ENGINE CONTROL SYSTEM OPERATION INSPECTION [AJ] (VIN: JM0 LW10J300 301406-, JMZ LW69J7*# 307683-, JM8 LW28J**# 301514-, JM8 LW28A**# 301514- (Assumed))

Input Signal System Investigation Procedure

1. Find an unusual signal. (See Finding unusual signals.)

2. Locate its source. (See Locating the source of unusual signals.)

3. Repair or replace the defective part.

4. Confirm that the unusual signal has been erased.

Finding unusual signals

While referring to ON-BOARD DIAGNOSTIC TEST [AJ], use the PID/DATA monitor and record function to inspect the input signal system relating to the problem.

1. Start the engine and idle the vehicle. You can assume that any signals that are out of specifications by a wide margin are unusual.

2. When recreating the problem, any sudden change in monitor input signals that is not consciously created by the driver can be judged as unusual.

Locating the source of unusual signals

Caution

• Compare the WDS or equivalent monitor voltage with the measurement voltage using the digital measurement system function. If you use another tester, misreading may occur.

• When measuring voltage, attach the tester GND to the GND of the PCM that is being tested, or to the engine itself. If this is not done, the measured voltage and actual voltage may differ.

• After connecting the pin to a waterproof coupler, confirming continuity and measuring the voltage, inspect the waterproof connector for cracks. If there are any, use sealant to fix them. Failure to do this may result in deterioration of the harness or terminal from water damage, leading to problems with the vehicle.

Variable resistance type 1 (TP sensor and EGR boost sensor)

Investigate the input signal system for variable resistance type 1

1. When you get an unusual signal, measure the #1 PCM terminal voltage.

• If the #1 terminal voltage and the WDS or equivalent monitor voltage are the same, proceed to the next step.

• If there is a difference of 0.5 V or above, inspect for the following points concerning the PCM connector.

- Female terminal opening is loose.

- Coupler (pin holder) damage

- Pin discoloration (blackness)

- Harness/pin crimp is loose or disconnected.

2. Measure the #2 sensor terminal voltage.

• If there is a 0.5 V or above difference between the sensor and WDS or equivalent voltages, inspect the harness for open or short circuits.

• If the sensor and WDS or equivalent voltages are the same, inspect for the following points concerning the sensor connector.

• If there are no problems, proceed to next investigation below.

- Female terminal opening is loose.

- Coupler (pin holder) damage

- Pin discoloration (blackness)

Investigate the standard power supply system for variable resistance type 1

•  Confirm that the #3 terminal is at 5 V.

- If the measured voltage on the #3 terminal is 5 V, inspect the following points on the sensor connector.

- If there is no problem, inspect for the following.

• Female terminal opening loose

• Coupler (pin holder) damage

• Pin discoloration (blackness)

- If the #3 terminal measures other than 5 V, inspect for the following.

• Open or short circuit in harness

• Harness/pin crimp is loose or disconnected.

Investigate the GND system for variable resistance type 1

• Confirm that terminal sensor #5 is at 0 V.

- If it is at 0 V, inspect the sensor.

• If necessary, replace the sensor.

- If not, inspect for the following.

• Open or short circuit in harness

• Female terminal opening is loose open or short circuit in harness

• Coupler (pin holder) damage

• Pin discoloration (blackness)

• Harness/pin crimp is loose or disconnected.

Variable resistance type 2 (fuel tank level sensor and mass air flow (MAF) sensor)

Investigate the GND system for variable resistance type 2

• Confirm that terminal sensor #4 is at 0 V.

- If it is at 0 V, inspect the sensor.

• If necessary, replace the sensor.

- If not at 0 V, inspect for the following.

• Open circuit in harness

• Female terminal opening is loose.

• Coupler (pin holder) damage

• Pin discoloration (blackness)

• Harness/pin crimp is loose or disconnected.

Investigate the input signal system for variable resistance type 2

1. When you get an unusual signal, measure the #1 PCM terminal voltage.

• If the #1 terminal voltage and the WDS or equivalent monitor voltage are the same, proceed to the next step.

• If there is a difference of 0.5 V or above, inspect for the following points concerning the PCM connector.

- Female terminal opening is loose.

- Coupler (pin holder) damage

- Pin discoloration (blackness)

- Harness/pin crimp is loose or disconnected.

