply uanking.
circuit Momentarily MOMENTARILYOPEN
open Slight shocks and surges may be
sensed depending on the duration of
Coil OPEN momentarily open circuit and the
operating conditions. Engine stall
Momentarily may occur if duration of momentarily
open open circuit is too long.
Ground OPEN
circuit
Momentarily
open
ECCS 8 IGN relay circuit OPEN
Throttle mntrol motor c i m i t OPEN1
Low
Thronle control motor relay /OPEN The same malfunctionmay occur as
circuit

Heatedoxygen sensor heater OPEN

I power supply open of throttle control
motor and throttle position sensor.

drcuit

EC-22 TB45 ENGINE

 TROUBLE SHOOTING

Symptoms 1 6;I 1 Ponr idle Poor driving wntml Engine stall Other

Descriptionhotable characteristicsof
the symptom

Actuator malfunction
b : Highly possible
t : Possible

Impossible to start
Fuel pump arwit
Ignition relay circuit Momentarily Surge may occur.
I ' I
Fuel pump pressure regulator Stuck

LPG injector drive Ti circuit OPEN

unit
SHORT

Tip arcuit OPEN

SHORT

PWM OPEN
circuit
SHORT

Power OPEN
supply
Ground OPEN

LPG injedor HI side

lcircuit / OPEN
I When selfdiagnosis NG LPG
interceptionOFF.

When self-diagnosisNG LPG

interceptionOFF.

When selfdiagnosis N G LPG

interceptionOFF.

When selfdiagnosis N G LPG

interceptionOFF.

SHORT When selfdiagnosis N G LPG

interceptionOFF.

LPG assistance injector

LPG interceptionvalve relay OPEN

I
Control unit
side short

Engine warning light

Improper TAS learning

I
Also check h e followino items other h a n the above:
Check harness tension.
. Check each mnnector mnneclion.
Check water and oil mndition. .Check fan belts b r looseness.
Check ground wire for looseness. .
Check banev wnnection for looseness or mrmsion.

EC-23 TB45 ENGINE

 TROUBLE SHOOTING

Diagnosis Chart by Symptom (Cont'd)

TB45 ENGINE RELATIONSHIP BETWEEN MALFUNCTIONING
SYMPTOM AND THE ENGINE MAIN BODYlAUXlLlARY
COMPONENT
When the three elements of combustion, compression pressure, fuel
mixture, and sparking are all normal, no malfunctions are caused in
the engine.
The ECM controls the fuel mixture and sparking (ignition timing). But
with malfunctions on the part of engine main body, malfunctioning
symptoms result.
The table below shows the possible symptoms caused by the
malfunction of engine main body system. It will be helpful in
malfunction trouble diagnosis. The table lists general symptoms and
some may not be applicable.

Poor idle Poor driving wntrol Engine stall Other

Descriptionhotable characteristicsof
the symptom

Main unit symptom

@ : Highly possible
:Possible
V : Not very possible

Air-fuel ratio bemmes LEAN.

High air-fuel correction factor.
Low suction power (vacuum pressure) of
intake manifold.
ieck the suction using a pressure gauge.
anerally applicable to air suction in air
lake system

Noise (high hissing tone)

Symptom depenas on clogg ng status Ttvs

tends to happen durlng
- htgh-speed
- or h ~ g h
load operation.
Symptom varies depending on oil quality.

Symptom varies depending on oil quality.

Starling ability in cold area is changed

depending on propane ratio.
Use LPG with proper propane ratio.
If the pressure is low, it is caused by p w r
output during high-speedor high load
operation.
If the pressure is excessivelyhigh, relief
valve operates and engine stalls at rich.
Symptom depends on fuel temperature.
Thls tends to happen dunng engme stall
and IS nnposs~bleto restan aunng engme
waning up.
Symptom depends on cloggingstatus. This
Lends to happen during high-speed or high
load operation.
The malfunctiontends to happen during
highspeed or high load operation (low
vacuum).

EC-24 TB45 ENGINE

 TROUBLE SHOOTING

Poor driving mntrol Engine stal

start

Descriptiodnotable characteristicsol
the symptom

Main unit symptom

63 : Highly possible
r : Possible
V : Not very possible

Spark. mpmper high-tensioncord Check the igniting sequence.

ing
mpmper ignition timing

Malfunctioning spark plug Check that the gap is proper. Check plug
for soil (smoking).
I I
.eakage from high-tensionm r d
, Symptom varies depending on the level of
leakage.
.eakage from distributor cap. I
.wse or open of primary wire
annedion
-
Corn- mproper bulb mntact The symptom occurs depending on
pres- malfunctioninggrade and the number of
sion Norn, stuck, broken piston ring malfunctioningcylinders.
pres-
sure 31ow out from head gasket The symptom occurs depending on
malfunctioninggrade and the number of
111. malfunctioningcylinders. Precautionsfor
head bolt tightening torque.
Imken or delenoration valve
ipring

;tuck and upthrust valve stern

lvl*
I 1
The symptom occurs depending on
malfunctioninggrade and the number of
malfunctionim- cvlinden.
.
The symptom occurs depending on
malfunct!onmg grade and Vle n k b e r of
malfuncl~on~ngcfl~nders
lressure leakage from spark plug I I Check gasket and lightening mndition.

Other .ow idle base speed

:rack and water leakage on

II Engine stall may ocwr by power steering
load and cargo load during decelerationor
at idlino.

Minder block
Excessive aankshafl end

Crankshaft and connecting Oil leakage around front or rear aankshaft.

rod bearing clearance task

Oil leakage around fmnt or rear crankshaft.

oil seal
Whitish exhaust gas. Wom piston or
between piston and cylinder cflinder.

