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2001 - Millenia - Workshop Manual - Engine

ENGINE CONTROL SYSTEM OPERATION INSPECTION [KL]

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 PID/DATA Monitor and Record Procedure.
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:

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

Investigate the input signal system
1. When you get an unusual signal, measure the #1 PCM terminal voltage.
2. Measure the #2 sensor terminal voltage.
Investigate the standard power supply system for variable resistance type 1
1. Confirm that the #3 terminal is at 5 V.
Investigate the GND system for variable resistance type 1
1. Confirm that terminal sensor #5 is at 0 V.
Thermistor type (ECT sensor, IAT sensor and transaxle fluid temperature sensor)

Investigate the input signal system for thermistor type
1. When you get an unusual signal, measure the #1 PCM terminal voltage.
2. When you get an unusual signal, measure the #2 sensor terminal voltage.
Investigate the GND system for thermistor type
1. Confirm that sensor #3 is at 0 V.
Variable resistance type 2

Investigate the input signal system for variable resistance type 2
1. When you get an unusual signal, measure the #1 PCM terminal voltage.
2. When you get an unusual signal, measure the #2 sensor terminal voltage.
Investigate the electrical supply system for variable resistance type 1
1. Confirm that the sensor #3 terminal is B+.
Investigate the GND system for variable resistance type 2
1. Confirm that terminal sensor #4 is at 0 V.

Switch Type (Closed Throttle Position, Transaxle Range and HOLD Switch)

1. Measure the PCM #1 terminal voltage and confirm that it is 0 V when the switch is on and B+ when the switch is off.
2. When the switch is off, measure the #2 sensor terminal voltage.
3. Confirm that the #3 terminal switch voltage is at 0 V.

Intake Manifold Vacuum Inspection

1. Verify that the intake-air hoses are installed properly.
2. Start the engine and run it at idle.
3. Measure the manifold vacuum using a vacuum gauge.

NOTE:

Idle Air Control Inspection

1. Start the engine and run it at idle.
2. Disconnect the IAC valve connector and verify that the engine rotation becomes rough or the engine stalls.
3. If the engine condition will not change, perform as follows.
a. Connect the SSTs (NGS tester) to the DLC-2.

b. Verify that DTC P0505 is not displayed.
  • If of DTC P0505 is shown, carry out DTC inspection.

c. Select the SIMULATION TEST function on the NGS display.
d. Change the duty value of the IAC valve to 100% using the IACV PID.
e. Verify that the idle speed increases.
4. Warm up the engine to normal operating temperature and run it at idle.
5. Turn the electrical loads on and verify that the engine speed is within the specification.
Engine speed (rpm)

No load

600--700

E/L operated

650--750

A/C operated

775--875

P/S operated

600--700


BAC Valve Inspection

CAUTION:

1. Short the DLC terminal TEN to body GND using a jumper wire.

2. Connect a dwell tacho tester to the DLC terminal IG–.

3. Start the engine at engine cold condition.
4. Verify that the idle speed decreases gradually as the engine warms up.

VRIS Control Inspection

1. Start the engine.
2. Verify that the rods of the shutter valve actuators No.1 and No.2 are not pulled.

a. Stop the engine.
b. Connect the SSTs (NGS tester) to the DLC-2.

c. Verify that DTCs P1521 and/or P1522 are not displayed.
  • If DTCs P1521 and/or P1522 are shown, carry out troubleshooting of the DTCs. P1521 and/or P1522.

  • If DTCs are not shown, start the engine and run it at idle.

d. Select the SIMULATION TEST function on the NGS display.
e. Turn the VRIS solenoid valve from OFF to ON using the “VRISV1” or “VRISV2” and inspect if operation sound of the valve is heard.
  • If the operation sound is heard, inspect the following.

    • VRIS shutter valve actuators

  • If the operation sound is not heard, inspect the following.

    • VRIS solenoid valve

3. Inspect the rod operation under the following conditions.Rod operation

Engine speed (rpm)

0

3750

4250

6250

7500

VRIS shutter valve actuator 1

Not operate

Operate

Not operate

VRIS shutter valve actuator 2

Not operate

Operate

Not operate


4. If rod operation is not as specified, perform as follows.
a. Stop the engine.
b. Connect the SSTs (NGS tester).
c. Verify that DTCs P1521 or P1522 is not displayed.
  • If DTCs P1521 or P1522 is shown, carry out troubleshooting of the DTCs P1521 and/or P1522.