2. Measure the #2 sensor terminal voltage.

• If there is a 0.5 V or above difference between the sensor and WDS or equivalent voltages, inspect the harness for open or short circuits.

• If the sensor and WDS or equivalent voltages are the same, inspect the following points concerning the sensor connector.

- Female terminal opening is loose.

- Coupler (pin holder) damage

- Pin discoloration (blackness)

- Harness/pin crimp is loose or disconnected.

• If there are no problems, proceed to next investigation below.

Investigate the electrical supply system for variable resistance type 2

• Confirm that the sensor #3 terminal is B+.

- If the measured voltage on the #3 terminal is B+, inspect the following points on the sensor connector.

- If there is no problem, inspect for the following.

• Female terminal opening is loose.

• Coupler (pin holder) damage

• Pin discoloration (blackness)

- If the #3 terminal measures other than B+, inspect the following.

• Open or short circuit in harness

• Harness/pin crimp is loose or disconnected.

Thermistor type (IAT sensor and ECT sensor)

Investigate the input signal system for thermistor type

1. When you get an unusual signal, measure the #1 PCM terminal voltage.

• If the #1 terminal voltage and the WDS or equivalent monitor voltage are the same, proceed to the next step.

• If there is a difference of 0.5 V or above, inspect the following points concerning the PCM connector.

- Female terminal opening loose

- Coupler (pin holder) damage

- Pin discoloration (blackness)

- Harness/pin crimp is loose or disconnected.

2. Measure the #2 sensor terminal voltage.

• If there is a 0.5 V or above difference between the sensor and WDS or equivalent voltages, inspect the harness for open or short circuits.

• If the sensor and WDS or equivalent voltages are the same, inspect the following points concerning the sensor connector.

- Female terminal opening is loose.

- Coupler (pin holder) damage

- Pin discoloration (blackness)

- Harness/pin crimp is loose or disconnected.

• If there are no problems, proceed to next investigation below.

Investigate the GND system for thermistor type

• Confirm that terminal sensor #3 is at 0 V.

- If it is at 0 V, inspect the sensor. If necessary, replace the sensor.

- If not, inspect for the following.

• Open circuit in harness

• Female terminal opening is loose.

• Coupler (pin holder) damage

• Pin discoloration (blackness)

• Harness/pin crimp is loose or disconnected.

VSS

1. Measure the #1 PCM terminal voltage and confirm that it is at 0 V or 5 V when the ignition switch at ON and the engine at idle.

• If it is at 0 V or 5 V, intermittent concern exists. (See INTERMITTENT CONCERN TROUBLESHOOTING [AJ].)

• If not, inspect the following points concerning the PCM connector.

• If there is no problem, inspect for the following.

- Female terminal opening is loose.

- Coupler (pin holder) damage

- Pin discoloration (blackness)

- Harness/pin crimp is loose or disconnected.

2. Measure the #2 sensor terminal voltage and confirm that it is at 0 V or 5 V when the ignition switch at ON and the engine at idle.

• If it is at 0 V or 5 V, intermittent concern exists. (See INTERMITTENT CONCERN TROUBLESHOOTING [AJ].)

• If not, inspect the following points concerning the sensor connector.

• If there is no problem, inspect for the following.

- Female terminal opening is loose.

- Coupler (pin holder) damage

- Pin discoloration (blackness)

- Harness/pin crimp is loose or disconnected.

3. Confirm that the #3 terminal switch voltage is at 0 V.

• If it is at 0 V, inspect the sensor. If necessary, replace the sensor.

- If necessary, replace the sensor.

• If not, inspect for the following.

- Open circuit in harness

- Female terminal opening is loose.

- Coupler (pin holder) damage

- Pin discoloration (blackness)

- Harness/pin crimp is loose or disconnected.

Intake Manifold Vacuum Inspection

1. Verify air intake hoses are installed properly.

2. Start the engine and run it at idle.

3. Measure the manifold vacuum using a vacuum gauge.

• If not as specified, inspect following.

