multipoint fuel injection (mpi) tech.mirage-performance.com/manuals/lancer/lancer... · 13a fuel...

13A FUEL MPI 1999 – General/General Information/Troubleshooting

MULTIPOINT FUEL INJECTION (MPI) <4G1>GENERALOUTLINE OF CHANGE� 4G15 engines have been added in vehicles for New Zealand. Service procedures are basically the

same as the conventional 4G15 engines in vehicles for Australia.� The diagnosis connector power supply circuit has been changed in 4G15 engines for Australia and

New Zealand.� The engine-ECU has been changed to correspond to the addition of stronger exhaust gas purification

measures in vehicles with 4G15 engine for Australia.

GENERAL INFORMATIONGENERAL SPECIFICATIONS

Items Specifications

Engine-ECU Identification No. E2T69285 <Vehicles with strengthened exhaustgas purification measures>

TROUBLESHOOTINGINSPECTION CHART FOR TROUBLE SYMPTOM

Trouble symptom InspectionprocedureNo.

Referencepage

Communication with MUT-II is impossi-ble

Communication with all systems is notpossible.

1 See below

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMINSPECTION PROCEDURE 1

Communication with MUT-II is not possible.(Communication with all system is not possible.)

Probable cause

The cause is probably a defect in the power supply system (including earth) for thediagnosis line.

� Malfunction of the connector� Malfunction of the harness wire

OK

Check trouble symptom.NG

Check the harness wire between thepower supply and diagnostic connector(16-pin), and repair if necessary.

Measure at the diagnosis connector(16-pin) B-18.� Voltage between 16 and earth

OK: Battery voltage

NGCheck the following connectors.B-67, B-74

NGRepair

OK

Measure at the diagnosis connector(16-pin) B-18.� Continuity between 4 and earth� Continuity between 5 and earth

OK: Continuity

NGCheck the following connector.B-47

OKCheck trouble symptom.

NG

Repair

NG

Check the harness wire between thediagnostic connector (16-pin) and earth,and repair if necessary.OK

Replace the MUT-II.

��

��

��

13A FUEL MPI 1999 – General/General Information

MULTIPOINT FUEL INJECTION (MPI) <4G9>GENERALOUTLINE OF CHANGE� 4G93 engines have been added in vehicles for New Zealand. Service procedures are basically the

same as the conventional 4G93 engines in vehicles for Australia.� The diagnosis connector power supply circuit has been changed in 4G93 engines for Australia and

New Zealand.� The following items have been changed to correspond to the addition of stronger exhaust gas purification

measures in vehicles with 4G93 engine for Australia.(1) The shape of the air flow sensor connector has been changed.(2) The fixed SAS has been abolished to correspond to changes in the throttle body. In addition,

the shape of the stepper motor connector has been changed.(3) The idle position switch has been abolished.(4) An evaporative emission control system utilizing a purge control solenoid has been adopted.

� The following items have been changed to correspond to specification changes to the 4G92 enginein vehicles for GCC.(1) The fixed SAS has been abolished to correspond to changes in the throttle body. In addition,

the shape of the stepper motor connector has been changed.(2) The idle position switch has been abolished.

GENERAL INFORMATIONGENERAL SPECIFICATIONS

Itemes Specifications

Engine-ECU Identification No. E2T73175 <Vehicles for GCC>E2T73772 <Vehicles for Australia with strength-ened exhaust gas purification measures>

��

��

��

13A FUEL MPI 1999 – General Information

MULTI-POINT FUEL INJECTION SYSTEM DIAGRAM

*1 Oxygen sensor*2 Air flow sensor*3 Intake air temperature sensor*4 Throttle position sensor*5 Camshaft position sensor*6 Crank angle sensor*7 Barometric pressure sensor*8 Engine coolant temperature sensor

� Power supply voltage� Vehicle speed sensor� A/C switch� Inhibitor switch� Power steering fluid pressure switch� Ignition switch – ST� Ignition switch – IG� Alternator FR terminal

�1 Injector�2 Idle speed control servo�3 Purge control solenoid valve

� Fuel pump relay� Control relay� A/C power relay� Engine warning lamp� Diagnosis signal� Ignition coil, power transistor� Fan motor relay� Alternator G terminal

Engine-ECU

�2 Idle speed control servo

*3 Intake air temperature sensor

Air flow sensor(with barometricpressure sensor)

Throttle position sensor

Canister

*6 Crank angle sensor

Catalytic converter

*1Oxygen sensor

*8 Engine coolant temperature sensor

�1 Injector

From fuelpump

*5 Camshaft position sensor

Fuel pressure regulator

Purge controlsolenoidvalve

Air cleanerAir

*2*7

P

*4

To fueltank

PCV valve

�3

��

��

��

13A FUEL MPI 1999 – Service Specifications/Special Tools/Troubleshooting

SERVICE SPECIFICATIONS

Items Specifications

Throttle position sensor adjusting voltage mV 535 – 735

SPECIAL TOOLS

Tool Number Name Use

MB991709 Test harness � Measurement of voltage during troubleshooting

� Inspection using an analyzer� Inspection of idle speed control servo

MB991536 Check harness forPS adjustment

� Adjusting the throttle position sensor

TROUBLESHOOTINGINSPECTION CHART FOR DIAGNOSIS CODES

Code No. Diagnosis item

12 Air flow sensor system

13 Intake air temperature sensor system

14 Throttle position sensor system

21 Engine coolant temperature sensor system

22 Crank angle sensor system

23 Camshaft position sensor

24 Vehicle speed sensor system

25 Barometric pressure sensor system

31 Detonation sensor system

41 Injector system

44 Ignition coil and power transistor unit system

54 Immobilizer system

61 Communication wire with A/T-ECU system <A/T>

64 Alternator FR terminal system

��

��

��

13A FUEL MPI 1999 – Troubleshooting

INSPECTION PROCEDURE FOR DIAGNOSIS CODES

Code No. 12 Air flow sensor system <Vehicles forAustralia with strengthened exhaust gas purificationmeasures>

Probable cause

Range of Check� Engine speed is 500 r/min. or more.Set conditions� Sensor output frequency is 3 Hz or less for 4 seconds.

