TM100

TRAINING MANUAL
AX20, BX20 & CX20 SERIES FORKLIFT TRUCKS
Federal Environmental Protection Agency (EPA) Emission Control Compliant

K21, K25 and TB45 Engines

AX20: FG15H/15S-17, FG18H/18S-17 S/N 670001A~
BX20: FG20/25/30-14 S/N 580001A~
CX20: FG35/40/40Z/50-8, FD40/40Z/45/50-8 S/N 130001A~

EPA

WARNING
Read and observe all warnings on this unit
before operating it.
DO NOT operate this equipment unless all
factory installed guards and shields are
properly secured in place.

Komatsu Forklift USA, Inc.

REVISED APRIL 2004
 CONTENTS
COPYRIGHT STATEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAJOR IMPROVEMENTS IN ENGINES TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF ABBREVIATIONS USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EPA STATEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY STATEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
APPLICABLE “EPA” LIFT TRUCK MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page No.
CHAPTER 1 - STUDY MATERIAL FOR “ECCS” BASIC CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 K21 Engine Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 K25 Engine Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 TB45 Engine Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 K21/25 - Ignition System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 K21/25 - Fuel and Engine Speed Control Systems Specifications . . . . . . . . . . . . . . . . . . . . . 4
1.6 K21/25 - Exhaust Gas Cleanup Device List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.7 TB45 - Ignition System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.8 TB45 - Fuel and Engine Speed Control Systems Specifications. . . . . . . . . . . . . . . . . . . . . . . 5
1.9 TB45 - Exhaust Gas Cleanup Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

CHAPTER 2 - ENGINE AND MAIN BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Main Engine System, Cylinder Block and Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Cylinder Head Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Cylinder Head Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Piston, Piston Pin and Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6 Connecting Rod and Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.8 Main Bearings and Bearing Cap Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.9 Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.10 Crankshaft Pulley Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.11 Crankshaft Pulley and Pulley Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.12 Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.13 Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.14 Rocker Cover and Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

CHAPTER 3 - VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Component Parts Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.4 Timing Chain and Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.5 Valve Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

CHAPTER 4 - LUBRICATION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Lubrication Diagram - K21/25 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.4 Oil Strainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.5 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.6 Engine Oil and Oil Level Gauge (Dipstick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CHAPTER 5 - INTAKE / EXHAUST SYSTEMS
5.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2 Manifold Component Parts Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.3 Engine Intake System Component Parts Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.4 Electric Throttle Control Actuator (ETCA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.5 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.6 Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

CHAPTER 6 - ENGINE CONTROL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2 K-Engine Electronically Controlled System Diagrams (Foldouts) . . . . . . . . . . . . . . . . . . . . . 23
6.2.1 Gasoline System Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2.2 LPG System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2.3 Dual-Fuel System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.3 Engine Control System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.4 K-Engine ECM Circuit Diagrams (Foldouts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.4.1 Gasoline System Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.4.2 LPG System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.4.3 Dual-Fuel System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.5 K-Engine ECM Terminal Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.5.1 Crankshaft Position Sensor (POS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.5.2 Electric Throttle Control Actuator (ETCA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.6 Fuel Injection Control (SOFIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.6.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.6.2 Gasoline System and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.6.3 LPG System and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.6.4 Basic Control - Gasoline and LPG Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.6.5 Air / Fuel Ratio Feedback Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.6.6 Learning Function of Air / Fuel Ratio Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.6.7 Fuel Cut-Off Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.6.8 Ignition Timing Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.6.9 Idle Speed Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.6.10 Fuel Pump Control - Gasoline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.6.11 Heated Oxygen Sensor Heater Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.6.12 Fail-Safe Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.6.13 Diagnostic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.6.14 Service Support Tool (SST) (Diagnostic Monitor) Function . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.6.15 LPG System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.6.16 Positive Crankcase Ventilation (PCV) Gas Recirculation Device . . . . . . . . . . . . . . . . . . . . . 66
6.7 K-Engine Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.8 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

APPENDIX 1 -THEORY OF FUEL INJECTION PULSE WIDTH INDICATION. . . . . . . . . . . . . . . . . A1-1

APPENDIX 2 - TB45 ENGINE ELECTRIC CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-1

A2.1 Gasoline Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-1
A2.2 LPG Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-3
A2.3 Dual-Fuel Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-5

APPENDIX 3 - SERVICE SUPPORT TOOL (SST) EXERCISE PROGRAM . . . . . . . . . . . . . . . . . . A3-1

APPENDIX 4 - DTC - ERROR CODE LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-1

APPENDIX 5 - SERVICE SUPPORT TOOL (SST) OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . A5-1

APPENDIX 6 - DISPLAY STEP CHARTS (FOLDOUTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-1

SECTION EC - K21/25 ENGINE CONTROL (Section EC of K21/25 Service Manual). . . . . . . . . . EC-1

Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC- 3
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC- 4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC- 5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-15
Power Supply & Ground System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-56
Crankshaft Position Sensor (POS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-57
Camshaft Position Sensor (PHASE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-58
Mass Air Flow Sensor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-59
Engine Coolant Temperature Sensor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-60
Heated Oxygen Sensor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-61
Throttle Position Sensor System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-62
Accelerator Pedal Position Sensor System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-63
Intake Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-65
PNP Switch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-66
Stop Lamp Switch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-67
Electric Load Switch System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-68
Vehicle Speed Sensor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-69
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-70
Fuel Injector System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-72
Engine Warning Light System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-73
Fuel Pump System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-73
LPG Injector System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-75
LPG Assist Injector System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-78
LPG Fuel Pressure Sensor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-79
Throttle Control Motor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-80
Heated Oxygen Sensor Heater System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-81
Blowby Gas Recirculation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-82
Fuel Cut Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-83
Removal and Installation of ECCS Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-84
Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-88

SECTION EC - TB45 ENGINE CONTROL (Section EC of TB45 Service Manual). . . . . . . . . . . . . EC-1

Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC- 3
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC- 4
Engine Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC- 5
Basic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-10
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-16
Power Supply & Ground System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-57
Crankshaft Position Sensor 1° (POS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-58
Crankshaft Position Sensor 120° (PHASE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-59
Mass Air Flow Sensor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-60
Engine Coolant Temperature Sensor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-61
Heated Oxygen Sensor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-62
Vehicle Speed Sensor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-63
Throttle Position Sensor System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-64
Accelerator Pedal Position Sensor System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-65
Intake Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-66
PNP Switch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-67
Stop Lamp Switch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-68
Electric Load Switch System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-69
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-70
Fuel Injector System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-72
Fuel Pump System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-73
Throttle Control Motor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-74
Engine Warning Light System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-75
Heated Oxygen Sensor Heater System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-76
LPG Injector System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-77
LPG Assist Injector System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-79
LPG Fuel Pressure Sensor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-80
Blowby Gas Restoration Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-81
Fuel Cut Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-82
Removal and Installation of ECM Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-83
Service Data and Specifications (SDS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-87
 APPLICABLE “EPA” LIFT TRUCK MODELS

Model Description

AX20 (K21 Engines)

FG15HC-17 3,000 lb. capacity, Clutch Spec, Pneumatic Tire

FG15HT-17 3,000 lb. capacity, Torqflow Spec, Pneumatic Tire

FG15HTLS-17 3,000 lb. capacity, Torqflow Spec, LP Special, Pneumatic Tire

FG15ST-17 3,000 lb. capacity, Torqflow Spec, Cushion Tire

FG15STLS-17 3,000 lb. capacity, Torqflow Spec, LP Special, Cushion Tire

FG18HT-17 3,500 lb. capacity, Torqflow Spec, Pneumatic Tire

FG18HTLS-17 3,500 lb. capacity, Torqflow Spec, LP Special, Pneumatic Tire

FG18ST-17 3,500 lb. capacity, Torqflow Spec, Cushion Tire

FG18STLS-17 3,500 lb. capacity, Torqflow Spec, LP Special, Cushion Tire

BX20 (K21/K25 Engines)

FG20C-14 4,000 lb. capacity, K21 Engine, Clutch Spec, Pneumatic Tire

FG20T-14 4,000 lb. capacity, K21 Engine, Torqflow Spec, Pneumatic Tire

FG20TUS-14 4,000 lb. capacity, K21 Engine, Torqflow Spec, Gasoline Special, Pneumatic Tire

FG20TLS-14 4,000 lb. capacity, K21 Engine, Torqflow Spec, LP Special, Pneumatic Tire

FG20ST-14 4,000 lb. capacity, K21 Engine, Torqflow Spec, Cushion Tire

FG20STUS-14 4,000 lb. capacity, K21 Engine, Torqflow Spec, Gasoline Special, Cushion Tire

FG20STLS-14 4,000 lb. capacity, K21 Engine, Torqflow Spec, LP Special, Cushion Tire

FG20HT-14 4,000 lb. capacity, K25 Engine, Torqflow Spec, Pneumatic Tire

FG20HTLS-14 4,000 lb. capacity, K25 Engine, Torqflow Spec, LP Special, Pneumatic Tire

FG20SHT-14 4,000 lb. capacity, K25 Engine, Torqflow Spec, Cushion Tire

FG25C-14 5,000 lb. capacity, K21 Engine, Clutch Spec, Pneumatic Tire

FG25T-14 5,000 lb. capacity, K21 Engine, Torqflow Spec, Pneumatic Tire

FG25TUS-14 5,000 lb. capacity, K21 Engine, Torqflow Spec, Gasoline Special, Pneumatic Tire

FG25TLS-14 5,000 lb. capacity, K21 Engine, Torqflow Spec, LP Special, Pneumatic Tire

FG25ST-14 5,000 lb. capacity, K21 Engine, Torqflow Spec, Pneumatic Tire

FG25STUS-14 5,000 lb. capacity, K21 Engine, Torqflow Spec, Gasoline Special, Cushion Tire

FG25STLS-14 5,000 lb. capacity, K21 Engine, Torqflow Spec, LP Special, Cushion Tire
 APPLICABLE “EPA” LIFT TRUCK MODELS

Model Description

FG25HT-14 5,000 lb. capacity, K25 Engine, Torqflow Spec, Pneumatic Tire

FG25HTUS-14 5,000 lb. capacity, K25 Engine, Torqflow Spec, Gasoline Special, Pneumatic

FG25HTLS-14 5,000 lb. capacity, K25 Engine, Torqflow Spec, LP Special, Pneumatic Tire

FG25SHT-14 5,000 lb. capacity, K25 Engine, Torqflow Spec, Cushion Tire

FG25SHTLS-14 5,000 lb. capacity, K25 Engine, Torqflow Spec, LP Special, Cushion Tire

FG30C-14 6,000 lb. capacity, K21 Engine, Clutch Spec, Pneumatic Tire

FG30HT-14 6,000 lb. capacity, K25 Engine, Torqflow Spec, Pneumatic Tire

FG30HTUS-14 6,000 lb. capacity, K25 Engine, Torqflow Spec, Gasoline Special, Pneumatic Tire

FG30HTLS-14 6,000 lb. capacity, K25 Engine, Torqflow Spec, LP Special, Pneumatic Tire

FG30SHT-14 6,000 lb. capacity, K25 Engine, Torqflow Spec, Cushion Tire

FG30SHTLS-14 6,000 lb. capacity, K25 Engine, Torqflow Spec, LP Special, Cushion Tire

CX20 (TB45E Engine)

FG35ST-8 8,000 lb. capacity, TB45E Engine, Torqflow Spec, Cushion Tire

FG35BCS-8 8,000 lb. capacity, TB45E Engine, Torqflow Spec, Box Car Special, Cushion Tire

FG40T-8 9,000 lb. capacity, TB45E Engine, Torqflow Spec, Pneumatic Tire

FG40T2-8 9,000 lb. capacity, TB45E Engine, Torqflow Spec, 2-speed, Pneumatic Tire

FG40T2LS-8 9,000 lb. capacity, TB45E Engine, Torqflow Spec, 2-speed, LP Special, Pneumatic

FG40ZT-8 8,000 lb. capacity, Compact Wheelbase, TB45E Engine, Torqflow Spec, Pneumatic

FG40ZT2-8 8,000 lb. capacity, Compact Wheelbase, TB45E Engine, Torqflow Spec, 2-speed,
Pneumatic Tire

FG40ZTUS-8 8,000 lb. capacity, Compact Wheelbase, TB45E Engine, Torqflow Spec, Gasoline
Special, Pneumatic Tire

FG40ZTLS-8 8,000 lb. capacity, Compact Wheelbase, TB45E Engine, Torqflow Spec, LP Special,
Pneumatic Tire

FG45BCS-8 10,000 lb. capacity, TB45E Engine, Torqflow Spec, Box Car Special, Cushion Tire

FG45T-8 10,000 lb. capacity, TB45E Engine, Torqflow Spec, Pneumatic Tire

FG45T2-8 10,000 lb. capacity, TB45E Engine, Torqflow Spec, 2-speed, Pneumatic Tire

FG45ST-8 10,000 lb. capacity, TB45E Engine, Torqflow Spec, Cushion Tire

FG45T2US-8 10,000 lb. capacity, TB45E Engine, Torqflow Spec, 2-speed, Gasoline Special,
Pneumatic Tire

FG45T2LS-8 10,000 lb. capacity, TB45E Engine, Torqflow Spec, 2-speed, LP Special, Pneumatic
 APPLICABLE “EPA” LIFT TRUCK MODELS

Model Description

FG50AT2-8 11,000 lb. capacity, TB45E Engine, Torqflow Spec, 2-speed, Pneumatic Tire

FD40T-8 9,000 lb. capacity, 6D102E Engine, Torqflow Spec, Pneumatic Tire

FD40T2-8 9,000 lb. capacity, 6D102E Engine, Torqflow Spec, 2-speed, Pneumatic Tire

FD40ZT-8 8,000 lb. capacity, Compact Wheelbase, 6D102E Engine, Torqflow Spec,
Pneumatic Tire

FD40ZT2-8 8,000 lb. capacity, Compact Wheelbase, 6D102E Engine, Torqflow Spec, 2-speed,
Pneumatic Tire

FD45T-8 10,000 lb. capacity, 6D102E Engine, Torqflow Spec, Pneumatic Tire

FD45T2-8 10,000 lb. capacity, 6D102E Engine, Torqflow Spec, 2-speed, Pneumatic Tire

FD45T2US-8 10,000 lb. capacity, 6D102E Engine, Torqflow Spec, 2-speed, Gasoline Special,
Pneumatic Tire

FD50AT2-8 11,000 lb. capacity, 6D102E Engine, Torqflow Spec, 2-speed, Pneumatic Tire

FD50AT2US-8 11,000 lb. capacity, 6D102E Engine, Torqflow Spec, 2-speed, Diesel Special,
Pneumatic Tire
1. STUDY MATERIAL FOR “ECCS” BASIC CONTROL
1.1 K21 Engine Specifications

ENGINE TYPE K21

ENGINE CONTROL SYSTEM ELECTRONICALLY CONTROLLED SPECIFICATIONS

FUEL SPECIFICATION GASOLINE LPG DUAL-FUEL

TOTAL DISPLACEMENT 126 in.2 (2,065cc)

SHAPE OF COMBUSTION CHAMBER BATHTUB

VALVE MECHANISM OHV

CYLINDER BORE X STROKE 3.5 X 3.27 in. (89MM X 83MM)

COMPRESSION RATIO 8.7:1 9.3:1 8.7:1

COMPRESSION PRESSURE (kPa (bar, kg/cm2, psi) / rpm 1,226 (12.3, 12.5, 178) / 250 1,275 (12.8, 13.0, 185) / 250 1,226 (12.3, 12.5, 178) / 250

HORSEPOWER SPECIFICATION 60.1 HP @ 2,950 rpm + 50 rpm

ENGINE SPEED CONTROL SYSTEM ECM, ELECTRONICALLY CONTROLLED THROTTLE

FUEL (SEE NOTE 1) UNLEADED REGULAR HP-5 DUAL-FUELS AT LEFT

MAXIMUM OUTPUT (kW (PS) / rpm) 42.0 (57.1) / 2,700

MAXIMUM TORQUE (Nm (kg-m) / rpm) 160.0 (16.3) / 2,000

INTAKE OPEN (BTDC) 14

INTAKE CLOSED (ABDC) 30

VALVE OPENING /
CLOSING TIMING (DEGREE)
EXHAUST OPEN (BBDC) 32

EXHAUST CLOSED (ATDC) 12

INTAKE (HOT)
VALVE CLEARANCE 0.015 in. (0.38MM)
EXHAUST (HOT)

FIRING ORDER 1-3-4-2

ATM
ON BOARD IDLE SPEED 700 rpm
MTM

ATM
ON BOARD HIGH-IDLE
2,700 rpm
SPEED
MTM

INSTANTANEOUS NO-LOAD 3,600 rpm

ALLOWABLE MAXIMUM
ENGINE SPEED
CONTINUOUS LOAD 3,000 rpm

PTO SYSTEM SILENT CHAIN - DRIVEN / SIDE PTO

SPECIFICATION 10W - 30 (CLASS SJ)

ENGINE OIL (ORIGINALLY
FILLED WHEN NEW)
AMOUNT 4.0 quarts (3.8 L) INCLUDING FILTER

ENGINE DIMENSIONS (LENGTH X WIDTH X HEIGHT) 28.85 X 22.16 X 29.25 in. (732.7 X 562.9 X 743MM)

ENGINE WEIGHT (W/O COOLANT & OIL) 304.24 lbs. (138 KG)

NOTE 1: Fuel (Gasoline) - Use unleaded regular gasoline with an Octane Rating of 89
or higher. (LPG) - Use a fuel of 30P or more in cold seasons. In ambient temperatures of 23° F (-5° C)
or less, use a 100P fuel.