- Air suction at throttle body, intake manifold and PCV valve installation points

- Accelerator cable free play

- Fuel injector insulator

- Engine compression

Above 60 kPa {450 mmHg, 18 inHg}

Idle Air Control Inspection

Engine coolant temperature compensation inspection

1. Connect the SSTs (WDS or equivalent) to DLC-2.

2. Select the PID/DATA MONITOR AND RECORD function on the WDS or equivalent display.

3. Select the following PIDs.

• ECT

• RPM

4. Verify that the engine is in cold condition, then start the engine.

5. Verify that the engine speed decreases as the engine warms up.

• If the engine speed does not decrease or decreases slowly, inspect the following.

- ECT sensor and related harness (See ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [AJ] (VIN: JM0 LW10J300 301406-, JMZ LW69J7*# 307683-, JM8 LW28J**# 301514-, JM8 LW28A**# 301514- (Assumed)).)

- IAC valve and related harness (See IDLE AIR CONTROL (IAC) VALVE INSPECTION [AJ] (VIN: JM0 LW10J300 301406-, JMZ LW69J7*# 307683-, JM8 LW28J**# 301514-, JM8 LW28A**# 301514- (Assumed)).)

Intake Manifold Communication Control (IMCC) System Inspection

1. Connect WDS or equivalent to DLC-2.

2. Verify that no DTC detected.

• If any DTC is detected perform appropriate DTC inspection. (See ON-BOARD DIAGNOSTIC TEST [AJ].)

3. Access the IMCC PID.

4. Remove the IMCC actuator with connector connected.

5. Turn the ignition switch to ON.

6. Verify that the IMCC actuator moves when the IMCC PID from OFF to ON using the simulation function.

• If the IMCC actuator does not move, inspect and repair or replace followings:

- IMCC actuator (See INTAKE MANIFOLD COMMUNICATION CONTROL (IMCC) ACTUATOR INSPECTION [AJ] (VIN: JM0 LW10J300 301406-, JMZ LW69J7*# 307683-, JM8 LW28J**# 301514-, JM8 LW28A**# 301514- (Assumed)).)

- Harness and connectors between PCM and IMCC actuator.

Fuel Injector Operation Inspection

Ignition Timing Control Inspection

1. Start the engine and run it at idle.

2. Warm up the engine to normal operating temperature.

3. Connect the SSTs (WDS or equivalent) to the DLC-2.

4. Select the PID/DATA MONITOR AND RECORD function on the WDS or equivalent display.

5. Select the SPARKADV PID.

6. Verify that SPARKADV PID is within the specification.

BTDC 4°-16° (10° ± 6°)

7. Increase the engine speed and verify that the SPARKADV PID value is advanced.

• If it is not advanced, inspect the following.

- CKP sensor and related harness (See CRANKSHAFT POSITION (CKP) SENSOR INSPECTION [AJ] (VIN: JM0 LW10J300 301406-, JMZ LW69J7*# 307683-, JM8 LW28J**# 301514-, JM8 LW28A**# 301514- (Assumed)).)

- MAF sensor and related harness (See MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION [AJ] (VIN: JM0 LW10J300 301406-, JMZ LW69J7*# 307683-, JM8 LW28J**# 301514-, JM8 LW28A**# 301514- (Assumed)).)

EGR Control System Inspection

1. Verify that EGR valve operation (initial operation) sound is heard when the ignition switch is turned to ON position.

• If the operation sound is not heard, connect WDS or equivalent to the DLC-2 and verify that the DTC P0403 is shown. Perform DTC inspection. (See DTC TABLE [AJ] (VIN: JM0 LW10J300 301406-, JMZ LW69J7*# 307683-, JM8 LW28J**# 301514-, JM8 LW28A**# 301514- (Assumed)).)

2. Start the engine and run it at idle.

3. Warm-up the engine to normal operating temperature.

4. Select the following PIDs:

• ECT

• RPM

• SEGRP

• TP

• VSS

5. Let the vehicle idle and verify that the SEGRP value is 0.

6. Put the vehicle in drive.

7. Depress the accelerator pedal and verify that the SEGRP value increases.

• If the SEGRP value does not increase, inspect the VSS, TP and ECT PIDs. (See PCM INSPECTION [AJ] (VIN: JM0 LW10J300 301406-, JMZ LW69J7*# 307683-, JM8 LW28J**# 301514-, JM8 LW28A**# 301514- (Assumed)).)