Whitish exhaust gas. lmpmper location of

installation mnnedina end and assemble it u ~ s i d e

Excessive piston ring Whitish exhaust gas. Worn piston ring

clearance glove or piston ring.
Worn torque converter pilot
lbushing II
ICrack and water leakage on
cylinder block II
deposit in
mmbustion chamber
Worn valve stern or guide Whitish exhaust gas

Deterioration of valve oil seal

-

EC-25 TB45 ENGINE

 ---- ~- -

TROUBLE SHOOTING

Symptoms Poor driving control Engine stall Other

Descriptionhotable characteristicsof
the symptom

Main unit symptom

f3: Highly possible
: Possible
V : Not very possible

Others Excessive or clogged valve Excessivedearance:

Idearance Chatteringnoise at idling
Clogged clearance:
Engine leakage at idling
Rocker cover gasket oil Loose or broken gasket
- lleakage
Islack of timing chain Wom chain tensioner shoe
Dropped chain guide
Check timing mark related to timing chain
for dislocation.
Loose or broken gasket

Improper engine oil Insufficient oil amount, improper grade,

deterioration
Refill full recommendedoil.

IMalfundoning oil pump Worn or broken rotor

Operation malfunctionor oil leakage of
regulator
Lome or bmken oil pan gasket
Loose oil pan drain plug
Dirt or entry of foreign material in engine oil

Oil leakage of oil filter Lome or bmken gasket

Apply oil to gasket when repladng oil filter.
Dirt or entry of foreign material in engine oil

Loose or malfunctioningoil
pressure switch
Foreign material in fuel tank With low fuel, this may easily occur.

Oil leakage from fuel systen Check LPG leakage by applying snoop.

l~otationmalfunctionof fan Slip or worn belt caused by belt looseness

or water pump
I~alfunctionin~
water pump Worn or broken bearing. Coolant leakage
from axle seal.
Malfunctioningthermostat

coolant temperature gauge

Deteriorationof radiator cap pressure. and

water leakaae
~ l o ~ ~ e d l r e ~ r radiator
i c f e d and condenser.
and water leakage
Contamination and
linsufident amount of coolan

ngine drive belt tenslon too high

sxcessive tension)
:logged three-way catalytic In some cases, aner engine stall, restarting
onverter /exhaust system IS possible.

- Wagging of brakes fireslwheels are hot.

EC-26 TB45 ENGINE

 TROUBLE SHOOT

Symptoms Poor driving control Engine stall Olher

Description/nolablecharacteristicsof
lhe symptom

Main unit symptom

$ : Highly possible
r : Possible
v : Not very possible
lnsumcient ATF amount, improper oil
specification (This -,...-.-... ma"
sumntnm ...- ,
espeaally occur in the cold.)

IHigh HYD PUMP load (PS.Cargo)

Clogged condenser
Malfunclioning oil pressure relief valve.
improper oil specification (This symptom
may especially occur in the mid.)

Aka check lhe following items other than lhe above:

.Check hamess lension. . Check ground for looseness. .Check each connector connection.
.
C h e c k engine drive beit for looseness. Check water and oil condition.
.
Check battery connection for lwseness or mnosion.

EC-27 TB45 ENGINE

 TROUBLE SHOOTING

(2)Component Parts Location

S~ecifications
Main component part Location
Combined
Gasoline injector High resistance Intake manifold 0 0
LPG injector Gas injection Integrated in injector holder (on 0
intake manifold)

--
Fuel pump Electric motorlturbine Integrated in fuel tank 0
Fuel pressure regulator Diaphragm 0
Throttle control motor Electric DC motor (DC motor) Integrated in electronic throttle 0 0
control actuator
Ignition coil Molded Integrated in distributor 0 0
Power transistor 1-channel
Crankshaft position sensor Photoelectric Integrated in distributor 0 0
Mass air flow sensor Hot wire Air horn 0 0
Accelerator pedal position Variable resistance Integrated in accelerator work 0 0
sensors 1 and 2 unit (accelerator pedal assembly)
Throttle position sensors 1 and Integrated in electronic throttle 0 0
2 2 control actuator
Engine coolant temperature Thermistor Thermostat housing 0 0
sensor
Intake air temperature sensor With air flow meter 0 0
Heated oxygen sensor Zirconia (with heater) Front tube 0 0
Vehicle speed sensor Electromagnetic power Body side 0 0
generation
ECCS CIU 121-pin digital control Body side 0 0
ECCS relay Compact general relay (2M) Body side 0 0

EC-28 TB45 ENGINE

 TROUBLE SHOOTING

Component Parts Location (Cont'd)

ECCS COMPONENT PARTS LOCATION: TB45 ENG
Specifications Reference
Component Location
Gasoline LPG Combined Actuator Sensor Other
Gasoline injector Intake manifold 0 0 0
LPG injector Integratedin injector holder (on intake 0 0 0
manifold)
ThroMe control motor Integratedin electronic throttle control 0 0 0 0
actuator
Throttle position sensors 1 and 2 Integrated in electronic throttle control 0 0 0 0
actuator
Ignition coil Integratedin distributor 0 0 0 0
Crankshafl position sensor 0 0 0 0
Power transistor 0 0 0 0
Mass air flow sensor Air horn 0 0 0 0
Intake air temperature sensor IWith air flow meter l o ) O I O I 1 ° 1
Engine coolant temperature sensor IThermostat housing 1 0 1 0 1 0 1 l o t
Accelerator pedal position sensors 1 and 2 lntegrated in accelerator work unit 0 0 0 0
(acceleratorpedal assembly)
Fuel pump Integrated in fuel tank 0 0 0
Fuel pressure regulator 0 0 0
Heated oxygen sensor (Vehide side) 0 0 0 0
Vehicle speed sensor (Vehicle side) 0 0 0 0
ECCS CIU (Vehicle side) 0 0 0
ECCS 8 IGN coil relay (Vehicle side) 0 0 0
Stop lamp switch (Vehicle side) 0 0 0 0
Thronle wntrol motor relay (Vehicle side) 0 0 0 0
Fuel pump relay (Vehicle side) 0 0
Vaporizer I(Vehicle side) I I 0 1 0 1 I I 0
LPG interception valve (Vehicle side) 0

EC-29 TB45 ENGINE

TROUBLE SHOOTING

Component Parts Location (Cont'd)