  • If DTCs are not shown, start the engine and run it at idle.

d. Select the SIMULATION TEST function on the NGS display.
e. Turn the VRIS solenoid valve from OFF to ON using “VRISV1” or “VRISV2” and inspect if operation sound of the valve is heard.
  • If the operation sound is heard, inspect the following.

    • Loose or damaged vacuum hose

    • VRIS shutter valve actuators

    • Throttle position sensor

  • If the operation sound is not heard, check the following.

    • VRIS solenoid valve

Fuel Injection Control Inspection

1. Connect the SSTs (NGS tester) to the DLC-2.

2. Warm up the engine to normal operating temperature and let it idle.
3. Select the PID/DATA MONITOR AND RECORD function of the NGS.
4. With no electrical load operating, select “INJ R” and “INJ L” on the NGS display. NGS measures and shows the fuel injector pulse widths.
5. Increase the engine speed and verify that the pulse width changes.

Fuel Pump Control Inspection

1. Turn the ignition switch to START and inspect for fuel pump relay operating sound.

Pressure Regulator Control Inspection

WARNING:

1. Connect the fuel pressure gauge.

2. Measure the fuel pressure under the following conditions.
Specifications

Fuel pressure (kPa {kgf/cm 2, psi})

Idling

210--260 {2.1--2.7, 30--38}

210--260 {2.1--2.7, 30--38}

270--310 {2.7--3.2, 39--45}

During 120 sec. of hot start

270--310 {2.7--3.2, 39--45}

After 120 sec. of hot start

210--260 {2.1--2.7, 30--38}

Judgement

Normal

Not normal

(Perform Inspection 1)

Not normal

(Perform Inspection 2)


Malfunction 1 inspection
1. Stop the engine.
2. Connect the SSTs (NGS tester) to DLC-2.

3. Start the engine and run it at idle.
4. Select the SIMULATION TEST function on the NGS display.
5. Turn the PRC solenoid valve from OFF to ON using the “PRCV” and inspect if the fuel pressure changes.
a. Stop the engine.
b. Turn the ignition switch to ON.
c. Turn the PRC solenoid valve from OFF to ON using the simulation function and inspect if the operation sound of the valve is heard.
  • If the operation sound is heard, check the pressure regulator.

  • If the operation sound is not heard, check the PRC solenoid valve and related harness.

Malfunction 2 inspection
1. Stop the engine.
2. Connect the SSTs (NGS tester) to the DLC-2.
3. Using the PID/DATA MONITOR AND RECORD function, verify that the PRC solenoid valve is off.
4. Select the SIMULATION TEST function on the NGS display.
5. Turn the PRC solenoid valve from OFF to ON using the “PRCV” and inspect if the operation sound of the valve is heard.

Electronic Spark Advance Control Inspection

1. Turn off following electrical loads.
2. Connect a timing light to the high-tension lead of No.1 cylinder.

CAUTION:

3. Short the DLC terminal TEN to body GND using a jumper wire.

4. Start the engine and verify that the ignition timing retards as the engine warms up.

5. Disconnect the SST.
6. Verify that the engine is completely warmed up.
7. Increase the engine speed and verify that the ignition advances accordingly.

EGR Control Inspection

1. Connect the SSTs (NGS tester) to the DLC-2.

2. Start the engine and let it idle.
3. Select the SIMULATION TEST function on the NGS display.
4. Increase the duty value of the EGR solenoid valve (vacuum) from 0% to 100% using the “EGRVAC”.
5. Operate the EGR solenoid valve (vacuum) and inspect if the engine speed becomes unstable or the engine stalls.
6. Increase the duty value of the EGR solenoid valve (vacuum) from 0% to 100% using the “EGRVAC”.
7. Operate the EGR solenoid valve (vacuum) and inspect if operation sound of the solenoid valve is heard.