� Malfunction of the air flow sensor� Improper connector contact, open circuit or

short-circuited harness wire of the air flow sensor� Malfunction of the engine-ECU

NG

OKOK

2. NGMeasure at the engine-ECU connectorB-37.� Connect the connector.� Voltage between 19 and earth (Igni-

tion switch: ON)OK: 6 – 9 V

NGCheck the following connector.A-101

Measure at the air flow sensor connectorA-101.� Connect the connector. (Use the test

harness: MB991709)1. Voltage between 3 and earth

(Engine: Idling)OK: 2.2 – 3.2 V

2. Voltage between 7 and earthOK: 0 – 1 V (Engine: idling)

6 – 9 V (2,000 r/min.)

1. NGCheck the air flow sensor circuit. (ReferINSPECTION PROCEDURE 45.)

Replace the engine-ECU. NGCheck the following connector.B-37

Repair

OK

Check trouble symptom.

NG

Replace the engine-ECU.

OK


NG

Replace the air flow sensor.

Repair

��

��

��

13A FUEL MPI 1999 – Troubleshooting13A FUEL MPI 1999 – Troubleshooting

Code No. 13 Intake air temperature sensor system<Vehicles for Australia with strengthened exhaust gaspurification measures>

Probable cause

Range of Check� Ignition switch: ON� Excluding 60 seconds after the ignition switch is turned to ON or immediately

after the engine starts.Set conditions� Sensor output voltage is 4.6 V or more (corresponding to an intake air temperature

of –45°C or less) for 4 seconds.or� Sensor output voltage is 0.2 V or less (corresponding to an intake air temperature

of 125°C or more) for 4 seconds.

� Malfunction of the intake air temperature sensor� Improper connector contact, open circuit or

short-circuited harness wire of the intake airtemperature sensor circuit

� Malfunction of the engine-ECU

OKNG

Check the intake air temperature sensorNG

Replace

Measure at the air flow sensor connectorA-101.� Disconnect the connector, and mea-

sure at the harness side.� Voltage between 6 and earth (Igni-

tion switch: ON)OK: 4.5 – 4.9 V

� Continuity between 5 and earthOK: Continuity

Check the following connector.B-34

OK

Check the following connector.A-101

NGRepair

OK



OK


NG

Check the harness wire between theengine-ECU and the intake air tempera-ture sensor connector.

OK


NG

Repair

NG

Repair

Code No. 14 Throttle position sensor system Probable causeRange of Check� Ignition switch: ON� Excluding 60 seconds after the ignition switch is turned to ON or immediately

after the engine starts.Set conditions� Engine speed is 3,000 r/min or less, and volumetric efficiency is 30% or less,

TPS output voltage is 4.6 V or more for 4 seconds.or� Engine speed is 2,000 r/min or more, and volumetric efficiency is 60% or more,

TPS output voltage is 0.8 V or less for 4 seconds.

� Malfunction of the throttle position sensor ormaladjustment

� Improper connector contact, open circuit orshort-circuited harness wire of the throttle positionsensor circuit


OK

OK


NGNG

Check the harness wire between theengine-ECU and the throttle positionsensor connector.

Repair

Check the throttle position sensor. NG

Replace

Measure at the throttle position sensorconnector A-05.� Disconnect the connector, and mea-

sure at the harness side.� Voltage between 1 and earth

(Ignition switch: ON)OK: 4.8 – 5.2 V



NGRepair

OK

Check the throttle position sensor outputcircuit. (Refer INSPECTION PROCED-URE 46 <Vehicles for Australia>

OK


��

��

��


Code No. 25 Barometric pressure sensor system<Vehicles for Australia with strengthened exhaust gaspurification measures>

Probable cause

Range of Check� Ignition switch: ON� Excluding 60 seconds after the ignition switch is turned to ON or immediately

after the engine starts.� Battery voltage is 8 V or more.Set conditions� Sensor output voltage is 4.5 V or more (corresponding to a barometric pressure

of 114 kPa or more) for 4 seconds.or� Sensor output voltage is 0.2 V or less (corresponding to a barometric pressure

of 5.33 kPa or less) for 4 seconds.

� Malfunction of the barometric pressure sensor� Improper connector contact, open circuit or

short-circuited harness wire of the barometric pressuresensor circuit


Measure at the air flow sensor connectorA-101.� Connect the connector. (Use the test

harness: MB991709)� Voltage between 2 and earth (Igni-

tion switch: ON)OK: 3.7 – 4.3 V (Altitude: 0 m)

3.2 – 3.8 V (Altitude: 1,200m)

NGMeasure at the air flow sensor connectorA-101.� Disconnect the connector, and mea-

sure at the harness side.� Voltage between 1 and earth (Igni-

tion switch: ON)OK: 4.8 – 5.2 V



OK

Measure at the engine-ECU connectorB-34.� Connect the connector.� Voltage between 85 and earth (Igni-

tion switch: ON)OK: 3.7 – 4.3 V (Altitude: 0 m)

3.2 – 3.8 V (Altitude: 1,200m)

NGCheck the harness wire between theengine-ECU and the barometric pres-sure sensor connector, and repair if nec-essary.

OK

Check the following connector. B-34NG

Repair

OK


NG


NG

OK


Repair

OK


NGNG

Check the harness wire between theengine-ECU and the barometric pres-sure sensor connector.

Repair

OK


NG

Check the harness wire between theengine-ECU and the barometric pres-sure sensor connector.


NG

Repair

NG

Repair

OK

Replace the air flow sensor.OK

��

��

��


INSPECTION CHART FOR TROUBLE SYMPTOMS

Trouble symptom InspectionprocedureNo.

Communication with Communication with all systems is not possible. 1MUT-II is impossible.

Communication with engine-ECU only is not possible. 2

Engine warning lampand related parts

The engine warning lamp does not illuminate right after the ignition switch isturned to the ON position.