• If the SEGRP value does increases, inspect the following:

- EGR valve (Stuck open or close)

- Wiring harness and connectors (Main relay-EGR valve-PCM)

8. Stop the vehicle and verify that the SEGRP value returns to 0.

Purge Control System Inspection

1. Start the engine.

2. Disconnect the vacuum hose between the purge solenoid valve and the charcoal canister.

3. Put a finger to the purge solenoid valve and verify that there is no vacuum applied when the engine is cold.

• If there is a vacuum, inspect the following:

- Wiring harness and connectors (Purge solenoid valve - PCM terminal 85)

- Purge solenoid valve

4. Warm-up the engine to the normal operating temperature.

5. Stop the engine.

6. Connect the WDS or equivalent to the DLC-2 and verify that the DTC P0443 is displayed. Perform DTC inspection. (See DTC TABLE [AJ] (VIN: JM0 LW10J300 301406-, JMZ LW69J7*# 307683-, JM8 LW28J**# 301514-, JM8 LW28A**# 301514- (Assumed)).)

7. Turn ignition switch to ON position.

8. Select ECT PID.

9. Verify that the engine coolant temperature is 60°C {140 °F} or above.

• If WDS or equivalent indicates less than 60°C {140 °F}, perform the ECT sensor inspection. (See ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [AJ] (VIN: JM0 LW10J300 301406-, JMZ LW69J7*# 307683-, JM8 LW28J**# 301514-, JM8 LW28A**# 301514- (Assumed)).)

10. Set the vehicle on the dynamometer or chassis roller.

Warning

• When the dynamometer or chassis roller is operating, there is a possibility that the operator may come into contact with or be caught up in the rotating parts, leading to serious injuries or death. When performing work while the dynamometer or chassis roller is operating, be careful not to come into contact with or be caught up in any of the rotating parts.

11. Drive vehicle with engine speed at approx. 2,000 rpm for more than 30 s.

12. Put a finger to the purge solenoid valve and verify that there is no vacuum applied.

• If there is no vacuum, inspect the following:

- Wiring harness and connector (Main relay- purge solenoid valve-PCM terminal 85)

- Purge solenoid valve

- MAF, TP and LOAD PIDs

• If there is vacuum, inspect the following:

- Vacuum hose (Purge Solenoid valve - charcoal canister)

Spark Test

1. Disconnect the fuel pump relay.

2. Verify that each ignition coil and connector is connected properly.

3. Inspect the ignition system in the following procedure.

Warning

• High voltage in the ignition system can cause strong electrical shock which can result in serious injury. Avoid direct contact to the vehicle body during the following spark test.

Main Fan/Additional Fan Motor Operation Inspection

1. Cool down engine.

2. Connect WDS or equivalent to the DLC-2.

3. Turn ignition switch ON.

4. Turn A/C switch OFF.

5. Verify that main fan/additional fan are not operated.

• If main fan/additional fan are operated, verify FAN_DUTY PID.

- If FAN_DUTY PID value is not 0%, inspect following PIDs.

• ECT (voltage)

• ACSW

- If FAN_DUTY PID value is 0%, inspect follow.

• Fan control module

• Open or short to ground circuit between fan control module and PCM

6. Increase FAN_DUTY PID value from 0% to 100% gradually by Datalogger/simulation function. Verify that both main fan and additional fan operation speed increase in accordance with FAN_DUTY PID value changes.

Note

• Main fan and additional fan are not rotate when FAN_DUTY PID value is lower than 30% by fan motor internal friction.

• If there is a problem, perform following steps.

(1) Verify clicking sound of fan relay when turn ignition switch OFF to ON.

• If there is no clicking sound, inspect follows.

- Fan relay

- Open circuit between main relay and fan relay

• If clicking sound heard, go to next step.

(2) Inspect following parts in order in accordance with fan operation condition.

• Both main fan and additional fan do not operate.

- Open circuit between fan control module and fan relay

- Open circuit in fan control module ground harness

- Poor connection of fan control module connector

- Fan control module

• Only main fan does not operate.

- Open or short to ground circuit between fan control module and main fan motor

- Poor connection of fan control module connector and/or main fan motor connector

- Main fan motor malfunction

- Fan control module

• Only additional fan does not operate.

- Open or short to ground circuit between fan control module and additional fan motor

- Poor connection of fan control module connector and/or additional fan motor connector

- Additional fan motor malfunction

- Fan control module