1
1.2 K25 Engine Specifications

ENGINE TYPE K25

ENGINE CONTROL SYSTEM ELECTRONICALLY CONTROLLED SPECIFICATIONS

FUEL SPECIFICATION GASOLINE LPG DUAL-FUEL

TOTAL DISPLACEMENT 151.8 in.2 (2,488cc)

SHAPE OF COMBUSTION CHAMBER BATHTUB

VALVE MECHANISM OHV

CYLINDER BORE X STROKE 3.5 X 3.94 in. (89MM X 100MM)

COMPRESSION RATIO 8.7:1 9.3:1 8.7:1

COMPRESSION PRESSURE (MPa (kg/cm2) / rpm 1.2 (12.5) / 250 1.3 (13.0) / 250 1.2 (12.5) / 250

HORSEPOWER SPECIFICATION 65.7 HP @ 2,900 rpm

ENGINE SPEED CONTROL SYSTEM ECM, ELECTRONICALLY CONTROLLED THROTTLE

FUEL (SEE NOTE 1) UNLEADED REGULAR At 20P

MAXIMUM OUTPUT (kw(PS)/rpm) 41.4 (56.3) / 2,400 44.0 (59.9) / 2,400

MAXIMUM TORQUE (Nm (kgfm)/rpm) 181.4 (18.5) / 1,600

INTAKE OPEN (BTDC) 14

INTAKE CLOSED (ABDC) 30

VALVE OPENING /
CLOSING TIMING (DEGREE)
EXHAUST OPEN (BBDC) 32

EXHAUST CLOSED (ATDC) 12

INTAKE (HOT)
VALVE CLEARANCE 0.015 in. (0.38MM)
EXHAUST (HOT)

FIRING ORDER 1-3-4-2

ATM
ON BOARD IDLE SPEED 700 rpm
MTM

ATM
ON BOARD HIGH-IDLE SPEED 2,700 rpm
MTM

INSTANTANEOUS NO-LOAD 3,600 rpm

ALLOWABLE MAXIMUM ENGINE
SPEED
CONTINUOUS LOAD 3,000 rpm

PTO SYSTEM SILENT CHAIN - DRIVEN / SIDE PTO

SPECIFICATION 10W - 30 (CLASS SJ)

ENGINE OIL (ORIGINALLY
FILLED WHEN NEW)
AMOUNT 4.0 quarts (3.8 L) INCLUDING FILTER

ENGINE DIMENSIONS (LENGTH X WIDTH X HEIGHT) 28.85 X 22.16 X 29.25 in. (732.7 X 562.9 X 743MM)

ENGINE WEIGHT (W/O COOLANT & OIL) 304.24 lbs. (138 KG)

NOTE 1: Fuel (Gasoline) - Use unleaded regular gasoline with an Octane Rating of 89
or higher. (LPG) - Use a fuel of 30P or more in cold seasons. In ambient temperatures of 23° F (-5° C)
or less, use a 100P fuel.

2
1.3 TB45 Engine Specifications

ENGINE TYPE TB45

ENGINE CONTROL SYSTEM ELECTRONICALLY CONTROLLED SPECIFICATIONS

FUEL SPECIFICATION GASOLINE LPG DUAL-FUEL

TOTAL DISPLACEMENT 273.3 in.2 (4,478cc)

SHAPE OF COMBUSTION CHAMBER Bathtub

VALVE MECHANISM OHV

CYLINDER BORE X STROKE (Standard) 3.9173 in. (99.500mm) X 3.779 in. (96.0mm)

COMPRESSION RATIO 8.5:1

COMPRESSION PRESSURE (MPa ( kg/cm2) / rpm 1,19 (12.1) / 200

HORSEPOWER SPECIFICATION 95hp / 2,400 rpm

ENGINE SPEED CONTROL SYSTEM ECM, ELECTRONICALLY CONTROLLED THROTTLE

FUEL (SEE NOTE 1) UNLEADED REGULAR HP-5

MAXIMUM OUTPUT (kw(PS)/rpm) 70 / (95) / 2,400

MAXIMUM TORQUE (Nm (kg-m)/rpm) 274 (28) / 1600

INTAKE OPEN (BTDC) 0°

INTAKE CLOSED (ABDC) 60°

VALVE OPENING /
CLOSING TIMING (DEGREE)
EXHAUST OPEN (BBDC) 52°

EXHAUST CLOSED (ATDC) 8°

INTAKE (HOT)
VALVE CLEARANCE 0.0138 in. (0.35MM)
EXHAUST (HOT)

FIRING ORDER 1-5-3-6-2-4

IGNITION TIMING ([BTDC] DEGREE / IDLE) 10 + 1

ON BOARD IDLE SPEED 675 + 50 rpm (N or P position)

ON BOARD HIGH-IDLE SPEED 2,400 + 50 rpm

INSTANTANEOUS NO-LOAD 3,500 rpm

ALLOWABLE MAXIMUM ENGINE
SPEED
CONTINUOUS LOAD 3,000 rpm

PTO SYSTEM Crankshaft Pulley PTO

SPECIFICATION 10W - 30 (CLASS SJ)

ENGINE OIL (ORIGINALLY
FILLED WHEN NEW)
AMOUNT 8.0 quarts (7.6 L) INCLUDING FILTER

ENGINE DIMENSIONS (LENGTH X WIDTH X HEIGHT) 39.92 x 24.52 x 36.14 in. (1,014 x 623 x 918mm)

ENGINE WEIGHT (W/O COOLANT & OIL) 672.41 lbs. (305 KG)

NOTE 1: Fuel (Gasoline) - Use unleaded regular gasoline with an Octane Rating of 89
or higher. (LPG) - Use a fuel of 30P or more in cold seasons. In ambient temperatures of 23° F (-5° C)
or less, use a 100P fuel.

3
1.4 IGNITION SYSTEM - SPECIFICATIONS
Engine Type K21 and K25
Engine Control System Electronically controlled specifications
Fuel Specification Gasoline LPG Dual-Fuel
Ignition Device Non-contact type (ECM)
Ignition Coil (with power transistor) Independent cylinder distribution type

Crankshaft Position Sensor POS IC Type

(POS) Camshaft Position Sensor (PHASE) IC Type
Distributor --
NGK type FR2A-D
Spark Plug
Gap (in. / mm) .035 / 0.9

1.5 FUEL SYSTEM and ENGINE SPEED CONTROL SYSTEM

Engine Type K21 and K25
Engine Control System Electronically controlled specifications
Fuel Specification Gasoline LPG Dual-Fuel
Fuel Device standard type Electronically controlled fuel injection type (ECM)
Gasoline LPG See the left
Fuel Device
injector injector columns
Air / Fuel ration Control Device Air / Fuel ration feedback control
Starting Auxiliary Device Electric throttle control actuator
Idle load control type Electric throttle control actuator
Engine speed control type Electric throttle control actuator

1.6 EXHAUST GAS CLEANUP DEVICE LIST

Engine Type K21 and K25
Engine Control System Electronically controlled specifications
Fuel Specification Gasoline LPG Dual-Fuel
Type Three-way catalyst
Catalytic Device
Location --
(Reducing HC, CO, Nox)
Capacity (qts. / L) 0.475 / 0.45
PCV Gas Recirculation Device Closed type

4
1.7 IGNITION SYSTEM - SPECIFICATIONS
Engine Type TB45
Engine Control System Electronic Concentrated Engine Control System (ECCS)
Fuel Specification Gasoline LPG Combined
Ignition Device Non-contact type (ECM)
Ignition Coil (with power transistor) Independent cylinder distribution type

Crankshaft Position Sensor POS IC Type

(POS) Camshaft Position Sensor (PHASE) IC Type
Distributor --
NGK type NGK/BPR4ES
Spark Plug
Gap (in. / mm) .031 - .035 / 0.8 - 0.9

1.8 FUEL SYSTEM and ENGINE SPEED CONTROL SYSTEM

Engine Type TB45
Engine Control System Electronically controlled specifications
Fuel Specification Gasoline LPG Combined
Fuel Device standard type Electronically controlled fuel injection type (ECM)
Gasoline LPG See the left
Fuel Device
injector injector columns
Air / Fuel ration Control Device Air / Fuel ration feedback control
Starting Auxiliary Device Electric throttle control actuator
Idle load control type Electric throttle control actuator
Engine speed control type Electric throttle control actuator

1.9 EXHAUST GAS CLEANUP DEVICE LIST

Engine Type TB45
Engine Control System Electronically controlled specifications
Fuel Specification Gasoline LPG Combined
Type Three-way catalyst
Catalytic Device
Location --
(Reducing HC, CO, Nox)
Capacity (qts. / L) 0.475 / 0.45
PCV Gas Recirculation Device Closed type

5
2. ENGINE AND MAIN BODY
2.1 Description
• The engines are water-cooled 4 cylinder types and have OHV turn-flow type intake /
exhaust ports. The displacement for the K21 is 126 cubic inches (2.065 L) and the K25 is
151.8 cubic inches (2.488 L).
• ECM has been adapted for engine control. See ‘ENGINE CONTROL SYSTEM” for
details.

2.2 Main Engine System

2.2.1 - Component Parts Location

6
• Main engine system dimension list (See Figure 2-0001)
Engine Model K21 K25
Cylinder block height (from crankshaft center) . . . . . H 8.94 in. (227.05mm)
Cylinder block total length . . . . . . . . . . . . . . . . . . . . Lb 18.11 in. (460mm)
Pitch between bores . . . . . . . . . . . . . . . . . . . . . . . . . P 3.94-4.17-3.94 in. (100-106-100mm)
Cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . D 3.50 in. (89.0mm)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S 3.27 in. (83.0mm) 3.94 in. (100.0mm)
Crankshaft journal diameter . . . . . . . . . . . . . . . . . . .Dj 2.48 in. (63.0mm)
Crankshaft pin diameter . . . . . . . . . . . . . . . . . . . . . dp 1.77 in. (45.0mm)
Crankshaft total length. . . . . . . . . . . . . . . . . . . . . . . Ls 20.96 in. (532.5mm)
Piston compression height . . . . . . . . . . . . . . . . . . . . C 1.28 in. (32.5mm)
Distance between connecting rod centers. . . . . . . . Lc 6.00 in. (152.5mm) 5.67 in. (144.0mm)

2.2.2 - Cylinder Block

• Full-jacket type cylinder block has been
adopted for more uniform cylinder cooling.
• The appearance of the cylinder block is the
same as that of the H-engine.

2.2.3 - Cylinder Head

• The cylinder head is common between the
K21 and K25 engines.
• The cylinder head is constructed of alum-
inum alloy. Turn-flow type and bathtub type
combustion chambers have been adopted
for intake / exhaust layout

• Valve sizes are expanded from H-engine models

(D1: 35 to 38mm; D2: 30 to 32mm dia.) to improve
intake efficiency. The valve seat material is a spe-
cial sintered alloy that has excellent wear resis-
tance.
• The intake port is in the upper position to improve
efficiency.

7
 • The spark plug is placed in the center of the
combustion chamber to help improve combustion
efficiency.

2.3 Cylinder Head Gasket

• The cylinder head gasket is made of a
stainless base metal construction. The
thickness differs between Gasoline and
LPG applications.

Thickness Metal layers

Gasoline (combined with LPG) .063 in. (1.6mm) 4

LPG .031 in. (0.8mm) 3

2.4 Cylinder Head Bolt

• Bolts are M10 x 1.5 in size. Tighten the bolts using a criss-cross pattern in order to
ensure even torqing of the bolts to minimize the potential for warping the head.

2.5 Piston, Piston Pin and Piston Rings

• Thermal flow type pistons have been adopted in
order to reduce piston temperatures.
• 3 rings (top ring, second ring and oil ring) are used
on the pistons. See Table on next page.

Engine Type K21 K25

Standard diameter 3.50 in. (89.0mm)

Total length (HD) 2.28 in. (58.0mm)

Piston Compression height (HC) 1.28 in. (32.5mm)

Pin hole diameter (d) .787 in. (20.0mm)

Material AC8A-T6

Outer diameter x Inner diameter x .787 x .465 x 2.24 in.

Length (20 X 11.8 X 57mm)
Piston pin
Material SCr42.0H

8
2.6 Connecting Rod and Connecting Rod Bearing
• High-strength and high-stiffness forged steel mate-
rials appropriate for the engine output are utilized.

Engine Type K21 K25

Distance between cen- 6.0 in. 5.67 in.

ters (D) (152.5mm) (144mm)

Connecting Large end dia. x Width B ø1.89 x 0.96 in.

rod xT (ø48 x 24.3mm)

Small end dia. x Width A ø0.79 x 0.59 in.

xt (ø20 x 15mm)

2.7 Crankshaft
• The crankshaft is balanced by 4 counterweights
and supported by 5 bearings.
2.8 Main Bearing and Bearing Cap Bolts
The 5-bearing support method used in the K21
and K25 engines is the same as used in the H-
series engines. The center main bearing (thrust
bearing) is common with the H-series also. Micro-
groove bearings (with fine grooves all around the
bearing surface) are utilized to reduce friction for main and rod bearings. K21 and K25
connecting rod bearings are common with each other. Note that rod bearings from an H-
25 engine are not interchangeable.
2.9 Oil Seal
• The rear oil seal is installed directly to the engine block and is the same as in the H-
series engines.
• The front oil seal is installed in the front cover.

2.10 Crankshaft Pulley Bushing

• The crankshaft pulley bushing for electronically
controlled engines is integrated with the signal
plate. See Figure 2-0009.
• The crankshaft pulley bushing for carburetor
engines uses the same design as the H-model
engines.

2.11 Crankshaft Pulley and Pulley Bolt

• The K21 and K25 engines use the same metal
plate pulley as the H-series engines.
• The pulley bolt is integral with the washer.

9
2.12 PTO (Power Take-Off)
• The same reliable chain drive PTO used in the H-series engines is used in the K21 and
K25 engines for the drive unit of the oil pressure pump. Crankshaft power is transmitted
to a PTO driven sprocket so that both axles are supported with ball bearings of the PTO
sprocket and the PTO chain. The oil pressure pump is then driven by a spline installed in
the inner diameter of the driven sprocket.
1. Rotation ratio (acceleration) of the oil pump to engine rotation is 1.037. The drive
sprocket has 28 teeth while the driven sprocket has 27.
2. The PTO chain is a newly designed narrow ¾” unit that is very quiet. The chain on the
H-engine is 1” wide.
3. The chain housing encloses the camshaft drive chain and the PTO drive chain. Oiling
for the PTO chain is provided on the lower side, and oiling for lubrication of the spline
joint between the PTO driven sprocket and the oil pump is to the upper side. Mount-
ing for the Crankshaft Position Sensor (PHASE sensor) is new and is located in front
of the camshaft.
4. Mounting points for the driven sprocket ball bearing and the Crankshaft Position Sen-
sor (POS) are shown in Figure 2-0010.

PTO chain width ¾ in.

PTO drive ratio 1.037

10
2.13 Oil Pan
• A metal plate type oil pan (shaped like those on H-
engines) is utilized.
• The oil drain plug is located at the bottom center of
the pan.

2.14 Rocker Cover and Gasket

• The K-engines use an aluminum die-cast rocker
cover to improve sealing.
• An oil separator has been incorporated into the
rocker cover.
• An inverse T-type rubber rocker cover gasket is
used to greatly improve sealing.

3.0 VALVES
3.1 Description
• The camshaft is driven by chain from the crankshaft sprocket.

11
3.2 Component Parts Location

3.3 Camshaft
• The K-engines use the same 3-bearing support
system that was successfully used on the H-
engines.

12
3.3.1 Valve Timing

3.4 Timing Chain and Sprocket

Camshaft sprocket Number of teeth 40

Crankshaft sprocket Number of teeth 20

Timing chain Number of links 54

1. Timing chain
• K-engines use the same chain as the H-engines.
2. Camshaft sprocket
• The new sprocket has provision for the cylinder
detection system.
• Works with the PHASE sensor installed in the
chain housing.
3. Crankshaft sprocket
• This sprocket drives the timing chain and is the
same as the H-engine sprocket.
4. Chain tensioner
• The K-engines use the same oil pressure type
chain tensioner as the H-engine series.
• The tensioner pushes the chain slack guide using engine oil pressure and spring ten-
sion, thus applying proper tension to the timing chain.

3.5 Valve Related Parts

1. Valve, valve guide and valve seat

• The K-engines use a newly designed valve guide. The valve seat is pressed into the cyl-
inder head.
• The K-series engines use one intake and one exhaust valve per cylinder with a stem
diameter of 0.2756 in. (7mm) each. The valves have been enlarged for greater air intake
efficiency. The intake valve is 1.496 in. (38mm) in diameter while the exhaust valve is
1.259 in. (32mm) in diameter.
2. Valve spring, valve spring seat and valve spring

13
 retainer.
• High-strength, low-load single valve springs are
used with each valve. These springs help to
reduce valve seat pressure and friction.
• The K-engine valve springs have a yellowish-green
color patch for identification.

3. Valve oil seal

• The seal uses a metal compression ring.

4. Valve lifter
• The K-engines use the same valve lifters as the H-
engines.

14
4.0 LUBRICATION SYSTEM
4.1 Description - The oil pump is driven through a “spindle” gear from the camshaft.
4.2 Lubrication Diagram

15
4.3 Oil Pump
• Gear type pump in which a coaxial drive is driven by the
camshaft through the oil pump spindle. This arrangement
is the same as that utilized in the H-series engines.

4.4 Oil Strainer

• Electronically controlled engines have a newly designed
oil pump drive.
• Carbureted engines use the same system components as
the H-engines.

4.5 Oil Filter

• A full-flow cartridge-type oil filter is utilized and is common
with H-engines.

• The oil filter is installed directly to the engine block.

Oil filter outer diameter x height ø3.15 x 2.76 in. (ø80 x 70mm)

Capacity 0.21 qt. (Approx. 0.2 L)

4.6 Engine Oil and Oil Level Gauge (Dipstick)

• 10W-30 (SL class) is installed in the engine prior to delivery.
• The oil level gauge (dipstick) is the same as used in H-engines.

Oil level (Oil Pan capacity)

“H” mark on dipstick: . . . . . . 1.03 gal (3.9 L)

“L” mark on dipstick:. . . . . . . 0.82 gal (3.1 L)

5.0 INTAKE / EXHAUST

5.1 Description
• Turn-flow type arrangement is utilized for the intake and exhaust system.
• K-engines have 12 intake / exhaust manifold attachment points. This will improve mani-
fold sealing characteristics over the 10 points used on H-engines.
• An electronic throttle control actuator provides the proper volume of intake air to the
engine.

16
• See the following Table for a comparison of intake air systems between electronically
controlled engines and carbureted engines.

Intake
Intake
manifold Engine
manifold Air Air
indirectly installed air
Specification directly volume volume
installed introduction
installed major control detection
major part
components
components

Electric throttle
control actuator, Air horn
Gasoline Electric Air horn
Electronically gasoline and adaptor throttle Mass air (installed to
controlled injector control flow sensor mass air flow
specifications
actuator sensor)
Electric throttle LPG injector
LPG
control actuator holder

• See the following Table for a comparison of exhaust systems between electronically con-
trolled engines and carbureted engines.

Exhaust
Exhaust
Specification manifold major Exhaust system major components
manifold
components

Electronically
controlled Gasoline Small heat shield Heated oxygen Exhaust pipe
specifications Common plate (exhaust sensor 3-way catalyst
outlet) (exhaust pipe) Muffler
LPG

17
5.2 Manifold Component Parts Location

18
5.3 Engine Intake System Component Parts Location

1. Electronically controlled specification

• LPG specification, Combined use specification
Electric throttle control actuator is installed on the intake manifold. The LPG injector
holder and air horn are installed on the throttle control actuator. The Mass Air Flow Sen-
sor is installed on the air horn.
• Gasoline specification
An air horn spacer is installed in place of the LPG injector holder. See Figure 5-0002.