3

The engine warning lamp remains illuminating and never goes out. 4

Starting No initial combustion (starting impossible) 5

Initial combustion but no complete combustion(starting impossible)

6

Long time to start (improper starting) 7

Idling stability Unstable idling (Rough idling, hunting) 8(Improper idling)

Idling speed is high. (Improper idling speed) 9

Idling speed is low. (Improper idling speed) 10

Idling stability When the engine is cold, it stalls at idling. (Die out) 11(Engine stalls)

When the engine becomes hot, it stalls at idling. (Die out) 12

The engine stalls when starting the car. (Pass out) 13

The engine stalls when decelerating. 14

Driving Hesitation, sag or stumble 15

The feeling of impact or vibration when accelerating 16

The feeling of impact or vibration when decelerating 17

Poor acceleration 18

Surge 19

Knocking 20

Dieseling 21

Too high CO and HC concentration when idling 22

Low alternator output voltage (approx. 12.3 V) 23

��

��

��


INSPECTION PROCEDURE FOR TROUBLE SYMPTOMSINSPECTION PROCEDURE 1 <Vehicles for Australia and New Zealand>

Communication with MUT-II is not possible.(Communication with all systems is not possible.)

Probable cause

The cause is probably a defect in the power supply system (including earth) for thediagnosis line.

� Malfunction of the connector� Malfunction of the harness wire

Measure at the diagnostic connector(16-pin) B-18.� Voltage between 16 and earth

OK: Battery voltage

NGCheck the following connectors.B-67, B-74

NGRepair

OK


Check the harness wire between thepower supply and diagnostic connector(16-pin), and repair if necessary.

OK

Measure at the diagnostic connector(16-pin) B-18.� Continuity between 4 and earth� Continuity between 5 and earth

OK: Continuity


OKCheck trouble symptom.

OK

Replace the MUT-II.

NG

Check the harness wire between thediagnostic connector (16-pin) and earth,and repair if necessary.

NG

Repair

��

��

��


INSPECTION PROCEDURE 6

Initial combustion but no complete combustion (starting impossible)

Probable cause

In such cases as the above, the cause is probably that the spark plugs are generatingsparks but the sparks are weak, or the initial mixture for starting is not appropriate.

� Malfunction of the ignition system� Malfunction of the injector system� Foreign materials in fuel� Poor compression� Malfunction of the engine-ECU

OK

OK

Check battery voltage when cranking.OK: 8 V or higher

NGCheck the battery

MUT-II: Check if uncompleted combustion occurs.(Refer INSPECTION PROCEDURE 36.)

OK

Can any sound be heard from the injectors when cranking?NG

Check the injector system, (ReferINSPECTION PROCEDURE FOR DIAGNOSIS CODE 41.)

OK

Is starting good if the engine is cranked with the accelerator pedalslightly depressed?

YesCheck ISC servo for operation sound.

NGCheck the ISC servo sys-tem. (Refer INSPECTIONPROCEDURE 33)

OK

� Clean the throttle body.

Check the following items.� Check the ignition coil, spark plugs, spark plug cables� Check if the injectors are clogged.� Check the compression pressure.� Check fuel lines for clogging.� Check if foreign materials (water, alcohol, etc.) got into fuel.

No

Check the ignition timing when cranking.OK: Approx. 5°BTDC

NGCheck that the crank angle sensor is installed properly.

��

��

��



Unstable idling (Rough idling, hunting) Probable causeIn cases as the above, the cause is probably that the ignition system, air/fuel mixture,idle speed control (ISC) or compression pressure is defective.Because the range of possible causes is broad, inspection is narrowed down to simpleitems.

� Malfunction of the ignition system� Malfunction of air-fuel ratio control system� Malfunction of the ISC system� Malfunction of the purge control solenoid valve system

<Vehicles for Australia>� Malfunction of the EGR solenoid valve system

<Vehicles for GCC>� Poor compression� Drawing air into exhaust system

OK

Were the battery terminals disconnected?Yes

After warming-up, let the engine run at idling for 10 minutes.

No

MUT-II Self-Diag codeAre diagnosis codes displayed?

YesRefer INSPECTION CHART FOR DIAGNOSIS CODES.

No

Does idling speed fluctuate excessively?Yes

Check if hunting occurs.(Refer INSPECTION PROCEDURE 37.)

No

Check the ISC servo for operation sound.NG

Check the ISC servo system.(Refer INSPECTION PROCEDURE 33.)

OK

Check the injector for operation sound.NG

Check the injector system. (ReferINSPECTION PROCEDURE FOR DIAGNOSIS CODE 41.)

OK

MUT-II: Check if idling speed is unstable.(Refer INSPECTION PROCEDURE 38.)

OK

Check the ignition timing.NG

Check that the crank angle sensor is installed properly.

Check the following items.� Check the ignition coil, spark plugs, spark plug cables.� Check the purge control system.� Check the EGR control system.� Check the compression pressure.� Check if foreign materials (water, alcohol, etc.) got into fuel.

��

��

��



Idling speed is high. (Improper idling speed) Probable causeIn such cases as the above, the cause is probably that the intake air volume duringidling is too great.

� Malfunction of the ISC servo system� Malfunction of the throttle body

OK



No



OK

MUT-II Data list21 Engine coolant temperature sensor

NGCheck the engine coolant temperature sensor system.(Refer INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.)

OK

MUT-II Data list28 A/C switch

NGCheck the A/C switch and A/C relay system.(Refer INSPECTION PROCEDURE 30.)

Basic idle adjustment


Clean the throttle valve area.


Idling speed is low. (Improper idling speed) Probable causeIn cases such as the above, the cause is probably that the intake air volume duringidling is too small.

� Malfunction of the ISC servo system� Malfunction of the throttle body

OK



No

Check the ISC servo for operation soundNG

Check the ISC servo system.(Refer INSPECTION PROCEDURE 33.)OK



OK

MUT-II Data list29 Inhibitor switch

NGCheck the ignition switch ST and inhibitor switch system <A/T>.(Refer INSPECTION PROCEDURE 28.)

Basic idle adjustment


Clean the throttle body.

��

��

��



When the engine is cold, it stalls at idling. (Die out) Probable causeIn such cases as the above, the cause is probably that the air/fuel mixture is inappropriatewhen the engine is cold, or that the intake air volume is insufficient.