EC-30 TB45 ENGINE

TROUBLE SHOOTING

Component Parts Location (Cont'd)

,

FUEL INJECTOR

EC-31 TB45 ENGINE

TROUBLE SHOOTING

Component Parts Location (Cont'd)

EC-32 TB45 ENGINE

TROUBLE SHOOTING

-
(4) Circuit Diagram ECCS
1. GASOLINE

ECM0239

EC-33 TB45 ENGINE

TROUBLE SHOOTING

Circuit Diagram (Cont'd)

2. LPG

EC-34 TB45 ENGINE

TROUBLE SHOOTING

Circuit Diagram (Cont'd)

3. COMBINED SPECIFICATION

EC-35 TB45 ENGINE

 TROUBLE SHOOTING

(5) Control Unit Terminal Layout

Data link connector

ECM0241

The symbol in ( ) next to terminal numbers indicates the data link

connector.

Terminal Description
1 CIU ground
2 -
3 Throttle control motor relay power supply
4 Throttle control motor (Close)
5 Throttle control motor (Open)

7 -
8 I LPG injector 1
9 LPG injector 2
10 -
11 LPG assistance injector
12 I Soft mode
13 I Crankshaft position sensor l o (POS) signal
14 Crankshaft position sensor 120° (REF) signal
15 -
16 -

20 -
21 Injector No. 5
22 Injector No. 3
23 Injector No. 1
24 I Heated oxwen sensor heater

28 -
29 -
30 Warning light
31 I LPG fuel pressure sensor
32 I Fuel changing
I - - switch 2 [Gasoline)
33 I Vehicle speed
I

34 Intake air temperature sensor

EC-36 TB45 ENGINE

 TROUBLE SHOOTING

Terminal Description
35 I Heated oxygen sensor

39 LPG injector drive keeping

40 Injector No. 6
41 Injector No. 4
42 I lniector No. 2
43 -
44 I LPG injector drive intake signal # I
46 -
47 I Sensor power supply (Throttle position sensor)
48 Sensor power supply
49 Fuel changing switch power supply
50 Throttle position sensor 1
51 Mass air flow sensor
52 Idle air volume learning operation
53 LPG injector check 2
54 / Maximum vehicle speed shifting

58 -
59 Inching switch
60 -
62 Ignition signal (power transmission drive signal)
63 LPG injector drive intake 2
64 -

66 I Sensor around (Throttle ~ositionsensor)

67 ( Sensor ground
68 -
69 Throttle position sensor #2
70 Fuel changing switch 1 (LPG)
71 -
72 ( LPG injector check # I
73 Engine coolant temperature sensor
74 -
75 -

78 I Sensor ground (Heated oxygen sensor)

79 -
82 ( Sensor ground (Accelerator pedal position sensor 1)
83 I Sensor ground (Accelerator pedal position sensor 2)
84 Headlamp switch
85 (K LINE) I K-line (CIU data transmiureceive) ---- ~ --

EC-37 TB45 ENGINE

 TROUBLE SHOOTING

Terminal Description
86 -

88 -
89 -
90 Accelerator pedal position sensor 1 power supply
91 I Accelerator pedal position sensor 2 power supply

96 -
97 -
98 Accelerator pedal position sensor 2

100 -
101 I Stop lamp switch
I

102 I PNP switch

103 -
104 Throttle control motor relay
105 -
106 I Accelerator pedal position sensor 1
107 -
108 -
109 (IGN) Ignition switch
110 -
111 ECCS 8 IGN coil relay
112 LPG interception valve relay
113 I Fuel pump relay
114 -
115 (-) CIU ground
116 (-) CIU ground

119 I Power supply for CIU

120 I Power supply for CIU
121 Power supply for CIU (Back-up)

EC-38 TB45 ENGINE

 TROUBLE SHOOTING

(6) ECCS InputIOutput Signal Specifications

REFERENCE VALUE LIST
Voltages is measured with a circuit tester, and the sample
waveforms obtained with an oscilloscope are shown below for
each ECM terminal. Measurement data varies depending on
variation in parts as well as many other factors. Such factors
include vehicle history, driving conditions, environmental
conditions, maintenance status, measuring instrumentlmethod,
etc. Data shown below are reference values.

Data link connector

ECM0243

Terminal Signal name Condition Data (DC value)

Heated oxygen sensor heater At idle after warming up Approx. 0.3V
Approx. 3600 rpm or more ( Battery voltage
Fuel pump relay For approximately 1 second after
ianition switch ON
I ApprOx I"

After that I Battery voltage

At cranking, engine running I Approx. 1V
ECCS 8 IGN coil relay control For approximately 10 seconds when Approx. 1V
ignition switch ON and after ignition
switch OFF
I lanition switch OFF I Batterv voltaae

EC-39 TB45 ENGINE

 TROUBLE SHOOTING

Terminal Signal name Condition Data (DC value)

62 gnition signal (power transmission 4t cranking 41 cranking: Approx. 0.5V
hive signal)

ECM0244

U idle after warming up 11idling: Approx. 0.5V

i t approx. 2,000rpm

101 ;top lamp switch !rake pedal released rpprox. 0V

!rake pedal depressed !attery voltage
109 (IGN) a nit ion switch anition switch OFF rpprox. 0V
anition switch ON lattery voltage
'NP switch l position ipprox. OV
Ither than above lattery voltage (A/T models)
ipprox. 4.8V ( M E models)
85 (K LINE) :-line (ECM data transmiureceive) Vhen connected to SST rpprox. 6.6- Battery voltage
Vhen not connected to SST rpprox. 6V
leadlamp switch ighting switch OFF rpprox. OV
ighting switch ON lattery voltage
ensor ground
./U ground

EC-40 TB45 ENGINE

 TROUBLE SHOOTING

Terminal Signal name Condition Data (DC value)