5.4 Electric Throttle Control Actuator (ETCA)

• The throttle valve in the ETCA is driven by the
throttle control motor which reacts to the ECM con-
trol signal.
• The ETCA is equivalent to a conventional throttle
body, and it serves to properly control the throttle
valve position according to driving conditions.
• Refer to “ELECTRIC THROTTLE CONTROL
ACTUATOR” in Section 6.6.2, for details.

19
5.5 Intake Manifold
• The intake manifold on electronically controlled
engines is equipped with a “boss” for installation of
the gasoline injector. Four bolts attach the electric
throttle control actuator to the manifold.
• The intake manifold for carbureted engines is the
same as the conventional type used with a pneu-
matic governor which is mounted with 2 bolts.

5.6 Exhaust Manifold

The exhaust manifold is made of lead cast iron in a
spherical shape. This material performs well under
high heat conditions.

20
6.0 ENGINE CONTROL SYSTEM
6.1 Description
• A single unit Electronic Concentrated Engine Control System manages the engine con-
trol functions such as fuel injection control, ignition timing control, idle speed control,
governor control, etc.
• The Electric Throttle Control Actuator system controls the electronically controlled gover-
nor.
• Utilizes a Hall IC type crankshaft position sensor (POS) and a camshaft position sensor
(PHASE).

Items Description

• Utilizes the electronic throttle control actuator with an integrated throttle control motor
Electric throttle
to adjust throttle valve opening optimally according to driving conditions and to improve
control actuator
safety and operability through the electronically controlled governor.

• With SOFIS control, the volume of injected fuel is optimized to improve exhaust perfor-
mance and response.
Fuel injection control • Using feedback control through the learning of air/fuel ration compensation, the system
corrects the ratio during transitional conditions, such as sudden, sharp changes in the
ratio, in order to improve drivability.

• Uses the Hall IC crankshaft position sensor (POS) and the camshaft position sensor
(PHASE) to perform controls so that optimum ignition timing is obtained for every oper-
ating condition. Optimum ignition timing set-up according to each fuel is also enabled
Ignition timing control
in combined use type engines.
• Adopts the electronic distribution system (NDIS) in which each cylinder is equipped
with an ignition coil incorporating a power transistor for better ignition performance.

• Adopts the electronic throttle control actuator that continuously regulates the intake air
Idle speed control
volume required for idling.

Governor speed • Performs maximum regulation of the engine speed for oil pressure pump protection by
control the engine speed signal.

• Performs maximum speed regulation by using the vehicle speed sensor signal. Also
Maximum speed regu-
performs variable control of the maximum speed by using the optional changeover
lation control
switch.

Idling area torque-up • Performs torque-up control in the idling area by using the engine speed signal in order
control to also enable cargo work while idling.

• Reduces engine heat generation by reducing the maximum engine speed and regulat-
ing the maximum throttle opening when engine coolant temperature reaches approxi-
Overheat prevention
mately 230° F (110° C).
control
• Prevents engine breakage from overheating by cutting fuel at some engine speeds or
when engine coolant temperature reaches approximately 275° F (135° C).

Slow operation mode • Utilizes a slow operation mode switch to change the throttle opening position which
control permits fine control of the engine speed.

Fuel pump drive • Turns the fuel pump relay ON / OFF depending on the engine speed signal.
control (Gasoline)

LPG interception valve • Turns the interception valve relay ON / OFF depending on the engine speed signal and
control fuel pressure sensor signal.

• Ensures safe operation of the vehicle and enables the vehicle to be driven in an emer-
Fail-safe function gency when any of the major system components (mass air flow sensor, engine cool-
ant temperature sensor, etc.) have malfunctioned.

Diagnostic system • Utilizes a self-diagnosis system for easier troubleshooting.

21
6.3 Engine Control System Components

Specifications
Main component part Type Location
Gasoline LPG Dual-Fuel

Actuators Gasoline injector High resistance Intake manifold √ √

LPG injector Gas injection Integrated in injector √ √
holder (on intake
manifold)
Fuel pump Electric motor/turbine Integrated in fuel tank √ √
Fuel pressure regulator Diaphragm √ √
Throttle control motor Electric DC motor (DC Integrated in electronic √ √ √
motor) throttle control actuator
Ignition coil Mold (built-in power Cylinder head (On each √ √ √
transistor) spark plug)

29
 Specifications
Main component part Type Location
Gasoline LPG Dual-Fuel

Sensors Crankshaft Crankshaft Hall IC (element) Front cover √ √ √

position position sensor
sensor (POS)
Camshaft Chain housing √ √ √
position sensor
(PHASE)
Mass air flow sensor Hot wire Air horn √ √ √
Accelerator pedal position Variable resistance Integrated in √ √ √
sensors 1 and 2 accelerator work unit
(accelerator pedal
assembly)
Throttle position sensors 1 and Integrated in electronic √ √ √
2 throttle control actuator
Engine coolant temperature Thermistor Water outlet √ √ √
sensor
Intake air temperature sensor With air flow meter √ √ √
Heated oxygen sensor Zirconia (with heater) Front tube √ √ √
Vehicle speed sensor Electromagnetic power Vehicle side √ √ √
generation
ECCS C/U 121-pin digital control Vehicle side √ √ √
ECCS & IGN coil relay Compact general relay Vehicle side √ √ √
(1M X 2)

30
6.5 K-Engine ECM Terminal Layout

NOTE: The symbol in ( ) next to terminal numbers indicates the DDL2 connector.
Terminal Description

24 Heated oxygen sensor heater

2 —
6 —
7 —
8 LPG injector
9 —
113 Fuel pump relay
11 LPG assistance injector
12 Soft mode
15 —
16 —
17 —
18 —
19 —
111 ECCS & IGN coil relay
62 No.1 cylinder ignition signal (power transistor drive signal)
81 No.1 cylinder ignition signal (power transistor drive signal)
61 No.3 cylinder ignition signal (power transistor drive signal)
80 No.4 cylinder ignition signal (power transistor drive signal)
25 —
27 ----
28 —
29 —
30 Warning light
31 LPG fuel pressure sensor
32 Fuel changing switch 2 (Gasoline)
94
86
36 —
37 —
38 —

37
 Terminal Description

39 LPG injector drive hold signal

101 Stop lamp switch
109 (IGN) Ignition switch

Terminal Description

102 Neutral switch

100 —
45 —
46 —
47 Sensor power supply (Throttle position sensor)
49 Fuel changing switch power supply
85 (K LINE) K-line (C/U data transmit/receive)
52 TAS learning
84 Head lamp switch
54 Maximum speed regulation
55 —
56 —
57 —
67 Sensor ground
115 (-) C/U ground
116 (-) C/U ground
13 Crankshaft position sensor (POS)
63 —
91 Accelerator pedal position sensor 2 power supply
48 Sensor power supply
121 Power supply for ECM (Backup)
68 —
70 Fuel changing switch 1 (LPG)
14 Camshaft position sensor (PHASE)
51 Mass air flow sensor
50 Throttle position sensor 1
69 Throttle position sensor 2
106 Accelerator pedal position sensor 1
98 Accelerator pedal position sensor 2
77 —
78 Heated oxygen sensor ground
79 —
34 Intake air temperature sensor signal
83 Accelerator pedal position sensor 2 ground
87 —
88 —
89 —
35 Heated oxygen sensor
92 —

38
 Terminal Description

73 Engine coolant temperature sensor signal

95 —
23 No.1 cylinder injector drive
42 No.2 cylinder injector drive
22 No.3 cylinder injector drive
41 No.4 cylinder injector drive
105 —
107 —

Terminal Description

108 —
119 Power supply for C/U
110
120 Power supply for C/U
104 Throttle control motor relay
3 Throttle control motor relay power supply
5 Throttle control motor (Open)
4 Throttle control motor (Close)
1 C/U ground
10 —
20 —
21 —
26 —
33 Vehicle speed
40 —
43 —
44 LPG injector drive intake
53 —
58 —
59 —
60 —
64 —
65 —
66 Sensor ground (Throttle position sensor)
71 —
72 LPG injector check
74 —
75 —
76 —
82 Accelerator pedal position sensor 1 ground
90 Accelerator pedal position sensor 1 power supply
93 —
96 —
97 —

39
 Terminal Description

99
103 —
112 LPG interception valve relay
114 —
117 —
118 —

6.5.1 Hall IC (Element) Crankshaft Position Sensor (POS)

The Hall IC crankshaft position sensor consists of two
sensors: the crankshaft position sensor (POS) and the
camshaft position sensor (PHASE). These 2 sensors are
generically called the crankshaft position sensor.
The crankshaft position sensor (POS) detects the position
of the crankshaft and detects a signal by the crankshaft
pulley bushing installed on the tip of the crankshaft. The
camshaft position sensor (PHASE) detects the position of
the camshaft and detects a signal created by several pro-
trusions, that correspond with the cylinder number, pro-
vided on the front of the camshaft sprocket.

NOTE:
• Semiconductor element that detects a magnetic field
using the Hall effect is used in the Hall IC.
• Hall IC crankshaft position sensor applies the principle of this Hall effect. It can perform
highly precise ignition timing control, and also is not influenced by the magnetic field of a
magnetic type crankshaft position sensor.

Each sensor function and representative diagram are shown in the following table.

Description Function

Crankshaft position Detection of crankshaft Detects engine speed and standard

Crankshaft position sensor sensor (POS) position position of each cylinder using 2 sig-
(POS) or PHASE Camshaft position nals. (Starting point of injection and
Cylinder detection ignition timing).
sensor (PHASE)

40
• How to detect standard position of each cylinder
Calculates standard position of each cylinder from the PHASE signal and the POS
signal (110° BTDC)
• Ignition method (Ex. No. 1 cylinder)
Note the POS signal when the No. 1 cylinder is 110° BTDC as a standard, and then
note ignition point. Use this as the ignition advance value described by the ignition
timing control. Measure the timing when the POS signal is at 10° and 30°.

6.5.2 Electric Throttle Control Actuator (ETCA)

[Link] Description
The Electronic Throttle Control Actuator is equivalent to the throttle body of a conventional car-
buretor. It drives the throttle control motor by a control signal from the ECM, and it controls the
throttle position to match varied driving conditions.

41
[Link] System and Operation

• The accelerator unit consists of the throttle position sensor that detects the pedal position.
The electronic throttle control actuator consists of the throttle sensor, gear mechanism and
the drive for the throttle valve.

42
• The electronic throttle control actuator controls the idle speed and governor speed.
• The throttle valve should be mechanically returned to the position in which a low-speed run
is possible even if the throttle control motor, motor drive system, accelerator pedal position
sensor and throttle position sensor systems are malfunctioning.
• It is necessary to reset the throttle valve closed position after repairs if the electric throttle
control actuator or ECM connector is disconnected. It is also necessary to reset throttle
valve closed position and idle air volume if the actuator or ECM is replaced. See the EC
Section of the Service Manual for the proper procedures.
• It will be necessary to reset accelerator pedal released position after repairs if the accelera-
tor pedal assembly is replaced or the pedal position sensor is disconnected. The proper pro-
cedures for this are shown in the EC Section of the Service Manual.

1. Slow operation mode control

Throttle opening characteristics for slow operation
mode and for normal mode can be obtained using a
switch, for ease of adjustment.

6.6 Fuel Injection Control

6.6.1 Description
SOFIS control is being used for gasoline spec engines so that injected fuel volume is optimized
for improvement of exhaust performance and response. The gas injection system is being uti-
lized for proper control on LPG engines. For combined use applications, the system utilizes a
combination of both the gasoline and LPG systems.
6.6.2 Gasoline System and Operation
See Figure No. 6-0001 (17” x 11” fold-out) on page 31.

43
SOFIS System Components (Gasoline)

Input Signal Description

POS
• Detects the crankshaft position and sets the injec- Starting point
Hall IC (element) crank- tion timing of each injec-
shaft position sensor tor injection
PHASE • Detects the cylinder
timing

• Detects the intake air volume and sets the basic fuel injection require-
Mass air flow sensor
ments to the engine load

Intake air temperature sensor signal • Corrects fuel injection control by reading intake air temperature

Ignition switch • Outputs fuel injection control signal by the ignition signal input

• Corrects by increasing engine coolant temperature

Engine coolant temperature sensor signal
• Changes the fuel-cut area based on engine coolant temperature

• Detects O2 density in exhaust gas and the feedback-control theoretical

Heated oxygen sensor
air / fuel ratio

• Interrupts injection
Accelerator pedal position sensor • Corrects remaining fuel flow during acceleration / deceleration
(throttle position sensor) • Determines the idle (Soft idle switch)
• Cuts fuel during deceleration by the idle detection ON signal

• Controls various fuel cuts and recoveries

Vehicle speed signal
• Controls maximum speed regulation

PNP switch • Prohibits fuel cut by PNP switch signal

Battery voltage • Corrects injection pulse width by battery voltage

1. SOFIS (Sophisticated and Optimized Fuel Injection System) control - Gasoline Spec
The air / fuel ratio is changed substantially in the tran-
sient area (i.e. from constant speed to acceleration)
during normal driving conditions. In conventional con-
trols, the more the fuel injection is increased, the more
fuel is applied to the intake manifold or inner wall cylin-
der head intake port.
For this reason, the air / fuel ratio over-corrects to a
lean condition and then to a rich condition. This time
lag causes poor driveability and exhaust performance
until the air / fuel ratio stabilizes. The same condition
occurs when repeated acceleration and deceleration is
used during operations. SOFIS maintains the correct
air / fuel ratio by calculating (assuming) the remaining fuel injection volume on the inner wall
of the intake manifold and the air flow time lag measured by the mass air flow sensor. It
attempts to project the amount of air and fuel actually taken in to the combustion chamber
based on capacity and engine speed and accelerator pedal position. In this way SOFIS
works to minimize time lag and excessive fuel feed during acceleration.

44
6.6.3 LPG System and Operation
See Figure No. 6-0002 (17” x 11” fold-out) on page 33.
SOFIS System Components (LPG)

Input Signal Description

POS
• Detects the crankshaft position and sets the injec- Starting point
Hall IC (element) crank- tion timing of LPG injec-
shaft position sensor tor injection
PHASE • Detects the cylinder
timing

• Detects the intake air volume and sets the basic fuel injection require-
Mass air flow sensor
ments to the engine load

Intake air temperature sensor signal • Corrects fuel injection control by reading intake air temperature

Ignition switch • Outputs fuel injection control signal by the ignition signal input

• Corrects by increasing engine coolant temperature

Engine coolant temperature sensor signal
• Changes the fuel-cut area based on engine coolant temperature

• Detects O2 density in exhaust gas and the feedback-control theoretical

Heated oxygen sensor
air / fuel ratio

• Interrupts injection
Accelerator pedal position sensor • Corrects remaining fuel flow during acceleration / deceleration
(throttle position sensor) • Determines the idle (Soft idle switch)
• Cuts fuel during deceleration by the idle detection ON signal

• Controls various fuel cuts and recoveries

Vehicle speed signal
• Controls maximum speed regulation

PNP switch • Prohibits fuel cut by PNP switch signal

Battery voltage • Corrects injection pulse width by battery voltage

Fuel pressure sensor • Corrects fuel injection control by the fuel pressure

6.6.4 Basic Control

1. Gasoline Specification
a. Fuel Injection type
Simultaneous injection of all cylinders (1 for every 1 engine rotation simultaneously for
each cylinder performed when the No. 1 cylinder is detected at engine start and cranking
(approx. 2 engine rotations)). After that, sequential injection (1 for every 2 engine rota-
tions according to the ignition cylinder) is performed.
b. Injection at engine start
The amount of fuel injection at starting is determined based on conditions such as engine
coolant temperature so that engine starts smoothly.
c. Normal injection
The volume of normal fuel injection is determined by the SOFIS control so that the air /
fuel mixture is always correct.
d. Injection interruption during acceleration
Performs injection interruption during acceleration in addition to normal fuel injection
based upon the changing speed of the vehicle in order to improve acceleration perfor-
mance.

45
2. LPG specification
The LPG injection system variable control pattern is displayed as follows:

a. Fuel Injection type

The entire range of the injection pattern is
changed as shown in the figures above and at the
right. Injection pattern calculation sets the thresh-
old value of each area (i.e. a 1 injection change to
2 injections as appropriate).

Subtract the flow (securing value) determined by

SOL/V simple flow to the injection pulse width for
subtraction of F/INJ when assistant F/INJ is
turned ON (DUTY 100%).

b. Injection at engine start

The fuel volume injected at starting is determined
based upon conditions at the time, such as
engine coolant temperature. This is done to
enhance smooth starting.

c. Injection interruption during acceleration\

The system performs injection interruption during
acceleration as well as normal fuel injection var-
ied throttle positions to improve acceleration performance.

46
6.6.5 Air / Fuel Ratio Feedback Control
The change in the volume of repeated fuel injections is based upon the air / fuel ratio RICH/
LEAN signal detected by the heated oxygen sensor. Then the air / fuel ratio is controlled in a
narrow range near the ideal theoretical ratio such that the conversion rate for the 3-way cat-
alyst is very efficient.
The heated oxygen sensor works with a heater so that warm-up time for the sensor is
reduced improving the air / fuel ratio feedback function.
Air / fuel ratio feedback control is stopped, and the system reads basic injection characteris-
tics from the standpoint of driveability and safety of the 3-way catalyst. These air / fuel ratio
feedback functions are performed at idle after warm-up.
a. Air / fuel ratio feedback control shuts down under the following conditions:
- At engine start - With low engine coolant temperature - At engine load - During deceler-
ation (accelerator pedal not depressed) - Heated oxygen sensor malfunctioning.
RICH/LEAN signal changing cycle of heated oxygen sensor taking too long -
Electric throttle control actuator malfunctioning.
b. Air / fuel ratio feedback monitor display
Displays on data monitor of SST or MIL (Malfunction Indicator Light) in combination
meter.

6.6.6 Learning Function of Air / Fuel Ratio Correction

Air / fuel ratio correction with a learning function is utilized to improve the ability of the sys-
tem to provide correct air / fuel ratios during operation.
Air / fuel ratio correction and feedback control during normal driving occurs based upon the
signal from the heated oxygen sensor. The system determines the number and volume of
fuel injections to closely match the ideal theoretical ratio for best performance and pollution
control.
6.6.7 Fuel Cut-off Control
a. Fuel injection is stopped at deceleration to improve HC control and fuel consumption.
Fuel cut-off and recovery functions are performed at certain engine speeds and is finely
tuned by idle adjustment. These functions are based on input from vehicle speed and
gear change position and engine coolant temperature. This is done to minimize exhaust
emissions, maximize fuel economy and improve driveability.
b. Fuel cut-off during excessively high engine speed
This function acts as a fail-safe when the governor control is malfunctioning to protect the
engine and for other safety reasons.
c. Fuel cut-off at high rpm
Fuel injection will be interrupted on all cylinders when the engine speed reaches 3,450
rpm (K21) or 3,400 rpm (K25). When the engine rpm drops back down to about 3,150
rpm (k21) or 3,100 rpm (K25) or less, fuel injection will resume.
d. Fuel cut-off when engine is overheated
When the engine coolant temperature sensor output voltage is less than approximately
0.35 V (or above 0.06 V) for a certain period of time, the system determines that the
engine is overheating. The fuel cut-off is activated at approximately 1,000 rpm. The MIL
turns ON when overheating is detected.