� Malfunction of the ISC servo system� Malfunction of the throttle body� Malfunction of the injector system� Malfunction of the ignition system

OK

OK



No



No

Does the engine stall right after the accelerator pedal is released?Yes


No

Is engine-idling stable after the warming-up?No

Check if the unstable idling (Rough idling, hunting).(Refer INSPECTION PROCEDURE 8.)

Check the fuel pressure.

OK



Yes



OK



OK


NGCheck the engine coolant temperature sensor system. (ReferINSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.)

Check the following items.� Check the ignition coil, spark plugs, spark plug cables� Check the compression pressure.� Check the engine oil viscosity.

��

��

��



When the engine is hot, it stalls at idling. (Die out) Probable causeIn such cases as the above, the cause is probably that ignition system, air/fuel mixture,idle speed control (ISC) or compression pressure is defective.In addition, if the engine suddenly stalls, the cause may also be a defective connectorcontact.

� Malfunction of the ignition system� Malfunction of air-fuel ratio control system� Malfunction of the ISC system� Drawing air into intake system� Improper connector contact

No

OK



No



No



OK



Yes

MUT-II: Engine stalling inspection when the engine is warm andidling. (Refer INSPECTION PROCEDURE 39.)

OK



OK

Does the engine stall right after the accelerator pedal is released?Yes

Clean the throttle valve area.

Does the engine stall easily again?No

While carrying out an intermittent malfunction simulation test (Refer – Points Note for Intermittent Malfunctions.), check for sud-den changes in the signals shown below.� Crank angle sensor signal� Air flow sensor signal� Injector drive signal� Primary and secondary ignition signal� Fuel pump drive signal� Engine-ECU power supply voltage

Check the following items.� Check the ignition coil, spark plugs, plug cables� Check if the injectors are clogged.� Check the compression pressure.� Check if foreign materials (water, alcohol, etc.) got into fuel.

��

��

��



The engine stalls when decelerating. Probable causeIn cases such as the above, the cause is probably that the intake air volume is insufficientdue to a defective idle speed control (ISC) servo system.

� Malfunction of the ISC system



No



No

MUT-II Data list14 Throttle position sensor

NGCheck the throttle position sensor system. (ReferINSPECTION PROCEDURE FOR DIAGNOSIS CODE 14.)

OK

MUT-II Data list45 ISC servo position� Is the idle speed control (ISC) servo position drops to 0 – 2

steps when decelerating (engine r/min less than 1,000)?

YesCheck the vehicle speed sensor system. (Refer INSPECTION PROCEDURE FOR DIAGNOSIS CODE 24.)

No

Check the following items.� Check the ignition coil, spark plugs, spark plug cables.� Clean the throttle body.

��

��

��



Hesitation, sag or stumble Probable causeIn cases such as the above, the cause is probably that ignition system, air/fuel mixtureor compression pressure is defective.

� Malfunction of the ignition system� Malfunction of air-fuel ratio control system� Malfunction of the fuel supply system� Malfunction of the EGR control solenoid valve system

<Vehicles for GCC>� Poor compression

OK



No

Check the injectors for operation sound.NG


OK

MUT-II: Check if hesitation, sag, stumble or poor acceleration occur.(Refer INSPECTION PROCEDURE 40.)

OK


Check the following items.� Check the ignition coil, spark plugs, spark plug cables.� Check the compression pressure.� Check the fuel filter or fuel for clogging.

OK

Check the ignition timingNG


��

��

��



The feeling of impact or vibration when decelerating Probable causeMalfunction of the ISC system is suspected. � Malfunction of the ISC system

OK



No



OK





Poor acceleration Probable causeDefective ignition system, abnormal air-fuel ratio, poor compression pressure, etc.are suspected.

� Malfunction of the ignition system� Malfunction of air-fuel ratio control system� Malfunction of the fuel supply system� Poor compression pressure� Clogged exhaust system

OK

OK

OK



No



OK



MUT-II: Check if hesitation, sag, stumble or poor acceleration occur.(Refer INSPECTION PROCEDURE 40.)


Check the following items.� Check the ignition coil, spark plugs, spark plug cables.� Check the compression pressure.� Check the fuel filter or fuel line for clogging.� Broken air intake hose� Clogged air cleaner

��

��

��



Surge Probable causeDefective ignition system, abnormal air-fuel ratio, etc. are suspected. � Malfunction of the ignition system

� Malfunction of air-fuel ratio control system� Malfunction of the EGR control solenoid valve system

<Vehicles for GCC>

OK

OK

OK



No



OK



MUT-II: Check if surge occurs. (ReferINSPECTION PROCEDURE 41.)


Check the following items.� Check the ignition coil, spark plugs, spark plug cables.

��

��

��



Too high CO and HC concentration when idling Probable causeAbnormal air-fuel ratio is suspected. � Malfunction of the air-fuel ratio control system

� Deteriorated catalyst

OK

NG



No



OK



Check the following items.� Check the injectors for operation sound.� Check the injectors for fuel leakage.� Check the ignition coil, spark plugs, spark plug cables� Check the compression pressure.� Check the positive crankcase ventilation system.� Check the purge control system.

Check the trouble symptom.

Replace the catalytic converter.


OK

MUT-II Data list13 Intake air temperature sensor

NGCheck the intake air temperature sensor system. (ReferINSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.)

OK

MUT-II Data list25 Barometric pressure sensor

NGCheck the barometric pressure sensor system. (ReferINSPECTION PROCEDURE FOR DIAGNOSIS CODE 25.)

OK

MUT-II Data list11 Oxygen sensor

OK: Repeat 0 – 400 mV and 600 – 1,000 mV alternately whenidling.

OKReplace the oxygen sensor.

OK


OK: 600 – 1,000 mV when racing suddenly

NGCheck the oxygen sensor system. (Refer INSPECTION PROCEDURE 49.)

Check trouble symptom.NG NG

��

��

��


INSPECTION PROCEDURE 33 <Vehicles for Australia with strengthened exhaust gaspurification measures>

Idle speed control (ISC) servo (Stepper motor) system Probable causeThe engine-ECU controls the intake air volume during idling by opening and closingthe servo valve located in the bypass air passage.