Crankshaft position sensor l o (POS) At cranking At cranking: Approx. 2.6V

9t idle after warming up At idling: Approx. 2.5V

4t approx. 2,000 rpm Approx. 2.5V

4ccelerator pedal position sensor 2 gnition switch ON, engine running Approx. 2.5V
)ewer supply

sensor power supply gnition switch ON, engine running Approx. 5V

'ower supply for ECM (Buck-up) Battery voltage
ilectric throttle control actuator power gnition switch ON, engine running Approx. 5V
;upply
ieated oxygen sensor ground Approx. OV
kcelerator pedal position sensor 1 Approx. OV
lround
kcelerator pedal position sensor 1 gnition switch ON, engine running Approx. 5V
lower supply

EC-41 TB45 ENGINE

 TROUBLE SHOOTING

Terminal Signal name Condition Data (DC value)

:rankshaft position sensor 120° (REF) At cranking At cranking: Approx. 0.5V

At idle after warming up At idling: Approx. 0.5V

At approx. 2,000 rpm Approx. 0.5V

Aass air flow sensor lgnition switch ON Approx. 1V

At cranking Approx. 1.5V
At idle after warming up Approx. 1.8 - 2.OV
At approx. 2,000 rpm Approx. 2.2 - 2.5V
'hrottle position sensor 1 At idle after warming up Approx. 0.6V
lgnition switch ON with engine stopped Approx. 0.75V
Accelerator pedal is released.
lgnition switch ON with engine stopped Approx. 0.75V
Accelerator pedal is fully depressed
At approx. 2,000 rpm Approx. 0.7V
'hrottle position sensor 2 At idle after warming up Approx. 4.5V
lgnition switch ON with engine stopped Approx. 4.35V
Accelerator pedal is released.
lgnition switch ON with engine stopped Approx. 4.35V
Accelerator pedal is fully depressed.
At approx. 2.000 rpm Approx. 4.4V
rccelerator pedal position sensor 1 41 Idle Approx.
.. 0.6V
Ignition switch ON with engine stopped Approx. 0.6V
iccelerator pedal is released.
Ignition switch ON with engine stopped Approx. 4.2V
4ccelerator pedal is fully depressed
4t approx. 2,000 rpm Approx. 0.65V
rccelerator pedal position sensor 2 4t Idle Approx. 0.3V
Ignition switch ON with engine stopped Approx. 0.3V
4ccelerator pedal is released.
gnition switch ON with engine stopped Approx. 2V
kcelerator pedal is fully depressed
41 approx. 2,000 rpm Approx. 0.35V

EC-42 TB45 ENGINE

 TROUBLE SHOOTING

Terminal Signal name Condition Data (DC value)

34 lntake air temperature sensor Intake air temperature is approx. 20% Approx. 3.5V

lntake air temperature is approx. 80°C Approx. 1.2V

(176°F).
Accelerator pedal position sensor 2 Always Approx. OV
ground
Heated oxygen sensor At idle after warming up Air conditioner OFF:
Clamp between 0 - 0.7V
Air conditioner ON:
Changes between approx. 0 - 0.3V I
approx. 0.5 - 1.OV

At approx. 2.000 rpm Changes between approx. 0 - 0.3V I

approx. 0.5 - 1.OV

3 g i n e coolant temperature sensor Engine coolant temperature is approx.

20°C.
Engine coolant temperature is approx.
BO°C.
njector drive signal At cranking

4t idle after warming up 3attery voltage

4t approx. 2,000 rpm ?elatively lower than battery voltage

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Terminal Signal name Condition Data (DC value)

Power supply for CIU Ignition switch ON, engine running Battery voltage

Throttle control motor relay Ignition switch ON, engine running Approx. 1V
Throttle control motor relay power Always Battery voltage
supply
Throttle control motor (Open) I At idle after warming up I Approx. 0.1 to 0.15V
At approx. 2000 rpm
Throttle control motor (Close) At idle after warming up Approx. 2 - 2.5V
( At approx. 2000 rpm I
Fuel changing switch 2 (Gasoline) Changing switch ON (At gasoline side) Approx. 5V
Changing switch ON (At LPG side or Approx. OV
I neutral)
Fuel changing switch power supply Changing switch ON Approx. 5V
Changing switch OFF (At neutral) Approx. OV
Fuel changing switch 1 (LPG) Changing switch ON (At LPG side) Approx. 5V

I
I
Changing switch OFF (At LPG side or
neutral)
I
Approx. OV

LPG interception valve relay I For approximately 1 second after I Battery voltage
.
ignition switch ON and for
approximately 10 seconds after ignition
switch is OFF
Ignition switch OFF Approx. OV
Idle air volume (TAS) learning operation When connecting tools for idle air Approx. 1.5V
volume learning
When not connecting tools for idle air Approx. OV
volume learning
Maximum speed shifting It varies depending on setting
condition.
Vehicle speed sensor signal Vehicle stopped Approx. 11V or approx. 1V

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(7) Service Tool

1. DESCRIPTION
The service tool executes the following functions using the
combination of data reception, instructions, and transmission
from the ECCS CIU via the communication line.

Diagnosis test mode Function

WORK SUPPORT Reduces the preparation work necessary for inspecting.
Displays inpuffoutput signal data related to the work.
Allows setting control target values of idle speed or ignition timing.
Allows performing "Idle Air Volume Learning".
SELF-DIAG RESULTS Displays names of freeze frame data and basic inspection stored in ECM.
Displays data recorded when DTC is detected.
Erases DTCs recorded in memory.
DATA DISPLAY Provides useful data along with self-diagnosis results to determine the main cause.
Displays inpuffoutput data of ECM in real time.
Records and stores data.
Detects malfunctions in real time.
ACTIVE TEST Can be used to determine and identify the primary sources of malfunctions based on self-diagnosis
results and data from DATA MONITOR.
Each actuator is activated after receiving a drive signal.
CIU PART NUMBER I Displays part number memorized by CIU

2. OPERATION PROCEDURE
Turn ignition switch OFF.
Connect service tool to data link connector.
Turn ignition switch ON.
Turn on power supply for the service tool.
With main menu, select "1. Trouble Diagnosis of Vehicle", and
press YES.
Perform the necessary trouble diagnosis mode.
Refer to "CONSULT-II Operation Manual" for further
information.