47
 Once the system determines that the engine has overheated, the MIL illuminates if the
coolant temperature drops back to the normal operating range.
The fuel cut-off will be canceled once the ignition switch is turned OFF and MIL illumina-
tion turns OFF.
CAUTION - Erase self-diagnostic results after checking the cause of the overheating
condition.
e. Fuel cut-off during MIL system malfunction
If the MIL system is malfunctioning, it cannot provide any warnings for any other malfunc-
tions. In this case, fuel cut-off will automatically occur at about 1,500 rpm and a warning
is produced.
f. Fuel cut-off when throttle is locked in wide open position
Fuel cut-off will occur when the electronic throttle control actuator is locked in the open
position. Starting is still possible to enable self-running.
6.6.8 Ignition Timing Control
[Link] Description
Ignition Timing Control is an electronic distribution control system that maintains high redun-
dant voltage and provides stability in high speed ranges. Ignition timing is controlled by the
use of the Hall IC (element) crankshaft position sensor which provides highly precise ignition
timing based upon different driving conditions.
Use unleaded regular gasoline (89 octane - gas spec engines) or LPG (LPG spec engines).
[Link] System and Operation
See Figure No. 6-0001 (17” x 11” fold-out) on page 31. (Gasoline)

Input Signal Description

POS
• Detects the crankshaft position and sets the injec- Starting point
Hall IC (element) crank- tion timing of ignition tim-
shaft position sensor ing (110°
PHASE • Detects the cylinder
BTDC)

• Detects the intake air volume and sets the basic fuel injection require-
Mass air flow sensor
ments to the engine load

Intake coolant temperature sensor signal • Controls ignition timing according to engine coolant temperature

Ignition switch • Outputs fuel injection control signal by the ignition signal input

• Interrupts injection
Accelerator pedal position sensor • Corrects remaining fuel flow during acceleration / deceleration
(throttle position sensor) • Determines the idle (Soft idle switch)
• Cuts fuel during deceleration by the idle detection ON signal

• Controls various fuel cuts and recoveries

Vehicle speed signal
• Controls maximum speed regulation

PNP switch • Prohibits fuel cut by PNP switch signal

• Ignition timing is controlled based upon engine speed and engine coolant temperature at
engine start-up.
• This system controls ignition timing during various driving conditions using data input on
engine speed, coolant temperature, accelerator pedal position and throttle position. Control

48
 is exercised through engine speed and fuel injection pulse width after engine start-up.
• The system provides correct ignition timing at idle for a smoother idle.
• Control is also implemented by varying current application time to the ignition coil based
upon engine speed and battery voltage. Current application angle is regulated so as to pre-
vent excessive primary voltage under deceleration conditions, and then increasing current
applications during acceleration in order to prevent secondary voltage from dropping.
• This system “learns” idle air volume requirements even when idle speed or ignition timing is
outside the standard ranges.

6.6.9 Idle Speed Control

[Link] Description
This system controls the intake air volume through the electric throttle control actuator
based driving condition signals such as electrical load and engine temperatures.

[Link] System and Operation

See Figure No. 6-0001 (17” x 11” fold-out) on page 31. (Gasoline)

Input Signal Description

Hall IC (element) crank- POS • Calculates the engine speed using 2 signals, then the control rpm is
provided as feedback.
shaft position sensor PHASE

Engine coolant temperature sensor signal • Sets target rpm based upon engine coolant temperature

Accelerator pedal position sensor • Performs the idle speed control at idle
(throttle position sensor)

• Performs the idle speed control when the vehicle speed is 1.24 mph (2
Vehicle speed signal
km/h) or less (idle judgement ON)

PNP switch • Performs idle speed control except for the N position

• Corrects the battery voltage if it is under the setting value and helps the
Battery voltage
battery charge

a. Electric throttle control actuator control

See section on “Electric Throttle Control Actuator” in Section [Link].

b. Idle speed feedback control

Control target value is determined by the shift position. During idle judgement, provide
feedback of the control speed to the target value if it is outside the target value when the
PNP switch turns ON or during excessive vehicle speed.
The ECM “learns” from the various signal inputs to establish idle speed (base rpm)
adjustment.
Idle air volume learning is necessary even when the idle speed or ignition timing is out-
side the standard ranges. See the EC Section of the Service Manual for further informa-
tion and details.

49
 c. Target value for Idle Speed Feedback Control
The control target value (guideline) becomes the
value, as shown in the figure at right, based upon
engine coolant temperature.
d. Each correction Control
• Controls each target rpm if each load (power
steering, electrical and work load) is applied
• Controls the throttle position properly to ease
shock and to provide clean exhaust gases at
deceleration (with accelerator pedal open-to-
closed).

1. Governor speed control

Exerts control over the electric throttle control
actuator so it cannot exceed set rpm to protect
the oil pressure pump.

2. Idling Area Torque-up Control

The forklift operator can still perform cargo work without using the accelerator pedal.
The electric throttle control actuator will maintain adequate idle speed when loads are
applied while at idle.

6.6.10 Fuel Pump Control (Gasoline)

[Link] Description
Turns the fuel pump relay ON / OFF based on driving conditions.

50
[Link] System and Operation
Turns the fuel pump relay ON under the following con-
ditions:
• For about 1 second after ignition switch is
turned ON
• With engine running while crankshaft position
sensor signal is being received
• For about 1 second after engine stops

[Link] LPG Interception Valve Control

Turns the LPG engine side interception valve ON/OFF
based upon driving conditions.
Turns the fuel pump relay ON under the following conditions:
• Fuel switch is in the LPG position at the time of combined fuel use
• Ignition switch is ON
• While engine is running with signal input from the crankshaft position sensor
• Fuel pump relay turns OFF immediately when an unusual rise in fuel pressure is
detected by the fuel pressure sensor or when the control unit determines that an LPG
injector has malfunctioned.

6.6.11 Heated Oxygen Sensor Heater Control

[Link] Description
Reduces the heated oxygen sensor warm-up time in order to improve the air / fuel ratio feed-
back function.

[Link] Operation
• Controls electrical current application time to the heater based upon engine coolant
temperature
• Current application time ratio (duty ratio) to heater is increased at engine start-up and
when coolant temperature is low just after starting. The duty ratio is reduced over
time as the engine warms up.
• The heater turns OFF when the engine is stopped.

6.6.12 Fail-Safe Function

[Link] Description
When any of the critical sensors or systems send a malfunction message, the fail-safe func-
tion estimates the driving conditions with other input signals, and selects safer conditions for
the engine (vehicle) control. This is based on information “learned” and stored previously in
the ECM.

51
[Link] Malfunction Warning Function
When a malfunction is detected with self-diagnostic functions, the system enters the warning
mode and informs the operator by turning on the MIL on the instrument panel display.

[Link] Fail-Safe Items

The major fail-safe items are shown in the following Table:

Malfunction
Related sensors Fail-safe or Back-up condition MIL
condition

Mass air flow sensor • Selects fuel injection pulse width depending on MIL
the engine speed and throttle position so the lights
vehicle can be driven. Fuel cut-off will occur up
when engine speed exceeds approx. 2,400
rpm.
• Idle speed is 800 rpm.
Engine coolant temper- • Uses the estimated engine coolant temperature *
Same as self-
ature sensor (varies with elapsed time after starting) to per-
diagnosis detec-
tion conditions. form control so the vehicle can be driven.
(See next page)
Accelerator pedal posi- • Fuel injection will be inhibited when 1 circuit is *
tion sensor opened. Releases valve mechanically until it
can drive at low speeds when disconnecting the
connector.
Throttle position • Fixes output to a preset level so the vehicle can *
sensor be driven. Fuel cut-off will occur when engine
speed exceeds approx. 2,400 rpm.

6.6.13 Diagnostic System

[Link] Description
This system has been modified to incorporate a self-diagnostic system that features SST
compatibility for easier trouble diagnosis.

[Link] Self-Diagnosis
When any of the critical sensors or actuators and exhaust gas control systems necessary for
engine control return a malfunction signal, and self-diagnosis conditions are satisfied, a DTC
(Error Code) corresponding to the suspect system is stored in the ECM. Over time this will
aid greatly in diagnosing faults.
Whenever the Malfunction Indicator Light (MIL) lights up, it is a warning to the operator that
the self-diagnostic system has detected a malfunction or failure.
Self-diagnostic results can be displayed with the Service Support Tool (SST).

52
The following Table shows MIL display procedures:

Diagnosis test mode Mode change Display

1 Malfunction warning (at normal) Change mode by operation of the Turns the MIL ON during a
ignition switch and accelerator malfunction warning.
pedal.
2 Self-diagnosis (with ignition switch ON) See “Self-Diagnosis Function” in Detected by blinking the
the EC Section of the Service MIL
3 Heated oxygen sensor monitor (while
Manual for further details.
engine running)

53
[Link] Self-Diagnosis and Malfunction Detection Condition

DTC
Diagnosis
(Code Malfunction Return Condition MIL Trip
item
number)

No DTC • No malfunction detected in any circuits -- --

P0102 • When the engine is stopped (ignition switch ON) and the mass air
P0103 flow sensor output voltage has been 4.9 V or more for a predeter-
mined period
Mass air flow sensor
• When the engine is running and the mass air flow sensor output ON 1
(MAFS)
voltage has been 0.5 V or less for a predetermined period
• When the mass air flow sensor output voltage remains approxi-
mately 1 V for a predetermined time while the engine is running

P0117 Engine coolant tem- • Engine coolant temperature sensor output voltage has been about
P0118 perature sensor 4.8 V or more (open) or less than 0.06 V (short) for a predetermined ON 2
(ECTS) (CIRCUIT) period

P0122 • Throttle position sensor signal circuit is open or shorted

ON*
P0123 • A malfunction occurs in the system between sensors 1 and 2
Throttle position sen-
P0222 1
sor signal circuit • When the throttle valve closed position learning valve was unusually
P0223
small or was not learning --
P2135

P2122 • Accelerator pedal position sensor signal circuit is open or shorted

P2123 • A malfunction occurs in the system between accelerator pedal posi-
Accelerator sensor
P2127 tion sensors 1 and 2 -- 1
signal circuit
P2128
P2138

P0134 Heated oxygen • Heated oxygen sensor signal circuit is open

ON 2
sensor (circuit)

P0132 Heated oxygen • Heated oxygen sensor output voltage is higher than normal (2 V or
-- 2
sensor (short) more)

P0031 Heated oxygen • Heated oxygen sensor heater signal circuit is open
ON 2
sensor heater

P0131 Fuel injection • After warming up the engine, the mixture ratio is too lean and the
-- 2
system too LEAN heated oxygen sensor output is stuck and not inverted.

P0132 Fuel injection • After warming up the engine, the mixture rate is too rich and the
-- 2
system too RICH heater oxygen sensor output is stuck and not inverted.

P0335 • The crankshaft position sensor (POS) signal is not detected for a
predetermined time at engine start or during engine running (during
Crankshaft position
camshaft position sensor (PHASE) signal input)
sensor (POS) signal ON 2
• A crankshaft position sensor (POS) signal irregular wave form is
circuit
detected for a predetermined time during engine running (during
camshaft position sensor (PHASE) signal input)

P0340 • At start-up, no PHASE signal has been detected for more than a
predetermined period of time
Camshaft position
• The PHASE signal is not detected for a predetermined period during
sensor (PHASE) sig- ON 2
engine running (during PHASE signal input)
nal circuit
• A PHASE signal irregular waveform is detected for a predetermined
time during engine running (during POS signal input)

P0605 Engine Control Mod- • CPU system or circuits in ECM have a malfunction 1 or 2
ON*
ule (ECM) (NOTE)

54
 DTC
Diagnosis
(Code Malfunction Return Condition MIL Trip
item
number)

U1001 • Malfunction occurs in CAN communication transmit/receive data or

CAN communication in ECM, and data transmission/reception cannot be confirmed
-- 2
system • CAN communication data is not transmitted/received for a predeter-
mined period

P1065 ECM power supply • Power is not supplied to ECM for some time
ON 2
circuit

P1121 Electric throttle con- • Because of mechanical malfunction of the electric throttle control
-- 1
trol actuator actuator, the actuator does not operate normally

P1122 Electric throttle con- • When a malfunction occurs in the relationship between the target
-- 1
trol function throttle position and the actual position.

P1124 • When the throttle control motor relay has been locked ON or OFF
Throttle control motor ON = 1
P1126 --
relay circuit OFF = 2
P1128

P1217 • Coolant temperature sensor output voltage has been approx. 0.35 V
Engine overheating
P1218 or lower for a predetermined period of time (with the coolant temper- ON 1
condition
ature sensor normal)

P0350 • Ignition signal has not been continuously generated while the
Ignition signal ON 2
engine is running

P1240 LPG injector signal • LPG injector signal circuit is open or shorted ON 1

P1245 LPG fuel pressure • LPG fuel pressure signal circuit is open or shorted
-- 1
sensor signal

P1249 LPG vaporizer fuel • LPG fuel pressure is excessively high

-- 1
pressure

P1805 Brake switch • Brake switch signal circuit is open -- 2

* CAUTION NOTE - Some DTCs specified above may refer to a malfunction in the self-
diagnostic system, excluding the engine system, whenever the system detects certain
other malfunctions. Check the self-diagnosis function, excluding the engine, if this
should happen.

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

ignition switch is turned ON (engine running) and then turned OFF (this is
defined as a “Trip”), the MIL is lighted. 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 DTC is recorded. If the same malfunction is detected again by
self-diagnosis on the next Trip (second Trip), the MIL is lighted and the
corresponding final DTC is recorded.
Even when the first Trip DTC is being memorized, the MIL lights up to notify the
operator that there is a potential problem.

55
Self-Diagnostic Results Timing
• For failures noted during Trip 1, timing “0” is displayed immediately after detection of
a malfunction.
• For failures noted on Trip 2, when a malfunction is detected for the first time (Trip 1),
timing “1t” is displayed. When the malfunction is detected again (Trip 2), it is dis-
played as “0”. Accumulated counting is performed at the end of the warming-up oper-
ation.

Conditions to Turn OFF MIL

• The MIL, marked with a “*” (See previous Table), is turned OFF when the ignition
switch is turned ON (engine starts) again after the initial problem has been corrected.
• For other self-diagnostic items, self-diagnostic results will be erased by turning the
ignition switch to OFF and then back ON. Normal operation is then resumed.

6.6.14 SST Function (Service Support Tool)

[Link] Description
• This service support tool is based on the hand-held SST (Diagnostic Monitor) equipped with
a cartridge for the K and TB45 engines. With this arrangement, the “tool” can be used effec-
tively to diagnose these electronically controlled engines in communication with the ECM. In
addition, diagnostic results can be recorded and displayed, stored and/or sent to a printer or
computer with outside communication ability.

[Link] SST Function

The following SST functions can be executed by combining data reception and command
transmission via the communication line from the ECM.
Mode Description

• Reduces the preparation work necessary for inspection

• Displays input/output signal data related to the work
Work Support
• Allows setting the control target values for idle speed and ignition timing
• Allows “Idle air volume learning” to be performed
• Displays names of suspect circuits stored in ECM
• Erases DTCs recorded in memory by the active test
Self-Diagnostic Results
SELF-DIAGNOSIS DETECTION ITEM: See “ERROR CODE LIST” in
APPENDIX 4.
• Provides useful data and self-diagnosis results to help determine the main cause
of errors and malfunctions
Data Monitor
• Displays ECM input/output data in real time
• Records and stores data
• Can be used to determine the primary sources of malfunctions based on self-diag-
Active Test nosis results and data from DATA MONITOR
• Each actuator if activated after receiving a drive signal
Function Test • Main input/output signal OK/NG judgement can be performed

• “On-screen” touch button operation changes mode

• Refer to APPENDIX 3 for further information.

56
[Link] System Components
[Link].1 ECM
• A small ECM is being utilized for under-hood space savings.
• Shape of connector is AMP 121-pin, and it is located
in the rear left-hand area of the engine compartment.
• It is necessary to perform idle air volume learning
when replacing the ECM. Refer to the Service Manual,
EC Section for detailed learning procedures.

[Link] Crankshaft Position Sensor (POS)

• Hall IC (element) crankshaft position sensor (POS) is
used in this system. the POS detects crankshaft posi-
tion through the crankshaft pulley bushing installed at
the tip of the crankshaft. This data is used for the set-
up of ignition timing or injection timing. The harness
receptacle for the POS sensor is bright green.
• Engine speed is detected by 2 signals; the POS and
the camshaft position sensor (PHASE). These are
installed in the front cover.

57
[Link] Camshaft Position Sensor (PHASE)
• Hall IC (element) camshaft position sensor (PHASE) is
utilized in this system. The PHASE detects PHASE
pulse through protrusions (cylinder number) on the
front sprocket of the camshaft. See Figure 6-0008A.
• This is installed on the front chain housing.

Cylinder No. 1 No. 2 No. 3 No. 4

Pulse 1 2 3 4

[Link] Throttle Position Sensor

• Installed to the electric throttle control actuator.

[Link] Accelerator Pedal Position Sensor

• Accelerator pedal position sensors 1 and 2, and the
actuator, are integrated into the accelerator pedal
assembly.
• The pedal position sensor emits a signal, based on
pedal position, to the ECM. This signal data is used by
the ECM to determine proper throttle position(s) based
upon the current driving conditions.
• The ECM also uses this data to determine “soft idle”
settings.

58
• It will be necessary to perform accelerator pedal
released position “learning” after repairs if the pedal
assembly is replaced or the pedal position sensor has
been disconnected for any reason. Refer to the Ser-
vice Manual, EC Section for further information.

[Link] Electric Throttle Control Actuator (ETCA)

• The ETCA is integrated with the throttle control motor
that is driven by ECM signals.
• The throttle position sensor detects the closed position
of the throttle valve and sends that signal to the ECM.

59
[Link] Mass Air Flow Sensor (MAFS)
• A hot wire type mass air flow sensor is integrated with
the thermistor intake air sensor.
• The sensor case is plastic.
• The sensor emits a voltage signal based upon the
intake air volume.
• The intake air sensor also detects intake air tempera-
ture and uses that signal to control fuel injection.