� Malfunction of ISC servo� Improper connector contact, open circuit or

short-circuited harness wire� Malfunction of the engine-ECU

OK

OK

OK

Measure at the ISC servo connector A-56.� Disconnect the connector and measure at the harness side.� Voltage between 2 and earth, and 5 and earth (Ignition switch:

ON)OK: System voltage

NGCheck the harness wire between control relay and ISC servo con-nector, and repair if necessary.

Check the ISC servoNG

Replace

Measure at the engine-ECU connector B-37.� Disconnect the connector, measure at the harness side.� Voltage between each of 4, 5, 17, 18 and earth (Ignition switch:

ON)OK: System voltage

NGCheck the followingconnector. A-56

NGRepair


NG

Check harness wire between engine-ECU and ISC servo connector,and repair if necessary.

OK

Check the followingconnector. B-37

NGRepair



OK


Check if hunting occurs.



NG

Inspect the intake of air into the air intake system� Broken intake manifold gasket� Broken air intake hose� Broken vacuum hose� Positive crankcase ventilation valve does not operate.

��

��

��


INSPECTION PROCEDURE 38 <Vehicles for Australia>

MUT-II: Check if idling speed is unstable.

<Vehicles for Australia with strengthened exhaust gas purification measures>

OK

OK


NGCheck the A/C switch and A/C relay system. (ReferINSPECTION PROCEDURE 30.)

OK

MUT-II Data list27 Power steering fluid pressure switch

NGCheck the power steeringfluid pressure switch sys-tem. (Refer INSPECTIONPROCEDURE 29.)



OK



OK



OK

MUT-II Actuator test08 Purge control solenoid valve

NGCheck the purge control solenoid valve system.(Refer INSPECTION PROCEDURE 48.)

OK


OK: 600 – 1,000 mV during sudden racing

NGCheck the oxygen sensor system. (ReferINSPECTION PROCEDURE 49.)


OK: Changes between 0 – 400 mV and 600 – 1,000 mV duringidling

NGCheck the fuel pressure.

OK1. Inspect the intake of

air into the air intakesystem.� Broken intake

manifold gasket� Broken vacuum

hose� PCV valve does

not operate.� Broken air intake

hose2. Check the injector for

clog.

OK


NGCheck the ignition switch-ST and inhibitor switch system. <A/T>(Refer INSPECTION PROCEDURE 28.)

OK

MUT-II Data list45 ISC Servo position

NGAdjust the basic idle speed

��

��

��



MUT-II: Engine stalling inspection when the engine is warmed up and idling.


OK


NGCheck the intake air sensor system. (ReferINSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.)

OK



OK



OK

MUT-II Actuator test08 Purge control solenoid valve

NGCheck the purge control solenoid valve system.(Refer INSPECTION PROCEDURE 48.)

OK


OK: Changes between 600 – 1,000 mV during sudden racing






air into the air intakesystem� Broken intake





clog.

OK

MUT-II Data list27 Power steering fluid pressure switch

NGCheck the power steeringfluid pressure switch sys-tem. (Refer INSPECTIONPROCEDURE 29.)OK


NGCheck the A/C switch and A/C relay system.(Refer INSPECTION PROCEDURE 30.)

OK


NGCheck the ignition switch-ST and inhibitor switch system. <A/T>(Refer INSPECTION PROCEDURE 28.)

OK

MUT-II Data list45 ISC servo position

NGAdjust the basic idle speed.

��

��

��



MUT-II: Check if hesitation, sug, stumble or poor acceleration occurs.


OK

OK





OK


NGCheck the engine coolant temperature sensor system. (ReferINSPECTION PROCEDURE FOR DIAGNOSTIC CODE 21.)

OK



OK



NGCheck the oxygen sensor system. (Refer INSPECTION PROCEDURE 49.)










clog.

��

��

��



MUT-II: Check if surge occurs.


OK

OK



OK





OK



OK













clog.


Check air flow sensor (AFS) control circuit.

OK

2, 3. NGCheck the followingconnector. B-34

NGRepair

Measure at the air flow sensor connector A-101.� Disconnect the connector and measure at the harness side.1. Voltage between 4 and earth (Ignition switch: ON)

OK: System voltage2. Voltage between 3 and earth (Ignition switch: ON)

OK: 4.8 – 5.2 V3. Continuity between 5 and earth

OK: Continuity

1. NGCheck the harness wire between the air flow sensor and controlrelay connector, and repair if necessary.


NG

Check the harness wirebetween the engine-ECUand air flow sensor con-nector.

NGRepair

OK


OK

Check the following connector. A-101

OK


NG

Replace the air flow sensor.

NG

Repair

��

��

��



Check throttle position sensor (TPS) output circuit.

OK

NG

OKCheck the followingconnector. B-34

NGRepairMeasure at the engine-ECU connector B-34.

� Connect the connector.� Voltage between 84 and earth (Ignition switch: ON)

OK: 0.535 – 0.735 V (Throttle valve at idle position)4.5 – 5.5 V (Throttle valve fully open) Check trouble symptom.

OK


Check the harness wire between engine-ECU and throttle positionsensor connector, and repair if necessary.

NG


NG

Check the following connector. A-05NG

Repair


Purge control solenoid valve system Probable causeThe purge control solenoid valve controls the purging of air from the canister locatedinside the intake manifold.

� Malfunction of solenoid valve� Improper connector contact, open circuit or

short-circuited harness wire.� Malfunction of the engine-ECU

NG

OK

OK

OK

Measure at the purge control solenoid valve connector A-81.� Disconnect the connector and measure at the harness side.� Voltage between 2 and earth (Ignition switch: ON)

OK: system voltage

NGCheck the harness wire between control relay and solenoid valveconnector, and repair if necessary.

Check the purge control solenoid valve.NG

Replace

Measure at the engine-ECU connector B-37.� Disconnect the connector and measure at the harness side.� Voltage between 9 and earth (Ignition switch: ON)

OK: system voltage

NGCheck the followingconnector. A-81

NGRepair

OK

Check the followingconnector. B-37

NGRepair


NG

Check the harness wire between engine-ECU and solenoid valveconnector, and repair if necessary.OK



��

��

��



Oxygen sensor system Probable causeIf the CO and HC contents are high, the probable causes mentioned to the rightcolumn are suspected.� The oxygen sensor detects the oxygen content in exhaust gas, converts it to

voltage, and sends the voltage to the engine-ECU.� The engine-ECU controls the fuel injection amount to adjust the air/fuel ratio to

theoretical one.