3. WORK SUPPORT
The service tool assists with idle adjustment work. With service tool,
it sends an operation command to ECCS CIU, and adjustment
control is performed accordingly. However, inspector performs
actual adjustment work.

DISPLAY ITEM LIST

Work support item Description

FUEL PRESSURE RELEASE Shuts down the fuel pump and stops the engine. (While cranking, pressure in the fuel piping can be
released.)
TAS LEARNING When replacing the electronic throttle control or ECCS CIU, learning of the minimum air volume for idling
operation under the idling speed control at specified operating conditions.
AIR-FUEL RATIO LEARNING Clear the data of compensation coefficient in controlling air-fuel rate feedback.
IGNITION TIMING It is possible to set the target value for the initial ignition timing. (-10 to 0 degree Centigrade)
COMPENSATION (*) NOTE: Inspector should confirm that set value and actual ignition timing, using a timing light.
COMPENSATION OF IDLING Possible to set the target idling speed (0to 250 rpm)
SPEED (')

': This function is not necessary in the usual service procedure.lt is used to change target value due to rough idle or similar reasons.

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Service Tool (Cont'd)

4. SELF-DIAGNOSTIC RESULTS
When a malfunction occurs in ECCS CIU inpuffoutput signal
circuit, the malfunctioning circuit is recorded. Then, that particular
system name and basic inspection items are displayed. Also,
malfunction data recorded is displayed.

1.1.1.1.2.1 Self Diagnosis Data [DISPLAY EXAMPLE] MALFUNCTION IN AIR FLOW METER
DTC Supplement SYSTEM
PO102 Air flow meter
The error code one error items are displayed in the alarm monitor
screen.

Dialog Code No. 9

Press YES.
Print I F2 I F3 I F4

Trip 1: If a malfunction is detected by self-diagnosis between the

time ignition switch is turned ON (engine is running) and then turned
OFF (this is defined as "trip"), Warning light is lit. The corresponding
trouble code is recorded immediately after detection.
Trip 2: When a malfunction is detected by self-diagnosis for the first
time in the first trip, a tentative trouble code is recorded. If the same
malfunction is detected again by self-diagnosis in the next trip
(second trip), warning light is lit and the corresponding final trouble
code is recorded.

SERVICE TOOL SELF-DIAGNOSTIC RESULTS TIMING

For items of trip 1, timing "0" is displayed immediately after
detection of a malfunction.
For items of trip 2, when a malfunction is detected for the first
time (trip I ) , timing "It" is displayed. When a malfunction is
detected again in the next trip (trip 2), it is displayed as "0".
Accumulative counting is performed at the end of warming-up
operation,

CONDITIONS TO TURN OFF MIL

The engine warning light, marked with *, is turned off when
ignition switch is turned ON (engine starts) again after normal
state is resumed.
For other self-diagnostic items, self-diagnostic results shall be
erased by turning ignition switch to OFF after normal operation
is resumed.

FREEZE FRAME DATA

Driving conditions stored at the moment a malfunction is
detected and displayed.
This data can be used to reproduce conditions leading up to the
malfunction.
If multiple trouble codes exist, only the first one detected will be
stored and displayed. If the same malfunction is detected
several different times, the data stored first will be displayed.

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DISPLAY ITEM LIST

Stored data item Unit Description

FUEL SYS-Bl Displays air-fuel ratio feedback conditions at the time a malfunction occurred.
FUEL SYS-B2 Mode 2: No feedback control performed because of the system malfunction.
Mode 3:Feedback control did not respond to driving conditions.
Mode 4: Feedback control performed using heated oxygen sensor.
Mode 5: Conditions to shift into the feedback control not established after ignition
switch was turned ON.
CLV: Calculated Load Value) Based on the fuel injection amount, it calculates and displays the engine load at
the time a malfunction is detected.
COOLANT TEMP Displays engine coolant temperature at the time a malfunction is detected.
S-FUEL TRIM-BI(') Displays air-fuel ratio feedback learned value at the time a malfunction is
L-FUEL TRIM-B2 detected.
S-FUEL TRIM-BI Displays air-fuel ratio feedback corrected value at the time a malfunction is
S-FUEL TRIM-B2 detected.
ENGINE SPEED Displays engine speed at the time a malfunction is detected.
VEHICLE SPEED kmlh Displays vehicle speed at the time a malfunction is detected.
PULSE WIDTH msec Dlsplays pulse width at the time a malfunction is detected.
INTAKE AIR TEMP "C Displays intake air temperature at the time a malfunction is detected.
L
Show B1: No. 1 and 4 cylinders, 82: No. 2 and 3 cylinders.

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Service Tool (Cont'd)

5. DATA MONITOR
Allows determination and identification of the possible source of
a malfunction based on self-diagnosis test results.
Displays ECCS CIU inpuffoutput signal data in real time.
Records and prints out the data before and after the engine
malfunction or stall, either automatically or manually.

DISPLAY ITEM LIST

Monitor item Unit Description

Engine rpm I rPm Engine speed computed from crankshaft angle sensor signal
Air flow meter bank 1 Air flow sensor output voltage
Air-fuel ratio compensation bank 1 Average value of the cycles in compensation coefficient for air-fuel ratio feedback
LPG air-fuel ratio compensation
bank I
Coolant emperature sensor Value converted into temperature calculated from the output voltage of the engine
coolant temperature sensor
I
Oxygen sensor bank 1 V Output voltage of heated oxygen sensor
Oxygen sensor monitor bank 1 LeanlRich Air-fuel status given by the oxygen sensor signal during air-fuel ratio feedback
control.
RICH: Judged as Rich from the oxygen sensor output The ratio will be set low.
LEAN: Judged as Lean from the oxygen sensor signal The ratio will be set high.
Battery voltage I V Battery voltage for ECCS CIU
ETC accelerator sensor 1 V Value converted to the accelerator opening angle from output voltage of the
ETC accelerator sensor 2 accelerator sensor.