[Link] Engine Coolant Temperature Sensor (ECTS)

• Thermistor type is utilized
• The ECTS is installed on the water outlet
• As the engine coolant temperature rises, the resis-
tance of the thermistor drops down which, in turn,
reduces the output voltage signal.

60
[Link] Heated Oxygen Sensor
• A waterproof “Zilconia” heated oxygen sensor, with it’s
own heater, is utilized.
• It is installed to the front exhaust tube.

[Link] Vehicle Speed Sensor

• The signal from the vehicle speed sensor is received
by the ECM via the CAN communication link from
VCM.

[Link] Ignition Coil

• This system utilizes an ignition coil with a power tran-
sistor installed directly to each spark plug.
• Firing order: 1 - 3 - 4 - 2

[Link] Spark Plug

• A small proprietary center-electrode plug is used with
a 2-step thermal capability which improves combus-
tion efficiency and reduces fuel smoke during start-up
and/or cold running conditions.
• Spark plug type is FR2A-D.

61
[Link] Injector
• A small top field type injector is utilized.

[Link] Fuel Pump, Fuel Filter and Pressure Regulator (Gasoline Specification)
A complete pump assembly consisting of a fuel gauge, fuel pump, fuel filter and pressure
regulator is used in this system.
• Fuel pump is a small, lightweight turbine type with a discharge rate of 19.8 - 30.4 gal-
lons/ hour (75 - 115 L/h @ 12 Volts).
• A plastic, cylinder-shaped fuel filter is utilized with a filtration area of 170 - 201 in.2
(1,100 - 1,300 cm2).
• The pressure regulator is set at 50.8 psi (0.35 MPa)(3.6 kgf/cm2 ).
• The fuel pump is located inside the gasoline fuel tank.

[Link] Relay
• The main engine control relay is shown at right.

62
6.6.15 LPG System Components
[Link] LPG Injector, Holder Assembly
• Includes a mechanical relief valve with an LPG injector, LPG assistance injector and fuel
pressure sensor.

a. LPG Injector
The injector is used for the actual injection of LPG
into the intake system.

b. LPG Assistance Injector

A single fuel injector may not be able to provide
adequate fuel output under severe high-speed and
heavy-load conditions. The LPG Assistance Injec-
tor helps the LPG Injector to maintain maximum
engine output when demand for fuel exceeds nor-
mal operating requirements.

c. Fuel Pressure Sensor

Sends a signal to control fuel injection at low fuel pressure (i.e. in low temperatures).

d. Mechanical Relief Valve

Operates when the fuel pressure is above the set pressure. It opens the fuel circuit,
sends fuel to the intake manifold and protects fuel piping by lowering the fuel pressure.

63
[Link] Vaporizer
a. Part Function (See Figure 6-0036)
• Decompression - Steps down the pressure from a high-pressure LPG tank to the
proper level used by the equipment of the lift truck.
• Fuel Carburetion - Carburetion gas is sent into the engine through a mixer or LPG
Injector.
• Pressure Control - Maintains a fixed pressure level in the fuel system.

b. Vaporizer on Electronically Controlled Lift Trucks

• Electronically controlled lift trucks have equipment considered only as a primary
decompression conventional vaporizer (primary decompression, secondary decom-
pression) with the adoption of a gas injection control system.

c. Vaporizer on Carbureted Lift Trucks

64
[Link] LPG Interception Valve
This portion of the fuel system is not any different from the H-engine series part.
The system that controls the LPG interception valve through the valve relay has been
adopted for use in the electronically controlled engines also.

[Link] LPG Interception Valve Relay

The relay works to control the LPG interception valve on electronically controlled engines.

65
[Link] LPG Injector Drive Unit
The injection volume of the LPG injector is controlled by the ECM based on the signal for the
air / fuel ratio control of the engine. There are 3 signal lines for the air / fuel ratio control: 1).
time of injection (Ti); 2). time of the suction pulse (Tip), and 3). time of the maintenance
pulse. The fuel control outputs to 2 lines (H, L) of the LPG injector from the LPG injector
drive unit based on the signal. There is a line for check signals the sends the output condi-
tion to the ECM.
Equipment with direct connections utilize waterproofed connectors. These securely fasten
using a levered side connector on the harness to the drive unit.
NOTE: PWM is an abbreviation for PULSE WIDTH MODULATION.

6.6.16 PCV Gas Recirculation Device

[Link] Description
A closed-type system is utilized. See Figure 6-0039.

66
[Link] System Diagram

67
[Link] PCV Valve
Installed in the rocker cover (valve cover) manifold side.
Fresh air is drawn into the crankshaft case from the rocker cover fan side for PCV passage
at low load. PCV gas is mixed with fresh air in the crankshaft case and is drawn, by vacuum,
into the intake manifold through the rocker cover and PCV valve.
PCV gas enters into the intake manifold from the fresh air inlet under high load.
[Link] Parts Construction

68
6.7 K-Engine Coolant System
6.7.1 Description of Coolant System
a. Description
• The K-engines use the same type of engine coolant temperature control as the H-
engines.
• The K-engine water pump impeller has been changed to provide about 15% more
coolant flow.
• The K-engines and H-engines use the same gasket arrangement.
• The fan is connected directly to the water pump and is driven by an engine drive belt.
• The water pump mounting position of the thermostat housing has been raised by
approximately 4.72 in. (120mm) which makes the fan mount higher on the K-engines.

6.7.2 System Diagram

69
6.7.3 Specifications

Item K21 K25

Fan outer diameter x num-

Cooling Fan ø 15¾” (400mm ) x 6
ber of blades

Water Pump Impeller ø 2.76” (70mm) x 8 (metal blade type)

Engine coolant tempera-

Inlet control type
Thermostat ture control type

Valve opening temperature 169.7° F (76.5° C)

6.7.4 Construction

70
6.8 Fuel System
6.8.1 Description
[Link] Electronically Controlled Gasoline Specification
• The K-engine system utilizes a fuel pump which draws from a fuel tank. The system is made
up of a fuel pump, fuel filter, pressure regulator and fuel gauge, and together they are called
a “Returnless Fuel Supply System”.

71
[Link] Engine Component Parts Location

[Link] Electronically Controlled LPG Specification

• This is an LPG gas injection system
• The LPG injector holder supports the injector, assistance injector, fuel pressure sensor and
relief valve as an assembly. This is on the electric throttle control actuator.

[Link] Electronically Controlled Combined Use Specification

• This system is a combination of the gasoline spec and the LPG spec parts.

72
 APPENDIX 1
Theory of Fuel Injection Pulse Width Indication
A1.

A1-1
A1.1 Basic Injection Pulse Width (Tp)
The pulse width is determined based upon inlet air volume and engine speed. This is
not affected by controlled pulse width correction .

Inlet Air Volume

= ------------------------------------- X Constant
Engine Speed

A1.2 Pulse Width Corrected by Voltage (Ts)

The rate of correction response is controlled by a voltage drop to the reference volt-
age of 14 V. This does not affect fuel injection directly. This function can be con-
firmed, using the service support tool.

= Corrected pulse width @ 14V + (14V - VB) X Constant

(VB = Battery Voltage)

A1-2
A1.3 Effective Injection Pulse Width (Te)
“Te” equals Ts minus Ti.

= Fundamental injection pulse width (Tp) X Air-to-fuel feedback correction factor X

Air / fuel ratio correction factor X Other correction factors X Fuel-cut-off factor

• Air-to-fuel feedback correction factor:For the purpose of maintaining an ideal the-

oretical air / fuel ratio under all driving conditions
• Air-to-fuel ratio correction factor (learned):For the purpose of maintaining a mem-
ory bank of the various correction factors used and reused during driving condition
changes. Keeping prior successful corrections i memory allows the system to
respond much more quickly to similar condition changes in the future.
• Other correction factors: Other correction functions work to provide increased
fuel supply at start-up, increased fuel supply when the engine coolant temperature
is low, under acceleration and heavy load conditions and other variable conditions
covered in this manual.
• Fuel-cut-off factor: Regular injection = 1; at fuel-cut-off = 0.

A1.4 Final Injection Width (Ti)

This term refers to the time duration of electrical current application to the injector
itself. This period is usually longer than that of the actual injection time of the fuel.

a. Simultaneous injection = Effective injection pulse width (Ta) + voltage corrected

pulse width (Ts)
b. Group injection and sequential injection = 2 X effective injection pulse width (Ta) +
voltage corrected pulse width (Ts).

A1-3
A1.5 Simultaneous Injection
After the engine starts up, fuel is injected to all cylinders at once based upon the initial
input of the 180° signal from the crankshaft position sensor. Following the initial injec-
tion, fuel is injected at each engine revolution.
Because these are 4-cycle engines, fuel is then properly injected to maintain proper
intake / combustion cycles based upon engine firing order.

A1-4
A1.6 Sequential Injection (After Engine Start-up)
Fuel is injected before the intake stroke for each cylinder. The injection sequence is
based upon the established firing order.

A1-5
 APPENDIX 3
Service Support Tool Exercise Program

1. The outline of the Service Support Tool (SST)

2. How to use the SST

• Confirm the ECM part for the vehicle when installed
• Confirm the part number of the ECM (ECU)
• Confirm the record of malfunctions on ECM
• If there is no record, Create a malfunction by removing the connector for the mass air
flow sensor. Malfunction (error) code No. P0102 will occur.
• Erase the self-diagnosis record results.
• Indicate data
• Display self-diagnosis results
• Storage data
• Display freeze-frame data
• Work support

A3-1
• Active Test

A3-2
 APPENDIX 4
Error Code List

No. Code No. Marking Figure Contents

1 P0031 02 HEATER B1 02 HEATER LOW INPUT (BROKEN WIRE)

2 P0032 02 HEATER B1 02 HEATER HIGH INPUT (SHORT)

3 P0102 MAF_SEN/CIRCUIT AIRFLOW METER LOW INPUT (BROKEN WIRE)

4 P0103 MAF_SEN/CIRCUIT AIRFLOW METER HIGH INPUT (SHORT)

5 P0117 WATER TEMPERATURE WATER TEMP SENSOR LOW INPUT (BROKEN WIRE)
SENSOR

6 P0118 WATER TEMPERATURE WATER TEMP SENSOR HIGH INPUT (SHORT)

SENSOR

7 P0122 THRTL POS SEN/CIRC TPS2 LOW INPUT FAILURE

8 P0123 THRTL POS SEN/CIRC TPS2 HIGH INPUT FAILURE

9 P0132 H02S1_(B1) FR 02/S ABNORMAL VOLTAGE (BANK 1)

10 P0134 H02S1_(B1) FR 02/S BROKEN WIRE (BANK 1)

11 P0222 THRTL POS SEN/CIRC 1 TPS1 LOW INPUT FAILURE

12 P0223 THRTL POS SEN/CIRC 1 TPS1 HIGH INPUT FAILURE

13 P0335 CKP /SEN/CIRCUIT CRANKSHAFT ANGLE POS SENSOR BROKEN WIRE

WHEN STARTING

14 P0335 CKP SEN/CIRCUIT CRANKSHAFT ANGLE POS SENSOR BROKEN WIRE

AFTER STARTING

15 P0335 CKP SEN/CIRCUIT CRANKSHAFT ANGLE POS SENSOR MOMENTARY

BROKEN WIRE - NOISE - TOOTH BROKEN

16 P0340 CMP SEN/CIRCUIT CAMSHAFT ANGLE PHASE SENSOR BROKEN WIRE

WHEN STARTING

17 P0340 CMP SEN/CIRCUIT CAMSHAFT ANGLE PHASE SENSOR BROKEN WIRE

AFTER STARTING

18 P0340 CMP SEN/CIRCUIT CAMSHAFT ANGLE PHASE SENSOR MOMENTARY

BROKEN WIRE - NOISY - TOOTH BROKEN

19 P0340 CMP SEN/CIRCUIT CRANKSHAFT POSITION SENSOR - DIAGNOSIS

MAGNETIC CRANKSHAFT PHASE SIGNAL

20 P0350 IGN SIGNAL - PRIMARY DIAGNOSIS IGNITION PRIMARY SIGNAL

21 P0500 VEH SPEED SEN/CIR- VEHICLE SPEED SENSOR OR SIGNAL NOT INPUT
CUIT DUE TO A CONDITION FOR A PREDETERMINED
TIME DURING DRIVING AFTER WARM-UP

22 P0605 ECM * SYNC MONITORING PART

A4-1
No. Code No. Marking Figure Contents

23 P0605 ECM * ALU FUNCTION DIAGNOSIS

24 P0605 ECM * MAKE QUESTIONS OF COMPUTING EXERCISE

25 P0605 ECM * FUNCTION FOR ACCOUNTS WITH COMPUTED

RESULTS

26 P0605 ECM * AD DIAGNOSIS

27 P0605 ECM * CPU FUNCTION DIAGNOSIS

28 P0605 ECM * TPS FOUR TIMES INPUT DIAGNOSIS

29 P0605 ECM * VAPO M-S MISMATCHING DIAGNOSIS

30 P0605 ECM * APO M-S MISMATCHING DIAGNOSIS

31 P0605 ECM * THROTTLE OPEN TARGET VALUE MISMATCHING

DIAGNOSIS

32 P0605 ECM * WATER TEMP SENSOR M-S MATCHING DIAGNO-

SIS

33 P0605 ECM * TQHOAP DEFICIENCY DIAGNOSIS

34 P0605 ECM * TTEPTD MISMATCHING DIAGNOSIS

35 P0605 ECM * TATE MISMATCHING DIAGNOSIS

36 P0605 ECM * TTEP MISMATCHING DIAGNOSIS

37 P0605 ECM * S/SOFF SYSTEM DIAGNOSIS

38 P0605 ECM * TASK EXECUTION CYCLE DIAGNOSIS (MAIN)

39 P0605 ECM * ROM FUNCTION DIAGNOSIS (MAIN)

40 P0605 ECM * RAM FUNCTION DIAGNOSIS (MAIN)

41 P0605 ECM * WTD FUNCTION DIAGNOSIS (MAIN)

42 P0605 ECM * TIMER / CLOCK FUNCTION DIAGNOSIS (MAIN)

43 P0605 ECM * EEP-ROM WRITING DIAGNOSIS (MAIN)

44 P0605 ECM * EEP-ROM READOUT DIAGNOSIS (MAIN)

45 P0605 ECM * ROM FUNCTION DIAGNOSIS (MAIN)

46 P0605 ECM * RAM FUNCTION DIAGNOSIS 2 (MAIN)

47 P0650 MIL * ENGINE CHECK LIGHT BROKEN WIRE

A4-2
No. Code No. Marking Figure Contents

48 P0650 MIL * ENGINE CHECK LIGHT WIRE (SHORT)

CAUTION - WHEN P0605 “CONTROL UNIT” WAS
INDICATED, CHANGE ECM ASSY.
WHEN P0650 “MIL” WAS INDICATED, AT TB45
ENGINE DIAGNOSIS, THIS CODE MEANS ALSO
VEHICLE SIDE FAILURE. PLEASE CHECK FUEL
LINES AND WIRING ON CHASSIS ALSO.

49 P1065 ECM BACK-UP CIRCUIT BACK-UP RAM SYSTEM DIAGNOSIS (MAIN)

50 P1121 ETC ACTR RETURN SPRING DIAGNOSIS

51 P1121 ETC ACTR DEFAULT MECHANISM DIAGNOSIS (SLIGHTLY

OPEN FIXED ANGLE)

52 P1121 ETC ACTR THROTTLE OPEN AND FIXED DIAGNOSIS

53 P1122 ETC FUNCTION / CIRCUIT THROTTLE F/B CONTROL MONITORING DIAGNOSIS

54 P1122 ETC FUNCTION / CIRCUIT THROTTLE SERVE ERROR DIAGNOSIS

55 P1122 ETC FUNCTION / CIRCUIT OVER CURRENT DIAGNOSIS

56 P1124 THROTTLE MOTOR THROTTLE MOTOR POWER SOURCE SHORT

POWER SOURCE

57 P1126 THROTTLE MOTOR THROTTLE MOTOR POWER SOURCE BREAK -

POWER SOURCE OPEN CIRCUIT

58 P1128 THROTTLE MOTOR THROTTLE MOTOR SHORT

59 P1217 ENG OVER TEMP OVERHEATING CONDITION

60 P1218 OVERHEAT STEP # 1 OVERHEAT STEP # 1

61 P1225 THROTTLE SENSOR - TPS FULLY CLOSE STUDY DATA DOWN

FULLY CLOSED STUDY

62 P1226 THROTTLE SENSOR - TPS FULLY CLOSE STUDY DATA UNUSUAL

FULLY CLOSE STUDY RENEWAL

63 P1229 THROTTLE / ACCELERA- AVCC WIRING SHORT

TOR S-POWER SOURCE

64 P1240 LPG_F/INJ1 MALFUNC- LPG_INJECTOR SIGNAL CIRCUIT IS OPEN

TION (INJECTION)

65 P1241 LPG_F/INJ MALFUNC- LPG_INJECTOR SIGNAL CIRCUIT IS OPEN

TION (NO INJECTION)

66 P1242 LPG_F/INJ MALFUNC- LPG_INJECTOR SIGNAL CIRCUIT IS OPEN

TION (INJECTION)

67 P1243 LPG_F/INJ MALFUNC- LPG_INJECTOR SIGNAL CIRCUIT IS OPEN

TION (INJECTION

A4-3
No. Code No. Marking Figure Contents

68 P1245 LPG FUEL PRESSURE LPG FUEL PRESSURE SENSOR HIGH, INPUT FAIL-
SENSOR HIGH, INPUT URE
MALFUNCTION

69 P1249 LPG FUEL PRESSURE LPG EXTRA HIGH FUEL PRESSURE DETECTED -
EXCESSIVELY HIGH, HIGH FUEL PRESSURE FAILURE
MALFUNCTION

70 P1805 BRAKE SW / CIRCUIT BRAKE SWITCH SIGNAL CIRCUIT IS OPEN OR

SHORTED

71 P1810 LIFT HEIGHT LOW LIFT HEIGHT LOW SWITCH OFF (HIGH POSITION
SWITCH SWITCH OFF ON) HOLD MALFUNCTION
HOLD MALFUNCTION

72 P1811 LIFT HEIGHT HIGH LIFT HEIGHT HIGH SWITCH OFF (LOW POSITION
SWITCH OFF HOLD MAL- ON) HOLD MALFUNCTION
FUNCTION

73 P2122 APP_SEN_1 / CIRC APS1 LOW INPUT MALFUNCTION

74 P2123 APP_SEN_1 / CIRC APS1 HIGH INPUT MALFUNCTION

75 P2127 APP_SEN_2 / CIRC APS2 LOW INPUT MALFUNCTION

76 P2128 APP_SEN_2 / CIRC APS2 HIGH INPUT MALFUNCTION

77 P2135 TP_SENSOR TPS1-2 MISMATCHING MALFUNCTION

78 P2138 APP_SENSOR APS1-2 MISMATCHING MALFUNCTION

79 U1001 CAN_COMM_CIRCUIT CAN NON-EMISSION RELATED COMMUNICATION

SYSTEM MALFUNCTION (BROKEN WIRE, CIRCUIT
MALFUNCTION)

A4-4
APPENDIX 5
Diagnostic Monitor Service Support Tool (SST)
for Fork Lift Truck Engines

1. Parts identification - Front View of SST

Legend

1 • Power Source Switch (Push & Push) 10 • Cartridge Slot

2 • Direction Keys (Moves cursor in direction of 11
• Diagnostic Communications Connector
arrow on the key)
3 • Yes Key - Affirm: Effect 12 • Measuring Connector CH1 (V/Ohm/Hz
• No Key - Deny: Stop mark)
4 13 • Measuring Connector COM (COM mark)
• C Key - Cancel. Back to previous scope
• COM is the common terminal of CH1 & CH2
5 14 • Measuring Connector CH2 (V mark)
• S Key - Special Action. Shift • Using CH1 & COM when measuring in CH1
• Using CH2 & COM when measuring in CH2
6 • Function Keys: F1, F2, F3, F4 15 • Power Source Connector: Center pole “+”
7 • Liquid Crystal Display (LCD) 16 • RS232 Connector
8 • Lead Effective Transistor Marking 17 • Optical Communications Port
9 • Power Source Monitor Light 18 • Wrist Strap Attachment Points

A5-1
2. Parts Identification - SST Key Pad

3. Parts Identification - Rear View

Legend

19 • Battery Cover 22 • Threaded Hole for Adhesion Plate

20 • Ejector 23 • Wrist Strap installing Thread (2)
21 • Threaded Hole for Tripod

A5-2
4. Parts Identification - Bottom View

Legend

24 • LCD Contrast Dial ----------

4. What does this SST do for you?

• You are able to diagnose/troubleshoot the electronically controlled engine system.
• You can more easily identify defective parts and wiring.
• The self-diagnostic function provides an error code (DTC) which is displayed on the
monitor screen.
• You can check the operation of actuators mounted on the engine.
• You can measure the electric current, voltage, resistance, frequency and temperature
using the measuring functions.
• You can measure data that changes periodically, and see the changes using the oscillo-
graph.
• You can keep and play back the control data which was measured by the ECM (ECU)
and is stored in the memory unit.
• You can send this data to a printer or personal computer using the outside communica-
tion functions.