� Malfunction of the oxygen sensor� Improper connector contact, open circuit or

short-circuited harness wire� Malfunction of the engine-ECU

OK

NG

OK

OK

OK

NG

OK

Check the oxygen sensorNG

Replace

Measure at the oxygen sensor connector A-87.� Disconnect the connector, and measure at the harness side.� Continuity between 2 and earth

OK: Continuity


NGRepair

Check the harness wire between theengine-ECU and the oxygen sensorconnector.

NGRepair


Check trouble symptom.OK


NGRepair


Check the harness wire between the engine-ECU and the oxygensensor connector.

NGRepair


��

��

��


DATA LIST REFERENCE TABLE

CautionWhen shifting the select lever to D range, the brakes should be applied so that the vehicle doesnot move forward.

NOTE*1. In a new vehicle [driven approximately 500 km or less], the air flow sensor output frequency is sometimes

10% higher than the standard frequency.*2. When idling to warm up from an engine coolant temperature of approx. –20�C, if the idling speed

is lower than the standard value even when the ISC motor is fully opened, the air volume limiterbuilt in the throttle body could be defective.

*3. The injector drive time represents the time when the cranking speed is at 250 r/min. or below whenthe power supply voltage is 11 V.

*4. In a new vehicle [driven approximately 500 km or less], the injector drive time is sometimes 10%longer than the standard time.

*5. In a new vehicle [driven approximately 500 km or less], the step of the stepper motor is sometimes30 steps greater than the standard value.

ItemNo.

Inspectionitem

Inspection contents Normal condition Inspection procedure No.

11 Oxygensensor

Engine: After havingwarmed upAir/fuel mixture ismade leaner when

When at 4,000 r/min,engine is suddenlydecelerated

200 mV or less Procedure No. 49

made leaner whendecelerating, and ismade richer whenracing.

When engine is sud-denly raced

600 – 1,000 mV

Engine: After havingwarmed upThe oxygen sensorsignal is used to

Engine is idling 400 mV or less(Changes)600 – 1,000 mV

check the air/fuelmixture ratio, andcontrol condition isalso checked by theECU.

2,500 r/min 400 mV or less(Changes)600 – 1,000 mV

12 Air flowsensor*1

� Engine coolanttemperature:

�

Engine is idling 25 – 51 Hz –

80 – 95�C� Lamps, electric

cooling fan and all

2,500 r/min 80 – 120 Hz

cooling fan and allaccessories:OFF

� Transmission:Neutral (A/T:P range)

Engine is raced Frequencyincreases inresponse toracing

��

��

��


ItemNo.

Inspection procedure No.Normal conditionInspection contentsInspectionitem

13 Intake airtempera-

Ignition switch: ONor with engine

When intake airtemperature is –20�C

–20�C Code No.13

turesensor

runningWhen intake airtemperature is 0�C

0�C

When intake airtemperature is 20�C

20�C


40�C


80�C

14 Throttle Ignition switch: ON Set to idle position 535 – 735 mV Code No.14positionsensor Gradually open Increases in

proportion tothrottle openingangle

Open fully 4,500 – 5,500 mV

16 Powersupplyvoltage

Ignition switch: ON System voltage ProcedureNo. 24

17 Mixtureadjustingscrew(variableresistor)

Ignition switch: ON 1,000 – 4,000 mV Procedure No. 32

18 Crankingsignal

Ignition switch: ON Engine: Stopped OFF Procedure No. 27 <M/T>Procedure No. 28 <A/T>signal

(ignitionswitch-ST) Engine: Cranking ON

Procedure No. 28 <A/T>

21 Enginecoolant

Ignition switch: ONor with engine

When engine coolanttemperature is –20�C

–20�C Code No.21

tempera-turesensor

runningWhen engine coolanttemperature is 0�C

0�C

When engine coolanttemperature is 20�C

20�C


40�C


80�C

��

��

��


ItemNo.

Inspectionitem


22 Crankanglesensor*2

� Engine: Cranking� Tachometer:

Connected

Compare the enginespeed readings onthe tachometer andthe MUT-II.

Accord Code No.22

� Engine: Idling When engine coolanttemperature is –20�C

1,400 – 1,600r/min


1,350 – 1,550r/min


1,300 – 1,500r/min


1,100 – 1,300r/min


650 – 850 r/min

25 Baromet- Ignition switch: ON At altitude of 0 m 101 kPa Code No.25ricpressure At altitude of 600 m 95 kPasensor

At altitude of 1,200 m 88 kPa

At altitude of 1,800 m 81 kPa

27 Powersteering

Engine: Idling Steering wheelstationary

OFF Procedure No. 29

fluid pres-sureswitch

Steering wheelturning

ON

28 A/C switch Engine: Idling(when A/C switch is

A/C switch: OFF OFF Procedure No. 30

ON, A/C compres-sor should be oper-ating.)

A/C switch: ON ON

29 Inhibitor Ignition switch: ON P or N P or N ProcedureNo. 28switch<A/T> D, 2, L or R D, 2, L or R

��

��

��


ItemNo.

Inspectionitem


41 Injector*3 Engine: Cranking When engine coolanttemperature is 0�C(injection is carriedout for all cylinderssimultaneously)

13 – 19 ms –


27 – 40 ms


5.9 – 8.9 ms

Injector*4 � Engine coolanttemperature:80 – 95�C

Engine is idling 1.7 – 2.9 ms

80 – 95 C� Lamps, electric

cooling fan and allaccessories:

2,500 r/min 1.4 – 2.6 ms

OFF� Transmission:

Neutral (A/T:P range)

When engine issuddenly raced

Increases

44 Ignitioncoils andpowertransistors

� Engine: Afterhaving warmedup

� Timing lamp is

Engine is idling 2 – 18�BTDC –

set. (The timinglamp is set inorder to checkactual ignitiontiming.)