ETC throttle sensor 1 Value converted to the throttle opening angle from output voltage of the throttle
ETC throttle sensor 2 sensor.

Intake air temperature sensor Value converted to the intake air temperature from the output of air temperature
sensor.
Idle SW ONIOFF ONIOFF status as judged by each input signal
AIC signal I
Neutral SW
Electric load signal
Fuel changing SW 1 I
Fuel changing SW 2
Ignition SW
Brake SW I
Injection pulse width bank 1 ms Value calculated by ECCS CIU
LPG injection width
Ignition timing I BTDC
Fuel pump relay ONIOFF Status of each control as calculated by ECCS CIU
Throttle relay
LPG fuel injection relay I
--
Oxygen sensor heater bank 1 II
TAS learning history I DonelNot done Status of TAS leaning
Vehicle speed sensor I kmlh Value calculated from the vehicle speed sensor signal
Precise vehicle speed Precise value calculated from the vehicle speed sensor signal
Value calculated from the speed limit input signal (by ECCS CIU)
Oxygen sensor heater Duty ratio of oxygen sensor heater
Real time display of trouble code
ms Value calculated from the air flow meter signal and engine speed (by ECCS CIU)

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Monitor item Unit Description

LPG basic injection amount ms Value calculated from the air flow meter signal and engine speed (by ECCS CIU)
Filling efficiency % Value converted to filling efficiency from aerometer output voltage
LPG filling efficiency
Fuel type 01112 Position of fuel changing switch 0: Gasoline 1:LPG 2:NEUT
LPG fuel pressure sensor kPa Value calculated to pressure from output voltage of LPG fuel pressure sensor

6. DATA MONITOR (REFERENCE)

Data Monitor (Reference) The normal data ranges during idling operation (after warmed-
Monitoring NormalI up) for three items (airflow meter, basic injection amount, and
Enging rpn I 650rpn air-fuel ratio compensation) are displayed with graphs. The
related data are also displayed on the screen at real time.

A Enlarge Rec. start

MODE I BACK I LIGHT 1 COPY

7. ACTIVE TEST
Use this mode to determine and identify the details of a malfunction,
based on self-diagnosis test results and data obtained from DATA
MONITOR mode. service tool, instead of the ECCS CIU on the
vehicle, sends a drive signal to actuators to check their operation.

DISPLAY ITEM LIST

Active test item Description

Fuel injection test Can increase or decrease the amount of fuel injection (*25%).
LPG fuel injection test Can reproduce conditions resulting from air-fuel ratio related malfunctions (e.g. hesitation, poor
acceleration, poor racing, etc.) and help solve these malfunctions by pinpointing the causes.
Ignition timing test - .(-10 - 0°)
Allows setting a correction coefficient for retarding
POWER BALANCE Stops operation of specified injector. Also, displays engine speed at that time.
Mainly used to inspect for misfiring cylinders.
Coolant temperature Temperature range can be changed (-30 to 110 degree Centigrade).
It is possible to reproduce the malfunction at high or low temperature.
ETC-ISC compensating amount Changing opening angle of electronic controlled throttle valve can alter engine speed.

EC-49 TB45 ENGINE

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Service Tool (Cont'd)

8. CONTROL UNIT PART NUMBER
Displays part number of ECCS CIU mounted on vehicle.

(8) Self-diagnosis Function (without Service

Tool)
1. DESCRIPTION
In self-diagnosis, when any of the critical sensors or actuator
and exhaust gas control systems necessary for ECCS control
return a malfunction and self-diagnosis detection conditions are
satisfied, a DTC corresponding to the suspect system is stored
in ECCS for easier trouble diagnosis. Self-diagnostic results can
be displayed w.ith engine warning light in the combination meter.
There are two diagnosis test mode; Mode 1 and Mode 2. Mode
1 is used under normal status. Mode 2 is used for self diagnosis
or for oxygen sensor monitoring.

2. OPERATION PROCEDURE
Refer to the following for how to activate self-diagnosis mode or
erase self-diagnostic results.
CAUTION:
When a malfunction occurs in accelerator pedal position
sensors, self-diagnosis (without Service tool) cannot be
activated. Thus, use Service tool to perform self-diagnosis,
and repair malfunctioning part.

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Self-diagnosis Function (without Service Tool)

(Cont'd)

[DIAGNOSTICTEST MODE 2 (SELF-DIAGNOSTICRESULTS) STARTING PROCEDURE]

1 Turn ignition switch ON with accelerator pedal released.

2 After 3 seconds, fully depress accelerator pedal and then release it. Quickly repeat this cycle 5 times within 5 seconds (end in released position).

3 Fully depress accelerator pedal 7 seconds after releasing it, and keep that position approximately 10 seconds (until engine warning light blinks.)
Diagnostic test mode 2 selfdiagnostic results starts.
4 Return accelerator pedal. Execute selfdiagnosis.
Perform selfdiagnosis with ignition switch ON. [Diagnostic test mode 2 (selfdiagnostic results)]
Starting engine in Diagnostictest mode 2 (selfdiagnostic results) opens heated oxygen sensor monitor. [Diagnostic test mode II (heated
oxygen sensor monitor)]
.Turning ignition switch OFF returns to mode 1 automatically. [Normal condition]

CAUTION: Count time accurately with watch or equivalent.

If mode 1 does not turn to mode 2, turn ignition switch OFF and wait for at least 10 seconds.

[SELF-DIAGNOSIS RESULTS ERASING PROCEDURE]

1 Fully depress accelerator pedal in Diagnostic test mode 2 (selfdiagnostic results), and keep the position at least 10 seconds. Selfdiagnostic
results are erased.
Release accelerator pedal. Make sure selfdiagnostic results are erased.
.Turning ignition switch OFF returns to mode 1.

$2 ON [
OFF
-4 l3sec.
Within
5sec.
- -' - Start Diagnostic test mode II
(selfdiagnostic results)
10 sec.