Fuel Tank Pressure, Graph Recording Procedure

1. After setting up the NGS tester for current vehicle, select “DIAGNOSTIC DATA LINK” and press the TRIGGER.

2. Select, “PCM–POWERTRAIN CONTROL MODULE” and press the TRIGGER.

3. Select “PID/DATA MONITOR AND RECORD” and press the TRIGGER.

4. Press Number 5 under CLEAR to clear previously selected PIDs.

NOTE:

5. Turn the menu dial clockwise or counterclockwise to highlight CDCV and select by pressing the TRIGGER.

6. Turn the menu dial clockwise or counterclockwise to highlight FTP and select by pressing the TRIGGER.

7. PUSH Number 7 under START to view PIDs.

8. When you begin the drive mode, PRESS TRIGGER to capture the data. (See OBD-II DRIVE MODE [KL].)

NOTE:

9. When the monitor changes back to OFF, wait a few seconds and press the TRIGGER to save the recorded information.

10. Select VIEW RECORDING the press the TRIGGER.
11. Select both PIDs by highlighting and pressing the TRIGGER.

12. Press the number key under GRAPH.

NOTE:

Evaporative System Test

Evaporative system test outline
Evaporative system test description

The PCM Evaporative (EVAP) system monitoring function is activated using the NGS tester. During monitoring, the PCM controls:

1. The PCM opens PRGV to apply vacuum to EVAP system and closes CDCV to shut off the EVAP lines the atmosphere.
2. When the vacuum in the EVAP system has reached a preset level or a preset time has passed, the PCM closes PRGV to seal the EVAP system.
3. The PCM will maintain this sealed condition for about 33 seconds while recording the FTP1SV and FTP2SV at each preset time interval.

Evaporative system test procedure

NOTE:

1. Turn the ignition switch on.
2. After setting up the NGS tester for the current vehicle, select DIAGNOSTIC DATA LINK and press TRIGGER.

3. Select PCM - POWERTRAIN CONTROL MODULE and press TRIGGER.

4. Select PID/DATA MONITOR AND RECORD and press TRIGGER.

5. Press Number 5 under CLEAR to clear previously selected PIDs.

NOTE:

6. Turn the menu dial clockwise to select BARO by pressing TRIGGER.

7. Turn the menu dial clockwise to select ECT, FTL V, and IAT by pressing TRIGGER.

8. Push Number 7 under START to view PIDs.

9. Record the data values for BARO, ECT, FTL V, and IAT.

NOTE:

Specification

PID

PID Range

BARO

72.3--100.9 kPa {21.4--29.9 inHg}

ECT

0--30 °C {32--86 °F}

FTL V

0.5--2.5 V

IAT

–10--60 °C {14--140 °F}

ECT-IAT

10 °C {18 °F} or less


10. Start the engine and race it at 3,500 rpm for 200 seconds to warm it up completely.
11. Press CANCEL two times.
12. Select DIAGNOSTIC SUPPORT PROCEDURE and press TRIGGER.

13. Select SINGLE TEST and press TRIGGER.

14. Select "EVAP LEAK TEST" in the second screen and press TRIGGER.

15. Press TRIGGER one more time to start the evaporative system test.

NOTE:

16. Verify that each result is within the specifications in the table or graphs, using the BARO PID value recorded in Step 9.

17. Scroll one line.

Large leak threshold value (Pa)

BARO

(kPa {inHg})

ECT (°C {°F})

25 {77} or below

26--30

{79--86}

72.3--85.1 {21.4--25.1}

–1,481 or below

–1,090 or below

85.2--100.9

{25.2--29.9}

–1,481 or below

–1,383 or below


Small leak threshold value (Pa)

BARO

(kPa {inHg})

ECT (°C{°F})

25 {77} or below

26--30

{79--86}

72.3--85.1 {21.4--25.1}

878 or below

1,123 or below

85.2--100.9 {25.2--29.9}

830 or below

830 or below


18. If NGS values are out of range, use the following procedure in DTC troubleshooting to diagnose the problem.

Failed item

Troubleshooting

Large leak

DTC P0455

Small leak

DTC P0442


19. Clear pending or stored DTCs.

Evaporative System Leak Inspection Using Leak Tester

1. Perform the following SST (Evaporative Emission System Tester MZ254AT3641) self-test:

NOTE:

a. Verify the gas cylinder valve is closed and the control valve located on the tester is in the TEST position. All tester displays should be off at this time.
b. Connect the long hose (part of SST) to the tester.