2,500 r/min 30 – 50�BTDC

45 ISC(stepper)motor

5

� Engine: coolanttemperature: 80– 95�C

�

A/C switch: OFF 2 – 25 STEP –

position*5 � Lamps, electriccooling fan and allaccessories:OFF

� Transmission:

A/C switch:OFF → ON

Increases by10 – 70 steps

Neutral (A/T:P range)

� Engine: Idling� When A/C switch

is ON, A/C com-pressor should beoperating

� A/C switch: OFF� Select lever:

N range → Drange

Increases by5 – 50 steps

49 A/C relay Engine: After havingwarmed up/Engineis idling

A/C switch: OFF OFF (Compres-sor clutch is notoperating)

Procedure No. 30

A/C switch: ON ON (Compressorclutch is operat-ing)

��

��

��


ACTUATOR TEST REFERENCE TABLE

ItemNo.

Inspectionitem

Drive contents Inspection contents Normal condition Inspection procedure No.

01 Injectors Cut fuel to No. 1injector

Engine:After having warmed up/

Idling conditionbecomes differ-

Code No. 41

02 Cut fuel to No. 2injector

Engine is idling(Cut the fuel supply to eachinjector in turn and check

ent (becomes un-stable).


cylinders which don’t affectidling.)


07 Fuel pump Fuel pump op-erates and fuelis recirculated.

� Engine:Cranking

� Fuelpump:ForceddrivingInspectaccord-

Pinch thereturn hosewith fingersto feel thepulse of thefuel beingrecircu-lated.

Pulse is felt. Procedure No. 25

ing toboth theabovecondi-tions.

Listen nearthe fueltank for thesound offuel pumpoperation.

Sound of opera-tion is heard.

08 Purgecontrolsolenoidvalve

Solenoid valveturns from OFFto ON.

Ignition switch: ON Sound of opera-tion can be heardwhen solenoidvalve is driven.

Procedure No. 48

17 Basic igni-tion timing

Set to ignitiontiming adjust-ment mode

Engine: IdlingTiming light is set

5� BTDC –

20 Condenserfan

Drive the fanmotors(condenser)

� Ignition switch: ON� A/C switch: ON

Fan motoroperates

Procedure No. 31

21 Radiatorfan

Drive the fanmotors(radiator)

� Ignition switch: ON Fan motoroperates

Procedure No. 31

��

��

��


CHECK AT THE ENGINE-ECU TERMINALSTERMINAL VOLTAGE CHECK CHARTEngine-ECU Connector Terminal Arrangement� The engine-ECU specifications have been changed in vehicles for GCC and vehicles for Australia

with stronger exhaust gas purification measures. The following changes have been made to correspondto this. Other items are the same as before.(1) Terminal No. 87 of the engine-ECU has been changed to the idle position signal terminal for

A/T control to correspond to the abolition of idle switch input.(2) A purge control solenoid valve has been added to terminal No. 9 of the engine-ECU <Vehicles

for Australia with strengthened exhaust gas purification measures>

Terminal No. Check item Check condition (Engine condition) Normal condition

9 Purge control Ignition switch: ON System voltagesolenoid valve

Running at 3,000 r/min while engine iswarming up after having been started.

0 – 3 V

87 Idle position signal Ignition switch: ON Set throttle valve toidle position

0 – 1 V

Slightly open throttlevalve

4 V or more

��

��

��


INSPECTION PROCEDURE USING ANANALYZERAIR FLOW SENSOR (AFS)� The shape of the air processor connector has been

changed in vehicles for Australia with 4G93 engine andstrengthened exhaust gas purification measures.Procedures other than the measurement method are thesame as before.

Measurement Method1. Disconnect the air flow sensor connector, and connect

the special tool (test harness: MB991709) in between.(All terminals should be connected.)

2. Connect the analyzer special patterns pickup to air flowsensor connector terminal 3.

Alternate Method(Test harness not available)1. Connect the analyzer special patterns pickup to

engine-ECU terminal 90.

STEPPER MOTOR� The shape of the stepper motor connector has been

changed to correspond to changes to the throttle body.Procedures other than the measurement method are thesame as before.

Measurement Method1. Disconnect the stepper motor connector, and connect

the special tool (test harness: MB991709) in between.(All terminals should be connected.)

2. Connect the analyzer special patterns pickup to thestepper motor-side connector terminal 1, terminal 3,terminal 4 and terminal 6 respectively.

Alternate Method(Test harness not available)1. Connect the analyzer special patterns pickup to

engine-ECU terminal 4, connection terminal 5, connectionterminal 17, and connection terminal 18 respectively.

��

��

��

Specialpatternspickup

Analyzer

Special patterns pickup

Analyzer

13A FUEL MPI 1999 – On-vehicle Service

ON-VEHICLE SERVICE� The following service procedures have been established

to correspond to changes in the throttle body in vehicleswith 4G92 engine for GCC and vehicles for Australia4G93 engine and stronger exhaust gas purificationmeasures. Other procedures are the same as before.

THROTTLE POSITION SENSOR ADJUSTMENT1. Connect the MUT-II to the diagnosis connector. Carry

out the following procedure if not using the MUT-II.

(1) Disconnect the throttle position sensor connector andconnect the special tool (MB991536 test harness)between the disconnected connectors. (Be carefulnot to mistake the terminal numbers.)

(2) Connect a digital-type voltage meter between terminal(3) (sensor output: yellow clip of the special tool)and terminal (1) (sensor earth: red clip of specialtool) of the throttle position sensor connector.

2. Turn the ignition switch to ON. (Do not start the engine.)3. Check the throttle position sensor output voltage.

Standard value: 535 – 735 mV

4. If the voltage is outside the standard value range, loosenthe throttle position sensor mounting bolt and turn thethrottle position sensor body to adjust.

5. Turn the ignition switch to OFF.6. Disconnect the MUT-II. If not using the MUT-II, remove

the special tool and re-connect the throttle position sensorconnector.

7. If a diagnosis trouble code has been output, use theMUT-II to erase the diagnosis codes, or disconnect the(–) terminal of the battery for 10 seconds or more andthen reconnect it. Then run the engine at idle for about10 minutes.