5. Operation of the SST (Diagnostic Monitor)

• Take the monitor out of the case. Remove the battery cover on the back side by pressing
against the two latching tabs. Install 4 AA batteries in proper sequence as marked on the
unit. These batteries act as the back-up power source for the RAM.
• Insert the diagnostic cartridge into the cartridge slot, located on the opposite side of the
monitor from the battery compartment. The indent in the cartridge faces the outside of
the monitor. Gently press the cartridge into the slot until the eject lid closes fully.
• Connect the communication cable connector to the top of the monitor (See item # 11 in
Figure A5-0001).
• Connect the other end of the communication cable to the failure diagnosis connector on
the engine harness. CAUTION: BE SURE THE LIFT TRUCK IGNITION SWITCH IS
TURNED OFF BEFORE CONNECTING THE CABLE TO THE HARNESS.

A5-3
 • After connecting the SST communication cable to the truck harness, turn the ignition
switch ON. Then turn ON the SST power source by pushing the button once.
Depressing the power button again will turn the monitor OFF.

6. Diagnosis Procedures
• The first monitor display will be a Title display as shown in “First View” below.
• About two seconds after the Title display pops up, the second view will automatically
appear. This is the “Main Menu” display.

A5-4
If you choose item # 1 - “DIAGNOSTIC SOFTWARE EXECUTE”, it will “highlight” as shown
below.

1. DIAGNOSTIC SOFTWARE EXECUTE

Then press the “YES” key on the keypad.

The “DIAGNOSIS MENU” will appear on the screen as shown below.

7. To Review self-diagnostic data, press the “Down Arrow” key on the keypad in order to
highlight menu item # 2 - “SELF-DIAG RESULTS” as shown below.

2. SELF-DIAG RESULTS

A5-5
 Now depress the “YES” key. The following window display will appear on your screen:

Depress the “YES” key again and the “RESULTS OF DIAGNOSIS” display will appear
(Example shown below). If there are any failures or malfunctions, the appropriate error
code (DTC) will appear on screen.

Entries in the “Add/exp” column above, indicate the failed part. Entries under the “Time”
column indicate the same failure whenever it repeats. An entry after “DIAG CODE No. :”
will show the failure repeat number. Return to the Self-Diag Menu.
8. When there are no failures or malfunctions, you will see the following displays:

A5-6
9. To eliminate (erase) the memory in the “Self-Diagnostic Results” menu, select “Eliminate
the Memory of Self-Diagnostic” and press “YES”.
Once you do this, the monitor will automatically revert to the “Self-Diagnostic Results”
menu.
When you p[ress “NO”, memory elimination will stop and the stored results will remain in
memory.

NOTE: In most cases, the engine will not return automatically to normal operation unless
you eliminate the self-diagnostic memory data. There may be some cases when it will
return to normal, but not often.
CONTINUE LEARNING ABOUT THE “SST” WITH THE FOLLOWING 17” x 11”
FOLD-OUT DISPLAY STEP CHARTS IN APPENDIX 6.

A5-7
 K-SERIES ENGINE CONTROL

SECTION EC
CONTENTS
PRECAUTIONS .................................................. EC-3 CAMSHAFT POSITION SENSOR (PHASE)
General precautions for service operations .... EC-3 SYSTEM ............................................................ EC-58
PREPARATION .................................................. EC-4 Control Unit Input/Output Signal
Special Service Tools ..................................... EC-4 Specifications ................................................ EC-58 EC
DESCRIPTION .................................................... EC-5 Circuit Diagram ............................................. EC-58
Basic inspection ........................................... EC-10 Component Parts Inspection ........................ EC-58
Inspection of Idle Speed, Ignition Timing, and MASS AIR FLOW SENSOR SYSTEM ............. EC-59
Air-fuel Ratio ................................................. EC-11 Service tool Data Monitor Display ................ EC-59
Learning Throttle Full-close Position ............. EC-12 Control Unit Input/Output Signal
Accelerator Pedal Released Position Specifications ................................................ EC-59
Learning ....................................................... EC-13 Circuit Diagram ............................................. EC-59
Fuel pressure inspection .............................. EC-13 Component Parts Inspection ........................ EC-59
TROUBLE SHOOTING ..................................... EC-15 ENGINE COOLANT TEMPERATURE SENSOR
How to Proceed with Trouble Diagnosis ...... EC-15 SYSTEM ............................................................ EC-60
Diagnosis Chart by Symptom ....................... EC-19 Service tool Data Monitor Display ................ EC-60
Component Parts Location ........................... EC-25 Control Unit Input/Output Signal
Control Unit Component ............................... EC-28 Specifications ................................................ EC-60
Circuit Diagram ............................................. EC-30 Circuit Diagram ............................................. EC-60
Control Unit Terminal Layout ........................ EC-33 Component Parts Inspection ........................ EC-60
ECCS Input/Output Signal Specifications .... EC-36 HEATED OXYGEN SENSOR SYSTEM ........... EC-61
Service Tool ................................................. EC-42 Service tool Data Monitor Display ................ EC-61
Self-Diagnosis Function (Without Service tool) ECCS Input/Output Signal Specifications .... EC-61
...................................................................... EC-48 Circuit Diagram ............................................. EC-61
Service tool Reference Value in Data Monitor THROTTLE POSITION SENSOR SYSTEM ..... EC-62
...................................................................... EC-52 Service tool Data Monitor Display ................ EC-62
Fail-Safe Function ........................................ EC-55 Control Unit Input/Output Signal
POWER SUPPLY AND GROUND SYSTEM .... EC-56 Specifications ................................................ EC-62
Control Unit Input/Output Signal Circuit Diagram ............................................. EC-62
Specifications ................................................ EC-56 Component Parts Inspection ........................ EC-62
Circuit Diagram ............................................. EC-56 ACCELERATOR PEDAL POSITION SENSOR
Component Parts Inspection ......................... EC-56 SYSTEM ............................................................ EC-63
CRANKSHAFT POSITION SENSOR (POS) Service tool Data Monitor Display ................ EC-63
SYSTEM ............................................................ EC-57 ECCS Input/Output Signal Specifications .... EC-63
Control Unit Input/Output Signal Circuit Diagram ............................................. EC-63
Specifications ................................................ EC-57 Component Parts Inspection ........................ EC-64
Circuit Diagram ............................................. EC-57
Component Parts Inspection ........................ EC-57
INTAKE AIR TEMPERATURE SENSOR ......... EC-65 Component Parts Inspection......................... EC-78
Service tool Data Monitor Display ................ EC-65 LPG FUEL PRESSURE SENSOR SYSTEM..... EC-79
Control Unit Input/Output Signal Control Unit Input/Output Signal
Specifications ................................................ EC-65 Specifications ................................................ EC-79
Circuit Diagram ............................................ EC-65 Circuit Diagram ............................................. EC-79
Component Parts Inspection ........................ EC-65 THROTTLE CONTROL MOTOR SYSTEM ....... EC-80
PNP SWITCH SYSTEM .................................... EC-66 Control Unit Input/Output Signal
Service tool Data Monitor Display ................ EC-66 Specifications ................................................ EC-80
Control Unit Input/Output Signal Circuit Diagram ............................................ EC-80
Specifications ................................................ EC-66 Component Parts Inspection ........................ EC-80
Circuit Diagram ............................................ EC-66 HEATED OXYGEN SENSOR HEATER
Component Parts Inspection ........................ EC-66 SYSTEM ........................................................... EC-81
STOP LAMP SWITCH SYSTEM ...................... EC-67 Service Tool Data Monitor Display ............... EC-81
Service Tool Data Monitor Display ............... EC-67 Control Unit Input/Output Signal
Control Unit Input/Output Signal Specifications ................................................ EC-81
Specifications ................................................ EC-67 Circuit Diagram ............................................ EC-81
Circuit Diagram ............................................ EC-67 Component Parts Inspection ........................ EC-81
Component Parts Inspection ........................ EC-67 BLOWBY GAS RECIRCULATION DEVICE ..... EC-82
ELECTRIC LOAD SWITCH SYSTEM .............. EC-68 System Diagram ........................................... EC-82
Service Tool Data Monitor Display ............... EC-68 Component Parts Inspection......................... EC-82
Control Unit Input/Output Signal FUEL CUT FUNCTION...................................... EC-83
Specifications ................................................ EC-68 Inspection Procedure .................................... EC-83
Circuit Diagram ............................................ EC-68 REMOVAL AND INSTALLATION OF ECCS
VEHICLE SPEED SENSOR SYSTEM .............. EC-69 COMPONENTS ................................................ EC-84
Service tool Data Monitor Display ................. EC-69 Removal and Installation of ECCS ............... EC-84
Control Unit Input/Output Signal Removal and Installation of Crankshaft Position
Specifications ................................................ EC-69 Sensor (POS) ............................................... EC-84
Circuit Diagram ............................................ EC-69 Removal and Installation of Camshaft Position
IGNITION SYSTEM ........................................... EC-70 Sensor (PHASE) .......................................... EC-84
Service Tool Data Monitor Display ............... EC-70 Removal and Installation of Mass Air Flow
Control Unit Input/Output Signal Sensor .......................................................... EC-85
Specifications ................................................ EC-70 Removal and Installation of Engine Coolant
Circuit Diagram ............................................ EC-70 Temperature Sensor. ................................... EC-85
Component Parts Inspection ........................ EC-70 Removal and Installation of Heated Oxygen Sensor
FUEL INJECTOR SYSTEM .............................. EC-72 (with Heated Oxygen Sensor Heater) .......... EC-85
Service Tool Data Monitor Display ............... EC-72 Removal and Installation of Throttle Position Sensor
Control Unit Input/Output Signal (Electric Throttle Control Actuator Assembly) .. EC-86
Specifications ................................................ EC-72 Removal and Installation of Accelerator Pedal Position
Circuit Diagram ............................................ EC-72 Sensor (Accelerator Pedal Assembly) .............. EC-86
Component Parts Inspection ........................ EC-72 Removal and Installation of Intake Air Temperature
ENGINE WARNING LIGHT SYSTEM ............... EC-73 Sensor (with Mass Air Flow Sensor) ................ EC-86
Service Tool Data Monitor Display ............... EC-73 Removal and Installation of Ignition Coil (with Power
Control Unit Input/Output Signal Transistor) .......................................................... EC-86
Specifications ................................................ EC-73 Removal and Installation of Fuel Injector ......... EC-86
FUEL PUMP SYSTEM....................................... EC-73 Removal and Installation of Fuel Pump ............ EC-86
Service Tool Data Monitor Display................ EC-74 Removal and Installation of Throttle Control Motor
Control Unit Input/Output Signal Spec. ......... EC-74 (Electric Throttle Control Actuator Assembly) .. EC-86
Circuit Diagram ............................................. EC-74 Removal and Installation of LPG Injector
Component Parts Inspection......................... EC-74 Holder ................................................................ EC-86
LPG INJECTOR SYSTEM ................................ EC-75 Removal and Installation of LPG Injector Drive
Control Unit Input/Output Signal Unit ..................................................................... EC-87
Specifications ................................................ EC-75 SERVICE DATA ................................................ EC-88
Circuit Diagram ............................................ EC-77 Standard, Repair Limit ...................................... EC-88
Component Parts Inspection ........................ EC-77
LPG ASSIST INJECTOR SYSTEM .................. EC-78
Control Unit Input/Output Signal
Specifications ................................................ EC-78
Circuit Diagram ............................................ EC-78
 PRECAUTIONS

PRECAUTIONS (1)General precautions for service opera-

tions
• 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.

GIM0059

• Be careful not to damage connector terminals when connecting

and [Link] the terminals for bend or breakage
before connecting.

ECS0010

• Check the input/output signal of terminal before replacing

control unit. Make sure that it operates normally.
Refer to EC-36, "ECM Input/Output 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.

ECS0012

EC-3 K-Series Engines

 PREPARATION

PREPARATION (1)Service Tools

Description Application

EGI fuel pressure indicator For measuring fuel pressure

ST19590000

ECS0013

Heated oxygen sensor wrench Removing and installing heated oxygen sensor
KV10113700

ECS0014

Service tool For system inspection and diagnosis

ECMECM0

EC-4 K-Series Engines

 DESCRIPTION

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.
• Adopts Hall IC type crankshaft position sensor (POS) and
camshaft position sensor (PHASE).
Items Description

Electric throttle control actuator • Adopts electronic throttle control actuator with integrated throttle control motor to adjust
throttle valve opening optimally according to driving conditions or to improve safety and
operability by electronically controlled governor.
Fuel injection control • With SOFIS 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 • Performs maximum regulation of engine speed for oil pressure pump protection by engine
speed signal.
Maximum speed regulation control • 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 up control • 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.
• 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.
Soft 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 (gasoline) • Turns fuel pump relay ON/OFF depending on engine speed signal.
LPG interception valve control • Turns interception valve relay ON/OFF depending on engine speed signal and fuel
pressure sensor signal.
Fail-safe function • 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.
Diagnostic system • Adopts self-diagnosis system for easier trouble diagnosis.

EC-5 K-Series Engines

 DESCRIPTION
K-ENGINE ELECTRONIC CONTROLLED SYSTEM DIAGRAM
(GASOLINE)

EC-6 K-Series Engines

 DESCRIPTION
K-ENGINE ELECTRONIC CONTROLLED SYSTEM DIAGRAM
(LPG)

EC-7 K-Series Engines

 DESCRIPTION
K-ENGINE ELECTRONIC CONTROLLED SYSTEM DIAGRAM
(LPG AND GASOLINE)

EC-8 K-Series Engines

 SENSORS AND ACTUATORS CONTROL ITEMS
Main sensors and actuators related to the ECCM are listed below.c

Combined
Gasoline std std std std std std std std opt std std

Fuel

Fuel changing (Gasoline and LPG) Combined

LPG std std std — std std std std opt std std

Control Item Fuel injection

control

Maximum vehicle speed control

Maximum engine speed control
Ignition timing control
Fuel injection control

A/F feedback control

Fuel pump control

Idle speed control

Self-diagnosis
mode control
Fuel cut off

Fail-safe
⊕: Significant impact to control
♦: Impact to control

Soft
Crankshaft position sensor (POS, PHASE) ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ♦
Mass air flow sensor ⊕ ⊕ ♦ ⊕ ♦ ♦
Intake air temperature sensor ♦ ♦
Engine coolant temperature sensor ♦ ♦ ♦ ♦ ♦ ♦
Heated oxygen sensor ⊕ ♦ ♦
Vehicle speed sensor & unit ♦ ♦ ♦ ♦ ⊕ ♦
Throttle position sensor ♦ ♦ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦
Accelerator pedal position sensor ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
Ignition switch ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕
Sensors

Neutral switch ♦ ♦ ♦ ♦ ♦
Stop lamp switch ♦
Headlamp (electrical load) switch ♦

Soft mode switch (opt) ⊕

Battery voltage ♦ ♦ ♦ ♦ ♦
LPG fuel pressure sensor ♦ ⊕ ♦
LPG injector drive unit check signal ♦
Fuel changing switch ⊕ ⊕ ⊕ ⊕ ⊕

EC-9 K-Series Engines

 Combined
Gasoline std std std std std std std std opt std std

Fuel

Fuel changing (Gasoline and LPG) Combined

LPG std std std — std std std std opt std std

Control Item Fuel injection

control

Maximum vehicle speed control

Maximum engine speed control
Ignition timing control
Fuel injection control

A/F feedback control

Fuel pump control

Idle speed control

Self-diagnosis
mode control
Fuel cut off

Fail-safe
⊕: Significant impact to control
♦: Impact to control

Soft
Gasoline injector ⊕ ⊕ ⊕
Power transistor ⊕ ♦
Ignition
system Ignition coil ⊕
Throttle control motor relay ⊕ ⊕ ♦
Throttle control motor ⊕ ⊕ ♦ ♦
Gasoline fuel pump relay ⊕ ⊕
Gasoline fuel pump ⊕ ♦
Actuators

Ignition relay ⊕
ECCS & ignition relay ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕
LPG injector drive unit ⊕ ⊕ ⊕
LPG injector ⊕ ⊕ ⊕ ♦
LPG assistance injector ⊕ ⊕ ⊕ ♦
LPG interception valve relay ⊕ ⊕ ♦
LPG interception valve ⊕ ♦

(1)Inspection of Idle Speed, Ignition Timing,

and Air-fuel Ratio
STANDARD AT IDLE
Transaxle M/T A/T

Idle speed (neutral or N position) (rpm) 750±50 750±50

Ignition timing (°BTDC/rpm) 0±2/750 0±2/750
CO density (%) 0.1 or less
HC density (ppm) 50 or less

CAUTION:
Perform "Idle Air Volume Learning" (on page EC-12) 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.