Fully-open 12345
Accelerator I
Fully-dosed
I
I
II
Diagnosis test mode Mode I(normal condition) I Mode 2 (self-diagnosis) I Mode 1

-
3. MODE 1 VALVE INSPECTION
The light turns ON when turning ON the key switch (engine not
running), and turns OFF when engine starts.

-
4. MODE 1 TROUBLE WARNING LIGHT
If trouble is detected in self-diagnosis mode, it becomes trouble-
warning mode. In this mode, the engine warning light in the
combination meter turns on to inform the trouble for the
operator.
There are two types of displays; Trouble items being turned on
at trip 1 and items being turned ON at trip 2. The trouble items
are turned on in either trip mode (Not in both modes).

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Self-diagnosis Function (without Service tool)

(Cont'd)

I Exampleof code No. 1320 In this mode, the MIL blinks (indicating the DTC) to identify the
system that returned a malfunction.
If no DTC is detected, DTC "0000" is displayed.

OFF
0.3 sec. X 10
0.3 sec.X 10
ECM0284

DTC
(code
number)
0000
0102
0103
No trouble
Diagnosis item

Air flow sensor signal circuit

Coolant temperature sensol

DISPLAY ITEM LIST

Malfunction Return Condition

No malfunction is detected in any of the circuits

When engine is stopped (ignition switch ON) and mass air
flow sensor output voltage has been 4.9V or more for
predetermined period.
During engine is running, airflow sensor output voltage has
been opprox. 0.5V or less for specified period.
During engine is running, airflow sensor output voltage has
been approx. 1V for specified period.'
Engine coolant temperature sensor output voltage has been
+ Trip

signal circuit approximately 4.8V or more (open) or less than 0.04V

(short) for predetermined period.
Throttle position sensor signal v Sensor power supply voltage has a malfunction.
circuit , Throttle position sensor signal circuit is open or shorted.
s A malfunction occurs in relation between throttle position

sensors 1 and 2.
p When the fully-closed position learning value was unusually
small or was not able to learn.
Acceleration sensor signal * Accelerator pedal position sensor signal circuit is open or
circuit shorted.
, A malfunction occurs in relation between accelerator pedal
position sensors 1 and 2.
Heated oxygen sensor (open When traveling afler warming up the engine, oxygen sensor
circuit) signal circuit is open.
Heated oxygen sensor signal When traveling after warming up the engine, oxygen sensor
(short circuit) output voltage is higher than normal (2V or more).
Heated oxygen sensor heater
Oxygen sensor signal circuit is open.
signal circuit
Crankshafl position sensor 120 The crankshaft position sensor (POS) signal is not detected
jeg. (REF) signal circuit for a predeterminedtime at the engine start or during
- engine
-
running (when inputting (REF) signal).
The crankshafl position sensor (POS) signal irregular
waveform is detected for a predetermined time during
engine running (when inputting (REF) signal).

EC-52 TB45 ENGINE

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DTC
(code
number)
Diagnosis item Malfunction Return Condition I MIL Trip

0340 Crankshaft position sensor 1 At start-up no (REF) signal has been detected for more than 2
deg. (POS) signal circuit a predetermined period.
The (REF) signal is not detected for a predetermined time
during engine running (during crankshaft position sensor
(POS) signal input)/
A (REF) signal irregular waveform is detected for a
predetermined time during engine running (during (POS)
signal input).
Vehicle speed signal circuit Vehicle sensor signal has not been input under specific
conditions for a predetermined time during driving after
warming up.
ECCS CIU CPU or circuits in ECCS have a malfunction. ON*
ECCS CIU power supply circuit When no power supplied to the ECCS CIU for more than ON
specified period.
Electric throttle control, actuator When electronic controlled throttle has malfunctions due to ON'
:ircuit the mechanical trouble in the throttle system.
Electric throttle control, Correlation between the target throttle opening angle and ON*
'eedback circuit the actual opening angle has become abnormal.
Excessive current in throttle motor control circuit.
Electric throttle control, motor ON*
lay circuit Open or short in the throttle motor power supply circuit.

Ingine overheat b Normal status of coolant temperature circuit (Output voltage

of approx. 0.35V for more than specified period.)
gnition signal circuit 8 No continuous ignition signal while the engine is running.
Stop lamp switch signal circuit 8 Stop lamp switch kept off more than specified time during
traveling.
Ingine overheat step #I t Output voltage of coolant temperature sensor has been
more than approx. 0.6V for specified time. I -
.PG injector signal circuit
, Abnormal current applied on the LPG injector.
I --m
.PG fuel pressure
iignal, open-circuit
.PG fuel pressure
sensor

sensor
LPG fuel pressure sensor circuit: OPEN

Short in the LPG fuel pressure sensor circuit.

I ON

ON
iignal, short-circuit Pressure in fuel piping to the LPG injector has been raised
abnormally for the specified period.

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Self-diagnosis Function (without Service tool)

(Cont'd)
Trip 1: If a malfunction is detected by self-diagnosis between the
time ignition switch is turned ON (engine is running) and then turned
OFF (this is defined as "trip"), Warning light is lit. The corresponding
DTC is recorded immediately after detection.
Trip 2: When a malfunction is detected by self-diagnosis for the first
time in the first trip, a tentative trouble code is recorded. If the same
malfunction is detected again by self-diagnosis in the next trip
(second trip), Warning light is lit and the corresponding final trouble
code is recorded. Even when 1st trip trouble code is being
memorized, the appropriate trouble code is displayed as self-
diagnostic results by MIL.

CONDITIONS TO TURN OFF ENGINE WARNING LIGHT

The warning light, marked with *, is turned off when ignition
switch is turned ON (engine starts) again after normal state is
resumed.
For other self-diagnostic items, self-diagnostic results shall be
erased by turning ignition switch to OFF after normal operation
is resumed.