��

��

��


MB991536 Throttle posi-tion sensor


BASIC IDLE SPEED ADJUSTMENT

NOTE(1) The standard idling speed has been adjusted by the

speed adjusting screw (SAS) by the manufacturer,and there should usually be no need for readjustment.

(2) If the adjustment has been changed by mistake, theidle speed may become too high or the idle speedmay drop too low when loads from components suchas the A/C are placed on the engine. If this occurs,adjust by the following procedure.

(3) The adjustment, if made, should be made after firstconfirming that the spark plugs, the injectors, the idlespeed control servo, the compression pressure, etc.,are all normal.

1. Before inspection and adjustment, set the vehicle to thepre-inspection condition.

2. Connect the MUT-II to the diagnosis connector (16-pin).

NOTEWhen the MUT-II is connected, the diagnosis controlterminal should be earthed.

3. Start the engine and run at idle.

��

��

��


4. Select the item No. 30 of the MUT-II Actuator test.

NOTEThis holds the ISC servo at the basic step to adjust thebasic idle speed.

5. Check the idle speed.

Standard value:700 ± 50 r/min <Vehicles for Australia>

NOTE(1) The engine speed may be 20 to 100 r/min lower

than indicated above for a new vehicle [drivenapproximately 500 km or less], but no adjustmentis necessary.

(2) If the engine stalls or the engine speed is low eventhough the vehicle has been driven approximately500 km or more, it is probable that deposits areadhered to the throttle valve, so clean it.

6. If not within the standard value range, turn the speedadjusting screw (SAS) to make the necessary adjustment.

7. Press the MUT-II clear key, and release the ISC servofrom the Actuator test mode.

NOTEUnless the ISC servo is released, the Actuator test modewill continue 27 minutes.

8. Switch OFF the ignition switch.9. Disconnect the MUT-II.10. Start the engine again and let it run at idle speed for

about 10 minutes; check that the idling conditions isnormal.

��

��

��


COMPONENT LOCATION

Name Symbol

Purge control solenoid valve A

Idle speed control servo B

Air flow sensor (with intake air temperature sensor andbarometric pressure sensor)

C

A B C

INTAKE AIR TEMPERATURE SENSOR CHECKThe shape of the air flow sensor connector has been changed.The check procedure is the same as before.

��

��

��

Equipment side connector

Air flow sensor


IDLE SPEED CONTROL (ISC) SERVO(STEPPER MOTOR) CHECKChecking the Operation Sound1. Check that the engine coolant temperature is 20�C or

below.

NOTEDisconnecting the engine coolant temperature sensorconnector and connecting the harness-side of theconnector to another engine coolant temperature sensorthat is at 20�C or below is also okay.

2. Check that the operation sound of the stepper motorcan be heard after the ignition is switched ON. (but withoutstarting the motor.)

3. If the operation sound cannot be heard, check the steppermotor’s activation circuit.If the circuit is normal, it is probable that there is amalfunction of the stepper motor or of the engine controlunit.

Checking the Coil Resistance1. Disconnect the idle speed control servo connector.2. Measure the resistance between terminal 2 and either

terminal 1 or terminal 3 of the connector at the idle speedcontrol servo side.

Standard value: 28 – 33 � (at 20�C)

3. Measure the resistance between terminal 5 and eitherterminal 6 or terminal 4 of the connector at the idle speedcontrol servo side.

Standard value: 28 – 33 � (at 20�C)

��

��

��Idle speedcontrol servo


Operation Check1. Remove the throttle body.2. Remove the idle speed control servo.

3. Connect the special tool (test harness set: MB991709)to the idle speed control servo connector.

4. Connect the positive (+) terminal of a power supply(approx. 6 V) to the terminals No. 2 and No. 5.

5. Hold the ISC servo as shown in the illustration. Connectthe negative (–) terminal of the power supply to eachclip as described in the following steps, and check whetheror not a vibrating feeling (a feeling of very slight vibrationof the stepper motor) is generated as a result of theactivation of the stepper motor.

(1) Connect the negative (–) terminal of the power supplyto the terminals No. 1 and No. 4.





(6) Repeat the tests in sequence from (5) to (1).

6. If, as a result of these tests, vibration is detected, thestepper motor can be considered to be normal.

PURGE CONTROL SOLENOID VALVE CHECKRefer – Emission Control System.

��

��

��

13A FUEL MPI 1999 – Throttle Body

THROTTLE BODYDISASSEMBLY AND REASSEMBLY

6

2

4

1

5

3

Disassembly steps�� 1. Throttle position sensor

2. Idle speed control servo3. O-ring4. Throttle body5. Speed adjusting screw6. O-ring

NOTE1. The speed adjusting screw is correctly adjusted at the

factory and should not be removed.2. If the speed adjusting screw has been removed, carry

out fixed SAS adjustment.3. If the speed adjusting screw should happen to have been

removed, carry out speed adjusting screw adjustment.

��

��

��

13A FUEL MPI 1999 – Throttle Body

CLEANING THROTTLE BODY PARTS(1) Clean all throttle body parts.

Do not use solvent to clean the following parts:� Throttle position sensor� Accelerator pedal position sensor� Idle speed control body assemblyIf these parts are immersed in solvent, their insulationwill deteriorate.Wipe them with cloth only.

(2) Check if the vacuum port of passage is clogged. Usecompressed air to clean the vacuum passage.

REASSEMBLY SERVICE POINTS�A� THROTTLE POSITION SENSOR (TPS)

INSTALLATION(1) Place the throttle position sensor against the throttle body

as shown by the dotted line in the illustration.(2) Turn the throttle position sensor to the position shown

in the illustration, and then tighten the screw.

(3) Connect a multimeter between terminal (4) (TPS powersupply) and terminal (3) (TPS output) of the TPSconnector, and check that the resistance increasesgradually as the throttle valve is opened slowly to thefully-open position.

(4) If there is an abnormality, replace the TPS.

��

��

��


TPS output

Earth TPS power supply

No connection

multipoint fuel injection (mpi) tech.mirage-performance.com/manuals/lancer/lancer... · 13a fuel...

Documents