EC-10 K-Series Engines

 • Make sure that engine is free of oil pressure pump loads and
any electrical loads. Perform the inspection with the shift lever in
the neutral or N position.
• Warm up engine and transaxle to the normal operating
temperature.

IDLE SPEED
When using special tool;
1. Connect service tool to the diagnosing connector.
2. Indicate "Engine speed" on the data indication menu to confirm
that the idle speed is in the range of 750 ±50 rpm.

CAUTION:
Perform "Idle Air Volume Learning" (on page EC-12) when idle
speed is outside the standard.
When special tool is not used;
1. Connect an induction type (current detection type) tachometer
to the primary wire of No.1 cylinder to check idle speed.
• The primary wire for the No.1 cylinder is looped and longer than
the wires for other cylinders. It is used for detecting idle speed
and ignition timing.
2. Make sure that idle speed is 750 ±50 rpm,

CAUTION:
Perform "Idle Air Volume Learning" (on page EC-12) when idle
speed is outside the standard.
IGNITION TIMING INSPECTION
1. Install a timing light to the primary wire for No.1 cylinder.
2. Make sure that ignition timing and idle speed are 0 ±2°BTDC/
750 rpm.

CAUTION:
Perform "Idle Air Volume Learning" (on page EC-12) when
ignition timing is outside the standard.

CO/HC 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 CO/HC density adjustment is necessary.
• Warm up engine to normal operating temperature. Confirm idle
speed and ignition timing are within the standards. Then, check
CO/HC density with a CO/HC measuring device.
• Check condition of air-fuel ratio feedback with the following
steps when measured values are outside the standard:

With Special tool

1. Indicate "O2 sensor monitor bank 1" on the data display
monitor.
2. Keep engine speed at approximately 2,000 rpm, and make sure
that "ON" and "OFF" are alternately displayed.

EC-11 K-Series Engines

 Without Special tool
1. Check it with heated oxygen sensor monitor mode. (Refer to
EC-49, 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:
• Although air-fuel ratio feedback control is activated during idle,
increase engine speed for thus inspection.

(2)Learning Throttle Full-close Position

DESCRIPTION
When electric throttle control actuator or ECCS C/U connector is
removed, it is necessary for ECCS 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 ECCS 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.
Idle 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.

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 the above, learning is complete.

CAUTION:
Throttle valve closed position learning cannot be performed
with Service tool.

OPERATION PROCEDURE FOR TAS LEARNING

1. Perform throttle valve closed position learning.
2. Fully warm up engine and transaxle. (Engine coolant
temperature: 70 - 99°C)
3. Set the selector lever to neutral or N position. Make sure that
the engine is free of electrical loads, such as air conditioner, oil
pressure pump, and other electrical components.
4. Execute the following contents while idling using service tool.

• Touch "YES" in "TAS learning history" of the data display menu.

CAUTION:
"TAS LEARN CLEAR (PLANT)" is the original setting on the
vehicle. Do not use it.

EC-12 K-Series Engines

 Throttle Valve Closed Position Learning and
Idle Air Volume Learning (Cont’d)
• 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.
• Confirm whether or not the learning has been completed by
checking the "TAS learning history" in data display menu.
Learning completed: finished
Learning not yet completed: finished

• Make sure that idle speed and ignition timing are within the
standard.
• Perform "TAS Learning" again if values are outside the
standard.

(3)Accelerator Pedal Released Position

Learning
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.

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).

(4)Fuel pressure inspection

FUEL PRESSURE RELEASE

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

EC-13 K-Series Engines

 Accelerator Pedal Released Position
Learning (Cont’d)
With Service tool:
1. Start engine.
2. Select "Fuel Pressure Release" in “Work support menu“, and
then press "OK".
3. Crank engine 2 or 3 times to consume the fuel in the fuel line
after it stalls.
4. Turn ignition switch OFF.

Without Special 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.

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 oper-
ating. Malfunctions may occur in fuel pressure value.
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: 0.35MPa (3.6 kgf/cm2)

• If the vehicle shows poor starting, check fuel pressure with fuel
pump operating for approximately 1 second after ignition switch
is turned ON, and during cranking.
For 1 second after ignition switch is turned ON and
during cranking: 0.35Mpa (3.6 kgf/cm2)

• 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 (with fuel pump)
• Poor fuel pump discharge

EC-14 K-Series Engines

 TROUBLE SHOOTING

TROUBLE SHOOTING (1)How to Proceed with Trouble Shooting

1. The most important point in performing trouble shooting of
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 sys-
tem) runs. Sensors transmit information on the running condi-
tion, which changes constantly, to C/U. It is important to
understand these cycles.
ECM0031

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 his/her concerns 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
ECM0032 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 actu-
ally been eliminated.
ECM0033
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 service tool or by checking the ECCS C/U signals. When
checking the ECCS C/U signals, connect a check adapter
(Special tool) to C/U in order to prevent misdiagnosis.
Special tool:
Check adapter V (EG1755 0000) (for SMJ 150-pin con-
nector)
Harness adapter (EG1755 0200) (150-pin → 121-pin
conversion adapter)

EC-15 K-Series Engines

 TROUBLE SHOOTING

How to Proceed with Trouble Shooting

(Cont’d)
5. Use the reference value of input/output data (guideline) in this
manual in order to judge the ECCM C/U 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.

ECM0034

TROUBLE SHOOTING FLOW CHART

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

ECM0035

EC-16 K-Series Engines

 TROUBLE SHOOTING

How to Proceed with Trouble Shooting

(Cont’d)
INTERVIEW DIAGNOSTIC SHEET
Description
• In order to clarify the malfunction symptom, it is important to ask
the customer and collect information about their concerns.
• Ask the customer about what symptoms are present under what
conditions. Use the information to clarify the symptom.
• Use the interview diagnosis sheet to be certain not to miss any
vital information.

ECM0036

EC-17 K-Series Engines

TROUBLE SHOOTING

How to Proceed with Trouble Shooting

(Cont’d)

ECM0037

EC-18 K-Series Engines

 TROUBLE SHOOTING

(2)Diagnosis Chart by Symptom

RELATIONSHIP BETWEEN MALFUNCTIONING SYMPTOMS
AND THE SENSOR CIRCUIT
The table below shows the possible symptoms caused by the
malfunction of each sensor circuit.

Poor starting

Check that symptoms are detected with self-diagnosis.

Impossible
to start
Engine

Other
Symptoms Poor idle Poor driving control

Check that symptoms are in fail-safe condition.

stall

Engine rpm does not increase smoothly.

During surge at constant speed driving

Inconsistent idle when engine is cold.

Engine over temperature (Overheat)

Inconsistent idle when warming up

Poor fuel consumption efficiency

During surge at acceleration
When engine is warming up
Fast idle is not effective Description/notable
No initial combustion

characteristics of the
When engine is cold

During deceleration
Under a heavy load
Poor power output
Poor acceleration
Initial combustion

symptom
High idle rpm
Low idle rpm

After-burn

At Driving
Knocking
Backfire

At Idle
Sensor malfunction
⊕: Highly possible
♦: Possible

Crankshaft position sensor OPEN ⊕ ⊕ ⊕ ⊕ ⊕ ♦ • An open circuit in either REF or

(POS, PHASE) POS signal makes it impossible
for the vehicle to start.
• Control signals for fuel system
and ignition system are not
output.
Momentarily ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ⊕ ♦ ♦ ♦ ♦ • The symptom depends on the
open duration of momentarily open
circuit and the operating
conditions. Slight shocks and
surges may be sensed during
driving, while engine stall may
be caused during idle.
Air flow meter Signal OPEN ♦ ♦ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • It will be in fail-safe condition,
and vehicle runs at an engine
speed of 1,600 rpm or less.

High output ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • The air-fuel ratio becomes rich.

Black smoke may accompany.
Poor connection of grounding
may be a possible cause.
Low output ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • The air-fuel ratio becomes lean.
Contaminated hot wire or
suction of air may be suspected.

Ground OPEN ⊕ ⊕ ⊕ ⊕ ⊕ ♦ • It will be over-rich.

Power OPEN ♦ ♦ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • It will be in fail-safe condition,

supply and vehicle runs at an engine
speed of 1,600 rpm or less.
Intake air temperature OPEN/ ♦
sensor SHORT

Engine coolant temperature OPEN/ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • will be in fail-safe condition, putting on

engine warning light, becoming to
sensor SHORT
overheat step #1 control. Normal
operation possible. This malfunction
tends to occur when engine is cold or
when the engine coolant temperature
is high.

Resistance ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • The engine coolant temperature

is large. is judged as low. This
malfunction tends to occur after
warming up.
Resistance ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • The engine coolant temperature
is small. is judged as high. This
malfunction tends to occur when
engine is cold.

Heated oxygen sensor OPEN/ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • It will be base air-fuel ratio.

SHORT

Vehicle speed sensor OPEN/ ♦ ♦ ♦ ♦ • Duration of fuel cut becomes

SHORT shorter or fuel may not be cut.

EC-19 K-Series Engines

 TROUBLE SHOOTING

Poor starting

Check that symptoms are detected with self-diagnosis.

Impossible
to start
Engine

Other
Symptoms Poor idle Poor driving control

Check that symptoms are in fail-safe condition.

stall

Engine rpm does not increase smoothly.

During surge at constant speed driving

Inconsistent idle when engine is cold.

Engine over temperature (Overheat)

Inconsistent idle when warming up

Poor fuel consumption efficiency

During surge at acceleration
When engine is warming up
Description/notable

Fast idle is not effective

No initial combustion

When engine is cold

characteristics of the

During deceleration
Under a heavy load
Poor power output
Poor acceleration
Initial combustion
symptom

High idle rpm

Low idle rpm

After-burn

At Driving
Knocking
Backfire

At Idle
Sensor malfunction
⊕: Highly possible
♦: Possible

Throttle position sensor OPEN/ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • Idle will be base rpm. No

SHORT addition for acceleration.
Output ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • Possible interruption by
fluctuation unnecessary fuel injection. Poor
ground or control unit
connection may be the cause.

Poor ♦ ♦ • Idling is judged as OFF during

adjustment idle. Turning ignition switch
repeatedly to ON and OFF will
set the system to normal.
Accelerator pedal position OPEN/ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
sensor SHORT

Output ♦ ♦ ♦ ♦ ♦ ♦ ♦
fluctuation

Ignition switch IGN OPEN ⊕ ⊕ ⊕ ⊕ ⊕ • Impossible to start without

outputs for fuel and ignition
systems.

Neutral SW OPEN ♦ ⊕ ♦ ⊕ ♦ ♦ ♦ • PNP switch is judged as OFF,

and the target cold engine
speed in N/P position is
lowered.
SHORT • PNP switch is judged as ON,
and fast idle is effective for cold
engine in positions other than N/
P position, making the creep
larger.
Stop lamp switch OPEN/
SHORT
Headlamp (electrical load) OPEN/ ♦ ♦
switch SHORT

Power supply for C/U OPEN ⊕ ⊕ ⊕ ⊕ ⊕ ♦ • Impossible to start without

outputs for fuel and ignition
systems.

Sensor ground (coolant OPEN/ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • The same as the open circuit in

temperature sensor, throttle SHORT the applicable sensor.
position sensor)
Control unit and connector Poor ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • A slightly raised connector often
connection, results in poor connection. Entry
water entry? of water causes engine stall,
and afterwards it is momentarily
impossible to restart engine. In
some cases, restarting is
possible after a short wait.
LPG fuel pressure sensor OPEN/ ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ • LPG valve OFF when Open.
SHORT Starting not possible.
LPG injector Check OPEN ♦
drive unit signal
line SHORT ♦
Fuel changing switch OPEN • Fuel changing cannot be done.

LPG pressure sensor OPEN ♦ ♦

EC-20 K-Series Engines

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

Poor starting

Check that symptoms are detected with self-diagnosis.

Impossible
to start
Engine

Other
Symptoms Poor idle Poor driving

Check that symptoms are in fail-safe condition.

stall

Engine rpm does not increase smoothly.

During surge at constant speed driving

Inconsistent idle when engine is cold.

Engine over temperature (Overheat)

Inconsistent idle when warming up

Poor fuel consumption efficiency

During surge at acceleration
When engine is warming up
Description/notable

Fast idle is not effective

No initial combustion

When engine is cold characteristics of the

During deceleration
Under a heavy load
Poor power output
Poor acceleration
Initial combustion

symptom

High idle rpm

Low idle rpm

After-burn

At Driving
Knocking
Backfire

At Idle
Actuator malfunction
⊕: Highly possible
♦: Possible

Gasoline injector Power OPEN ♦ ♦ ♦ ♦ ⊕ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • No fuel injection to cylinder with

supply open circuit, resulting in LEAN
circuit Momentarily ♦ ♦ ♦ ♦ output of heated oxygen
open sensors.
• Starting engine is impossible
Coil OPEN ♦ ♦ ♦ ♦ ⊕ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ when the circuits for all the
cylinders are open.
Momentarily ♦ ♦ ♦ ♦
open

Drive OPEN ♦ ♦ ♦ ♦ ♦ ⊕ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
circuit
(C/U Momentarily ⊕ ♦
side) open

SHORT ♦ ♦ ♦ ♦ ⊕ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • Continuous fuel injection to

cylinder with short circuit,
resulting in OVER-RICH and
misfiring.
• Starting engine is impossible
when the circuits for all the
cylinders are open.
Nozzle Foreign ♦ ♦ ♦ ♦ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • The cylinder with foreign
hole material material will keep injecting.
intrusion

Clogging ♦ ♦ ♦ ♦ ♦ ⊕ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • The symptom depends on

clogging status. The correction
factor of air-fuel ratio becomes
larger.

Ground OPEN ♦ ♦ ♦ ♦ ♦ • Shocks may be sensed and

circuit engine stall may be occur
(ECM) depending on the duration of the
operation conditions.

Momentarily ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
open

Ignition signal circuit OPEN ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • Slight shocks and surges may

be sensed depending on the
Momentarily ♦ ♦ ♦ duration of momentarily open
open circuit and the operating
conditions.

Ignition coil Power OPEN ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ •

supply
circuit Momentarily ♦ ♦ ♦ • Engine stall may occur if
open duration of momentarily open
circuit is too long.
Coil OPEN ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • Shocks may be sensed and
engine stall may be occur
depending on the duration of the
operation conditions.
Ground OPEN ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • Injects fuel toward spark plug without
burning on the cylinder with open circuit.
circuit
Momentarily ♦ ♦ ♦
open

ECCS & IGN relay circuit OPEN ⊕ ♦ ⊕ ⊕ ⊕ ⊕

EC-21 K-Series Engines

 TROUBLE SHOOTING

Poor starting

Check that symptoms are detected with self-diagnosis.

Impossible
to start
Engine

Other
Symptoms Poor idle Poor driving

Check that symptoms are in fail-safe condition.

stall

Engine rpm does not increase smoothly.

During surge at constant speed driving

Inconsistent idle when engine is cold.

Engine over temperature (Overheat)

Inconsistent idle when warming up

Poor fuel consumption efficiency

During surge at acceleration
When engine is warming up
Description/notable

Fast idle is not effective

No initial combustion

When engine is cold

characteristics of the

During deceleration
Under a heavy load
Poor power output
Poor acceleration
Initial combustion
symptom

High idle rpm

Low idle rpm

After-burn

At Driving
Knocking
Backfire

At Idle
Actuator malfunction
⊕: Highly possible
♦: Possible

Throttle control motor circuit OPEN/ ♦ ♦ ♦ ♦ ♦ ♦

SHORT

Throttle motor relay circuit OPEN ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • The same malfunction may

occur as power supply open of
throttle control motor and
throttle position sensor.

Heated oxygen sensor OPEN

heater circuit
• Fuel pump relay circuit OPEN ⊕ ⊕ ⊕ ⊕ ⊕ • Impossible to start
• Fuel pump circuit
• Ignition relay circuit Momentarily ♦ ♦ ♦ ♦ ♦ • Impossible to start
open

Fuel pump OPEN/ ♦ ♦ ♦ ♦

Pressure regulator SHORT

LPG injector Ti circuit OPEN ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ • When self-check is NG, LPG

drive unit interception valve is OFF.

SHORT ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ • Over-Rich engine stall. When self-

check is NG, LPG cutoff valve is
OFF.

Tip OPEN ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ • When self-check is NG, LPG

circuit interception valve is OFF.

SHORT ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ • Over-Rich engine stall. When self-

check is NG, LPG cutoff valve is
OFF.

PWM OPEN ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ • When self-check is NG, LPG

circuit interception valve is OFF.

SHORT ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ • Over-Rich engine stall. When self-

check is NG, LPG cutoff valve is
OFF.

Power OPEN ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ • When self-check is NG, LPG

supply interception valve is OFF.

Ground OPEN ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ • When self-check is NG, LPG

interception valve is OFF.

LPG injector HI side OPEN ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ • When self-check is NG, LPG

circuit interception valve is OFF.

SHORT ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ • When self-check is NG, LPG

interception valve is OFF.

Coil OPEN ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ • When self-check is NG, LPG

interception valve is OFF.

LO side OPEN ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ • When self-check is NG, LPG

circuit interception valve is OFF.

SHORT ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ • When self-check is NG, LPG

interception valve is OFF.

LPG assistance injector OPEN ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦

Control unit ♦ ♦ ♦ ♦ ♦
side short

LPG interception valve relay OPEN ⊕ ⊕ ⊕ ⊕ ⊕

Control unit
side short
LPG interception valve OPEN

Malfunction indicator lamp OPEN ♦ ♦

Improper TAS learning OPEN ♦ ♦ ♦ ♦ ♦ ♦ ♦

EC-22 K-Series Engines

 TROUBLE SHOOTING

RELATIONSHIP BETWEEN MALFUNCTIONING SYMPTOM AND

THE ENGINE MAIN BODY/AUXILIARY COMPONENT
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 starting
Impossible
to start
Engine

Other
Symptoms Poor idle Poor driving
stall

Engine rpm does not increase smoothly.

During surge at constant speed driving

Inconsistent idle when engine is cold.