c. Connect the manifold assembly (part of SST) to the long hose as shown.
d. Open the gas cylinder valve and verify the gas cylinder regulator left gauge reads 10 to 12 psi (preset at factory).
  • If not, refer to the tester operators manual to contact tester manufacturer.

e. Press the ON/OFF switch to turn on the SST and make sure the left display reads 0.0.
f. Turn the control valve on the tester to the FILL position.
g. Verify the left display reading is within 13.9 to 14.0 in of water.
  • If not, adjust the pressure using the regulator knob located on the right side of the tester.

h. Turn the control valve to TEST position and press the START switch.
i. After the 2 min countdown (left display) is completed, the right display shows the total pressure loss for that period. A 0.5 in of water loss is acceptable on the self-test.
  • If the loss is more than 0.5 inch of water, do one or more self-test. If the failed test repeats, check for leak using the ultrasonic leak detector (part of SST).

2. Press the RESET switch to set the left display reading to 0.0.
3. Connect the fuel cap test adapter (part of SST) to the manifold assembly and fuel-filler cap from the vehicle.
4. Connect the threaded test adapter (part of SST) to the manifold assembly and fuel-filler neck.

5. Connect the NGS tester to DLC-2.
6. Turn the ignition key to ON (engine OFF).
7. Select GENERIC OBD-II FUNCTIONS.
8. Press CONT (#8).
9. Select ON BOARD DEVICE CONTROL.
10. Press TRIGGER to close the canister drain cut valve (CDCV).

NOTE:

11. Turn the control valve to the FILL position.
12. Wait ( maximum 40 s) until the left display reads 13.5 to 14 in of water.
13. Turn the control valve to the TEST position and press the START switch.
14. After the 2 min countdown (left display) is completed, check the test result (the failed/passed light on the tester).
15. Close the gas cylinder valve.
16. Turn the control valve to the FILL position.
17. Press the ON/OFF switch to turn off the tester.

Evaporative System Leak Inspection Using Vacuum Pump

Whole system inspection
1. Disconnect the vacuum hose between the purge solenoid valve and the charcoal canister from the purge solenoid valve side.
2. Insert hose on the vacuum pump.

3. Connect the SSTs (NGS tester) to the DLC‐2.
4. Turn the ignition switch on.
5. Select GENERIC OBD-II FUNCTIONS and press the TRIGGER.

6. Press Number 8 under CONT to continue the GENERIC OBD-II FUNCTIONS.

NOTE:

7. Turn the menu dial clockwise or counterclockwise to select the ON BOARD DEVICE CONTROL and press the TRIGGER.

8. Press CANCEL two times.
9. Select DIAGNOSTIC DATA LINK and press the TRIGGER.

10. Select PCM–POWERTRAIN CONTROL MODULE and press the TRIGGER.

11. Select PID/DATA MONITOR AND RECORD and press TRIGGER.

12. Press Number 5 under CLEAR to clear previously selected PIDs.

13. Turn the menu dial clockwise or counterclockwise to select FTP and press TRIGGER.

14. Press Number 7 under START to view PIDs.

15. Apply vacuum of 1.7 kPa { 13 mmHg, 0.5 inHg} and they should remain at the specified readings for a minimum of 2 min.

16. Return to the “Fuel Tank Pressure, Graph Recording”, and answer questions.
Inspection from charcoal canister to fuel tank
1. Inspect for loose and improperly connected hoses between the charcoal canister and the fuel tank. (See EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM LOCATION INDEX.)
2. Disconnect the vacuum hose between the charcoal canister and the pressure control valve from the charcoal canister.
3. Insert hose on the vacuum pump.

4. Connect the SSTs (NGS tester) to the DLC‐2.
5. Turn the ignition switch on.
6. Select GENERIC OBD-II FUNCTIONS and press the TRIGGER.