DIAGNOSTIC TEST MODE II HEATED OXYGEN -

SENSOR MONITOR
In this mode, status of air-fuel ratio is displayed by blinking of
MIL.
Make sure that MIL blinks at least 5 times within 10 seconds
ON (LEAN)
after warming up engine and keeping engine speed at
OFF (RICH)
approximately 2,000 rpm.

LEAN:Af(A+B)XlOO
-
NOTE:
Although air-fuel ratio feedback control is active at idle, increase
Duty ratio of 1 cyde engine speed and check.
RICH :BI(A+B)X100

During air-fuel ratio feedback control

Heated oxygen sensor output is large (rich): OFF
Heated oxygen sensor output is small (lean): ON
Air-fuel ratio feedback control is stopped: OFF
Air-fuel ratio feedback control is clamped: State immediately
before clamping is maintained.

(9) Service Tool Reference Value in Data

Monitor
Values in the table are reference values.
Values in the table are values detected in ECCS CIU or input1
output values sent from ECCS CIU. Thus, they may differ from
actual part values. [Example: ignition timing checked using
timing light and display on "IGN TIMING" screen in "DATA
MONITOR mode could be different. This happens because
values on "IGN TIMING" screen is calculated by ECCS using
input signal from various sensors. They are crankshaft position
sensor (POS) and other ignition timing related sensors.]

EC-54 TB45 ENGINE

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Service Tool Reference Value in Data Monitor

(Cont'd)

Monitor item Measuring condition Reference value

Engine rpm I Almost in accordance
Airflow meter bank 1 After engine warming up At Idle Approx. 1.8 - 2.OV
Selector lever: N
At approx. 2,000 rpm Approx. 2.5 - 2.8V
No load
Basic fuel injection amount AHer engine warming up At Idle Approx. 2.5 - 4 msec
Selector lever: N
No load
I I

Air-fuel ratio compensation After engine warming up At Idle Approx. 90 - 110%

bank 1
Coolant temperature sensor After engine warming up Approx. 80°C or more
Oxygen sensor bank 1 After engine warming up At Idle Changes between approx. 0.1 -
0.4V00.6 - 0.9V
Maintain at approx. 2,000 rpm Changes between approx. 0.1 -
0.4V00.6 - 0.9V
Oxygen sensor monitor AHer engine warming up At Idle Switches slowly between
bank 1 LEANWRICH.
Maintain at approx. 2,000 rpm Switches between LEANoRlCH at
least 5 times for 10 seconds.
Vehicle speed sensor Drive, and compare with the value displayed on speedometer. Almost in accordance
Battery voltage Ignition switch: ON (with engine stopped) Approx. 11 - 14V
ETC accelerator sensor 1 AHer engine warming up At Idle Approx. 0.6 - 0.65V
Approx. 2,000 rpm Approx. 0.75 - 0.8V
Ignition switch ON with Approx. 4.1 - 4.3V
accelerator pedal depressed (With
engine stopped)
Throttle sensor 1 After engine warming up At Idle Approx. 0.5 - 0.55V
Approx. 2,000 rpm Approx. 0.65 - 0 . N
Ignition switch ON with Approx. 0.7 - 0.75V
accelerator pedal depressed (With
engine stopped)
Intake air temperature After engine warming up N position ON
I
sensor lgnition switch: ON (Engine not Other than above OFF
running)
ldle SW Ignition switch: ON IAccelerator pedal: released 1 ON
I
I
Accelerator pedal: fully depressed OFF
Neutral SW Ignition switch: ON I N range 1 ON
Other than above OFF
Electric load signal Ignition switch: ON Head light switch: ON ON
Head light switch: OFF OFF
I I

lgnition SW Ignition switch: ON IOFF 1 ON 1 OFF

Brake SW Ignition switch: ON Brake pedal depressed ON
Brake pedal released OFF
Injection pulse width bank 1 After engine warming up At Idle Approx. 4 - 6 msec (Gasoline)
LPG fuel injection width Selector lever: N
At approx. 2,000 rpm Approx 4 - 6 msec (LPG)
No load
lgnition timing After engine warming up At Idle Approx. 1O"BTDC
Selector lever: N At approx. 2,000 rpm Approx. 35 - 45"BTDC
No load
Fuel pump relay For 1 second after ignition switch is ON ON
While engine is running and cranking
B Other than above OFF

EC-55 TB45 ENGINE

 TROUBLE SHOOTING

Monitor item Measuring condition Reference value

Throttle relay Ignition switch: ON /OFF ON /OFF
Oxygen sensor bank 1 . After engine warmed up (at idle) Approx. ? rpm or more OFF
Other than above ON
TAS leaning history After engine warmed up (at idle) Idle air volume learning DONE
All electrical load switches: OFF comoleted.
Selector lever: N
ldle air volume learning not yet YET
Throttle valve closed position
completed,
learning completed

(10) Fail-safe Function

When any of the critical sensors or systems sends a
malfunction message, the fail-safe function estimates the
driving conditions with other input signals and selects safer
conditions for engine (vehicle) control, based on data previously
stored in ECCS.

Related sensors

Mass air flow sensor

Malfunction
condition
Same as self-
Fail-safe

Selects fuel injection pulse width depending on engine speed

I Warning light

ON
jiagnosis and throttle position so the vehicle can be driven. However, fuel
malfunction detection injection will be inhibited (fuel cut-off) when engine speed
:onditions. exceeds approximately 800 rpm.
ldle speed is 800 rpm.
Engine coolant Uses the estimated engine coolant temperature (varies with ON
temperature sensor elapsed time after start) to perform controls so the vehicle can
be driven.
Accelerator pedal Fuel injection will be inhibited when 1 circuit is opened. Release ON
position sensor valve mechanically until it can drive at low speed when
disconnecting connector.
Throttle position sensor Fixes output to a preset value so the vehicle can be driven. ON
However, fuel injection will be inhibited (fuel cut-off) when
engine speed exceeds approximately 2,500 rpm.
Engine warning light Fuel injector will be inhibited at approximately 2,500 rpm to
prevent warning light malfunction if exhaust performance and
driving performance malfunctions are occurring.

EC-56 TB45 ENGINE