7. Press Number 8 under CONT to continue the GENERIC OBD-II FUNCTIONS.

NOTE:

8. Turn the menu dial clockwise or counterclockwise to select the ON BOARD DEVICE CONTROL and press the TRIGGER.

9. Press CANCEL two times.
10. Select DIAGNOSTIC DATA LINK and press the TRIGGER.

11. Select PCM–POWERTRAIN CONTROL MODULE and press the TRIGGER.

12. Select PID/DATA MONITOR AND RECORD and press the TRIGGER.

13. Press Number 5 under CLEAR to clear previously selected PIDs.

14. Turn the menu dial clockwise or counterclockwise to select the FTP and press TRIGGER.

15. Press the Number 7 under START to view PIDs.

16. Apply vacuum of 1.7 kPa { 13 mmHg, 0.5 inHg} and they should remain at the specified readings for a minimum of 2 min.

17. Return to the “Fuel Tank Pressure, Graph Recording Procedure”, and answer questions.
Inspection from charcoal canister to purge solenoid valve
1. Inspect for loose and improperly connected hoses between the charcoal canister and the purge solenoid valve. (See EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM LOCATION INDEX.)
2. Disconnect the vacuum hose between the charcoal canister and the purge solenoid valve from the charcoal canister.
3. Insert hose on the vacuum pump.

4. Apply vacuum of 3.3 kPa { 25 mmHg, 1.0 inHg} and they should remain at the specified readings for a minimum of 2 min.
5. Return to the “Fuel Tank Pressure, Graph Recording Procedure”, and answer questions.

Purge Control 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 port and verify that there is no vacuum felt when the engine is cold.
4. Warm up the engine to the normal operating temperature.
5. Stop the engine.
6. Connect the SSTs (NGS tester) to the DLC‐2.

7. Turn the ignition switch on.
8. Select PID/DATA MONITOR AND RECORD and press TRIGGER.
9. Select ECT and press TRIGGER, then verify that the engine coolant temperature is above 60°C { 140°F}.
10. Press START.
11. Select SIMULATION TEST and press TRIGGER.
12. Select PRGV and press TRIGGER.
13. Press START.
14. Increase the duty value of the purge solenoid valve to 50% and verify if the operation sound of the valve is heard.

Electrical Fan Control Inspection

1. Verify that the engine is cold.
2. Turn the ignition switch to ON.
3. Verify that the cooling fan is not operating.
4. Connect the SSTs (NGS tester) to the DLC-2.

5. Select the PID/DATA MONITOR AND RECORD function on the NGS display.
6. Using "FAN 1" and "FAN 2", verify that the cooling fan control signal is off.

NOTE:

CAUTION:

7. Short the DLC terminal TEN to body GND using a jumper wire.

8. Depress the accelerator pedal and verify that the cooling fan operates.
9. Connect the SSTs (NGS tester).
10. Select the SIMULATION TEST function on the NGS display.
11. Turn the fan relay from OFF to ON using "FAN 1" and "FAN 2" and inspect for the cooling fan operation.
a. Turn the fan relay from OFF to ON using the simulation function. Operate the fan relay and inspect if the operation sound of the relay is heard.
  • If the operation sound is heard, check the fan motor and related harness.

  • If the operation sound is not heard, check the cooling fan relay and related harness.

A/C Cut-off Control Inspection

1. Position the vehicle on a chassis roller and start the engine.
2. Shift the selector lever into other than P and N.
3. Turn the A/C switch and the fan switch on.
4. Fully open the throttle valve. Then, 3--6 s after, check if the operation sound of the A/C compressor electromagnetic clutch is heard.
5. Turn the ignition switch ON.
6. Turn the A/C relay from OFF to ON by connecting a jumper wire between LG/R terminal of A/C relay connector and ground, and inspect for the operation sound of the relay.

Traction Control Inspection

1. Warm up the engine to normal operating temperature and let it idle.
2. Connect NGS tester to the DLC‐2 and retrieve DTC.
3. Connect the NGS tester to the DLC-2. Retrieve the DTC for the ABS system.
4. With no electrical load operating, inspect the torque reduction inhibit signal at the ABS/TCS control module L terminal using an oscilloscope.

5. Lift up the vehicle.
6. Shift the selector lever to D.
7. Depress the accelerator pedal, and verify that the engine speed does not exceed 1,500 rpm.

8. Depress the accelerator pedal, and verify that the signal changes as shown in the figure.


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