Engine over temperature (Overheat)

Inconsistent idle when warming up

Poor fuel consumption efficiency

During surge at acceleration
When engine is warming up
Fast idle is not effective

Description/notable
No initial combustion

When engine is cold

During deceleration
Under a heavy load
Poor power output
Poor acceleration
characteristics of the symptom
Initial combustion

High idle rpm

Low idle rpm

After-burn

At Driving
Knocking
Backfire

At Idle
⊕: Highly possible
♦: Possible
∇: Not very possible
Air sucked from oil level gauge ♦ ∇ ♦ ♦ ∇ ∇ ∇ • Air-fuel ratio becomes LEAN.
• High air-fuel correction factor.
Air sucked from oil filler cap ♦ ∇ ♦ ♦ ∇ ∇ ∇ • Low suction power (vacuum pressure) of
intake manifold.
Air sucked from PCV hose ♦ ∇ ♦ ∇ ♦ ♦ ♦ ♦ ♦ ∇ ∇ ♦ ♦ ♦ ∇ * Check the suction using a negative
(downstream of PCV) pressure gauge.
* Generally applicable to air suction in air
Air sucked from intake manifold and ♦ ∇ ♦ ∇ ♦ ♦ ♦ ♦ ♦ ∇ ∇ ♦ ♦ ♦ ∇ intake system
gasket

PCV kept open ♦ ♦ ∇ ♦ ♦ ♦ ♦ ♦ • Noise (high hissing tone)

Clogged fuel strainer ♦ ∇ ♦ ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ∇ ♦ ♦ • Symptom depends on clogging status.

This tends to happen during high-speed
Clogged air cleaner element ♦ ♦ ♦ ♦ ♦ ♦ or high load operation.

Malfunctioning gasoline pressure ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • Symptom varies depending on

regulator combustion pressure.
Fuel mixture

Poor quality gasoline ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ∇ ♦ ♦ ♦ ♦ ∇ • Symptom varies depending on oil quality.

Improper LPG fuel (cold area and ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ∇ ♦ ♦ ♦ ♦ ∇ • Starting ability in cold area is changed
propane ratio) depending on propane ratio.
• Use LPG with proper propane ratio.
Malfunctioning LPG vaporizer ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • If the pressure is low, it is caused by poor
pressure adjusting valve output during high-speed or high load
operation.
• If the pressure is excessively high, relief
valve operates and engine stalls at rich.
Clogged LPG vaporizer hot water ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • Symptom depends on fuel temperature.
circuit This tends to happen during engine stall
and is impossible to restart during engine
warming up.
Clogged LPG interception valve ♦ ∇ ♦ ∇ ♦ ♦ ♦ ♦ ♦ ∇ ♦ ∇ • Symptom depends on clogging status.
filter This tends to happen during high-speed
or high load operation.
Valve deposit ♦ ♦ ♦ ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ∇ • Air-fuel ratio becomes LEAN. High air-
fuel correction factor.

EC-23 K-Series Engines

 TROUBLE SHOOTING

Poor starting
Impossible
to start
Engine

Other
Symptoms Poor idle Poor driving
stall

Engine rpm does not increase smoothly.

During surge at constant speed driving

Inconsistent idle when engine is cold.

Engine over temperature (Overheat)

Inconsistent idle when warming up

Poor fuel consumption efficiency

During surge at acceleration
When engine is warming up
Fast idle is not effective
Description/notable
No initial combustion

When engine is cold

During deceleration
Under a heavy load
Poor power output
Poor acceleration
characteristics of the symptom
Initial combustion

High idle rpm

Low idle rpm

After-burn

At Driving
Knocking
Backfire

At Idle
⊕: Highly possible
♦: Possible
∇: Not very possible
Improper connection of wire ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ ∇ • Check that wiring route is proper.
connector
Poor connection of wire connector ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • Check that connector is slightly raised.
Poor starting if slightly raised connectors
are in all cylinders.
Sparking

Improper ignition timing adjustment ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ —

Malfunctioning spark plug ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ∇ ∇ ∇ • Check that the gap is proper. Check

spark plug for electric wear, soil (fuel
injection, smoking), and damaged
insulator.

Leakage from high-pressure parts ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • Symptom varies depending on the level

of leakage.

Improper bulb contact ∇ ♦ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ ♦ ♦ ♦ • Symptom varies depending on contact

Compression

condition and the number of cylinders.

pressure

Worn piston ring ∇ ♦ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ ♦ ♦ • Symptom varies depending on degree of

wear and the number of cylinders.

Clogged three-way catalytic ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • In some cases, after engine stall,

converter /exhaust system restarting is possible.

Low idle base speed ∇ ∇ ∇ ∇ ♦ ♦ ♦ ♦ • Engine stall may occur by power steering
load and cargo load during deceleration
or at idling.

Dragging of brakes ♦ ♦ ♦ ♦ • Tires/wheels are hot.

Belt tension too high (excessive ♦ ♦ ♦ ♦ ♦ —

tension)

High A/C load ♦ ♦ ∇ ∇ ∇ ∇ ∇ ♦ ∇ ♦ ♦ ♦ • Too much refrigerant

Other

High A/T load ∇ ∇ ♦ ∇ ♦ • Insufficient ATF amount, improper oil

specification (This symptom may
especially occur in the cold.)
High HYD PUMP load (PS, Load) ∇ ∇ ∇ ♦ ♦ ∇ ∇ ∇ ♦ • Malfunctioning oil pressure relief valve,
improper oil specification (This symptom
may especially occur in the cold.)
Foreign material in fuel tank (such ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • With low fuel, this may easily occur.
as dust)

Damaged fan, malfunctioning water ♦ • Noise

pump

Clogged ejecter/condenser ♦ —

Also check the following items other than the above:

• Check harness tension.
• Check each connector connection.
• Check ground wire for looseness.
• Check battery connection for looseness or corrosion.
• Check water and oil condition.
• Check fan belts for looseness.

EC-24 K-Series Engines

 TROUBLE SHOOTING

(3)Component Parts Location

Specifications
Main component part Type Location
Gasoline LPG Dual-Fuel

Actuators Gasoline injector High resistance Intake manifold √ √

LPG injector Gas injection Integrated in injector √ √
holder (on intake
manifold)
Fuel pump Electric motor/turbine Integrated in fuel tank √ √
Fuel pressure regulator Diaphragm √ √
Throttle control motor Electric DC motor (DC Integrated in electronic √ √ √
motor) throttle control actuator
Ignition coil Mold (built-in power Cylinder head (On each √ √ √
transistor) spark plug)

EC-25 K-Series Engines

 TROUBLE SHOOTING

Component Parts Location (Cont’d)

Specifications
Main component part Type Location
Gasoline LPG Combined

Sensors Crankshaft Crankshaft Hall IC (element) Front cover √ √ √

position position sensor
sensor (POS)
Camshaft position Chain housing √ √ √
sensor (PHASE)
Mass air flow sensor Hot wire Air horn √ √ √
Accelerator pedal position Variable resistance Integrated in accelerator √ √ √
sensors 1 and 2 work unit (accelerator
pedal assembly)
Throttle position sensors 1 and 2 Integrated in electronic √ √ √
throttle control actuator
Engine coolant temperature Thermistor Water outlet √ √ √
sensor
Intake air temperature sensor With air flow meter √ √ √
Heated oxygen sensor Zirconia (with heater) Front tube √ √ √
Vehicle speed sensor Electromagnetic power Vehicle side √ √ √
generation
ECCS C/U 121-pin digital control Vehicle side √ √ √
ECCS & IGN coil relay Compact general relay Vehicle side √ √ √
(1M X 2)

(4)ECCS Component
Specifications NOTE
Component Location
Gasoline LPG Combined Actuator Sensor Other

Gasoline injector Intake manifold √ √ √

LPG injector Integrated in injector holder (on √ √ √
intake manifold)
Throttle control motor Integrated in electronic throttle √ √ √ √
control actuator
Throttle position sensors 1 and 2 √ √ √ √
Ignition coil Cylinder head (on each spark plug) √ √ √ √
Crankshaft position sensor (POS) Front cover √ √ √ √
Camshaft position sensor (PHASE) Front housing √ √ √ √
Mass air flow sensor Air horn √ √ √ √
Intake air temperature sensor With air flow meter √ √ √ √
Engine coolant temperature sensor Water outlet √ √ √ √
Accelerator pedal position sensors Integrated in accelerator work unit √ √ √ √
1 and 2 (accelerator pedal assembly)
Fuel pump Integrated in fuel tank √ √ √
Fuel pressure regulator √ √ √
Heated oxygen sensor (Vehicle side) √ √ √ √
Vehicle speed sensor (Vehicle side) √ √ √ √
ECCS C/U (Vehicle side) √ √ √
ECCS & IGN coil relay (Vehicle side) √ √ √

Stop lamp switch (Vehicle side) √ √ √ √

Throttle control motor relay (Vehicle side) √ √ √ √
Fuel pump relay (Vehicle side) √ √
Vaporizer (Vehicle side) √ √ √

EC-26 K-Series Engines

 TROUBLE SHOOTING

Specifications NOTE
Component Location
Gasoline LPG Combined Actuator Sensor Other

LPG interception valve (Vehicle side) √ √ √

EC-27 K-Series Engines

 ECCS Component (Cont’d)

EC-28 K-Series Engines

 ECCS Component (Cont’d)

ECM0040

EC-29 K-Series Engines

 (5)Circuit Diagram
K-ENGINE ELECTRONIC CONTROLLED ECM CIRCUIT DIA-
GRAM (GASOLINE)

ECM0041

EC-30 K-Series Engines

 Circuit Diagram (Cont’d)
K-ENGINE ELECTRONIC CONTROLLED ECM CIRCUIT DIA-
GRAM (LPG)

ECM0042

EC-31 K-Series Engines

 Circuit Diagram (Cont’d)
K-ENGINE ELECTRONIC CONTROLLED ECCS CIRCUIT DIA-
GRAM (DUAL-FUEL)

ECM0043

EC-32 K-Series Engines

 (6)Control Unit Terminal Layout

ECM0044

The symbol in ( ) next to terminal numbers indicates the DDL2

connector.
Terminal Description

24 Heated oxygen sensor heater

2 —
6 —
7 —
8 LPG injector
9 —
113 Fuel pump relay
11 LPG assistance injector
12 Soft mode
15 —
16 —
17 —
18 —
19 —
111 ECCS & IGN coil relay
62 No.1 cylinder ignition signal (power transistor drive signal)
81 No.1 cylinder ignition signal (power transistor drive signal)
61 No.3 cylinder ignition signal (power transistor drive signal)
80 No.4 cylinder ignition signal (power transistor drive signal)
25 —
27 ----
28 —
29 —
30 Warning light
31 LPG fuel pressure sensor
32 Fuel changing switch 2 (Gasoline)
94
86
36 —
37 —
38 —
39 LPG injector drive hold signal
101 Stop lamp switch
109 (IGN) Ignition switch

EC-33 K-Series Engines

 ECCS Terminal Layout (Cont’d)
Terminal Description

102 Neutral switch

100 —
45 —
46 —
47 Sensor power supply (Throttle position sensor)
49 Fuel changing switch power supply
85 (K LINE) K-line (C/U data transmit/receive)
52 TAS learning
84 Headlamp switch
54 Maximum speed regulation
55 —
56 —
57 —
67 Sensor ground
115 (-) C/U ground
116 (-) C/U ground
13 Crankshaft position sensor (POS)
63 —
91 Accelerator pedal position sensor 2 power supply
48 Sensor power supply
121 Power supply for ECM (Backup)
68 —
70 Fuel changing switch 1 (LPG)
14 Camshaft position sensor (PHASE)
51 Mass air flow sensor
50 Throttle position sensor 1
69 Throttle position sensor 2
106 Accelerator pedal position sensor 1
98 Accelerator pedal position sensor 2
77 —
78 Heated oxygen sensor ground
79 —
34 Intake air temperature sensor signal
83 Accelerator pedal position sensor 2 ground
87 —
88 —
89 —
35 Heated oxygen sensor
92 —
73 Engine coolant temperature sensor signal
95 —
23 No.1 cylinder injector drive
42 No.2 cylinder injector drive
22 No.3 cylinder injector drive
41 No.4 cylinder injector drive
105 —
107 —

EC-34 K-Series Engines

 ECCS Terminal Layout (Cont’d)
Terminal Description

108 —
119 Power supply for C/U
110
120 Power supply for C/U
104 Throttle control motor relay
3 Throttle control motor relay power supply
5 Throttle control motor (Open)
4 Throttle control motor (Close)
1 C/U ground
10 —
20 —
21 —
26 —
33 Vehicle speed
40 —
43 —
44 LPG injector drive intake
53 —
58 —
59 —
60 —
64 —
65 —
66 Sensor ground (Throttle position sensor)
71 —
72 LPG injector check
74 —
75 —
76 —
82 Accelerator pedal position sensor 1 ground
90 Accelerator pedal position sensor 1 power supply
93 —
96 —
97 —
99
103 —
112 LPG interception valve relay
114 —
117 —
118 —

EC-35 K-Series Engines

 (7)ECCS Control Unit Input/Output Signal
Reference Specifications
REFERENCE VALUE LIST
• Voltage is measured with a circuit tester, and the sample
waveforms obtained with an oscilloscope are shown below for
each C/U 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 instrument/method,
etc. Data shown below are reference values.

ECMECM

Terminal
Signal name Measurement condition Measured value
signal

24 Heated oxygen sensor heater At idle after warming up Approx. 0.3V

113 Fuel pump relay For approximately 1 second after ignition Approx. 1V
switch ON
After that Battery voltage
At cranking, engine running Approx. 1V
111 ECCS & IGN coil relay For approximately 10 seconds with Approx. 1V
ignition switch ON and after ignition
switch OFF
Ignition switch OFF Battery voltage

EC-36 K-Series Engines

 ECCS C/U Input/Output Signal Reference
Specifications (Cont’d)
Terminal
Signal name Measurement condition Measured value
signal

61 Ignition signal (power transistor drive At cranking Approx. 0.2V

62 signal)
80
81

ECM0047

At idle after warming up Approx. 0.1V

ECM0048

At approx. 2,000 rpm Approx. 0.1V

ECM0049

101 Stop lamp switch Brake pedal released Approx. 0V

Brake pedal depressed Battery voltage
109 (IGN) Ignition switch Ignition switch OFF Approx. 0V
Ignition switch ON Battery voltage
102 Neutral switch Neutral, or N position Approx. 0V
Other than above Battery voltage (A/T models)
Approx. 4.8V (M/T models)

EC-37 K-Series Engines

 ECCS C/U Input/Output Signal Reference
Specifications (Cont’d)
Terminal
Signal name Measurement condition Measured value
signal

85 (K LINE) K-line (C/U data transmit/receive) When connected to SST Approx. 6.6 - Battery voltage
When not connected to SST Approx. 6V
84 Headlamp switch Lighting switch OFF Approx. 0V
Lighting switch ON Battery voltage
67 Sensor ground Always Approx. 0V
115 C/U ground Always Approx. 0V
116
1
13 Crankshaft position sensor (POS) At cranking Approx. 2.6V

ECS0052

At idle after warming up Approx. 3V

ECM0053

At approx. 2,000 rpm Approx. 3V

ECM0054

91 Accelerator pedal position sensor 2 Ignition switch ON, engine running Approx. 2.5V
power supply
48 Sensor power supply Ignition switch ON, engine running Approx. 5V
121 Power supply for ECM (Backup) Always Battery voltage
47 Electric throttle control actuator power Ignition switch ON, engine running Approx. 5V
supply
78 Heated oxygen sensor ground Always Approx. 0V
82 Accelerator pedal position sensor 1 Always Approx. 0V
ground
90 Accelerator pedal position sensor 1 Ignition switch ON, engine running Approx. 5V
power supply

EC-38 K-Series Engines

 ECCS C/U Input/Output Signal Reference
Specifications (Cont’d)
Terminal
Signal name Measurement condition Measured value
signal

14 Camshaft position sensor (PHASE) At cranking Approx. 0.15V

ECM0055

At idle after warming up Fluctuates between approx. 1.5 - 2V.

ECM0056

At approx. 2,000 rpm Approx. 2V

ECM0057

51 Mass air flow sensor Ignition switch ON Approx. 1V

At cranking Approx. 1.5V
At idle after warming up Approx. 1.8 - 2.0V
At approx. 2,000 rpm Approx. 2.2 - 2.5V
50 Throttle position sensor 1 At idle after warming up Approx. 0.6V
Ignition switch ON with engine stopped Approx. 0.75V
Accelerator pedal is released
Ignition switch ON with engine stopped Approx. 0.75V
Accelerator pedal is fully depressed
At approx. 2,000 rpm Approx. 0.7V
69 Throttle position sensor 2 At idle after warming up Approx. 4.5V
Ignition switch ON with engine stopped Approx. 4.35V
Accelerator pedal is released
Ignition switch ON with engine stopped Approx. 4.35V
Accelerator pedal is fully depressed
At approx. 2,000 rpm Approx. 4.4V
106 Accelerator pedal position sensor 1 At Idle Approx. 0.6V
Ignition switch ON with engine stopped Approx. 0.6V
Accelerator pedal is fully depressed
Ignition switch ON with engine stopped Approx. 4.2V
Accelerator pedal is released
At approx. 2,000 rpm Approx. 0.65V

EC-39 K-Series Engines

 ECCS C/U Input/Output Signal Reference
Specifications (Cont’d)
Terminal
Signal name Measurement condition Measured value
signal

98 Accelerator pedal position sensor 2 At Idle Approx. 0.3V

Ignition switch ON with engine stopped Approx. 0.3V
Accelerator pedal is released
Ignition switch ON with engine stopped Approx. 2V
Accelerator pedal is fully depressed
At approx. 2,000 rpm Approx. 0.35V
34 Intake air temperature sensor signal Intake air temperature is approx. 20°C. Approx. 3.5V
Intake air temperature is approx. 80°C. Approx. 1.2V
83 Accelerator pedal position sensor 2 Always Approx. 0V
ground
35 Heated oxygen sensor At idle after warming up Changes between approx. 0.1 -
0.4V⇔;approx. 0.6 - 0.9V

ECM0058

At approx. 2,000 rpm Changes between approx. 1 -

0.4V⇔;approx. 0.6 - 0.9V

ECM0059

73 Engine coolant temperature sensor Engine coolant temperature is approx. Approx. 3.5V
signal 20°C.
Engine coolant temperature is approx. Approx. 1.2V
80°C.

EC-40 K-Series Engines

 TROUBLE SHOOTING

ECCS C/U Input/Output Signal Reference

Specifications (Cont’d)
Terminal
Signal name Measurement condition Measured value
signal

22 Injector drive signal At cranking Approx. 10.5V

23
41
42

ECM0060

At idle after warming up Battery voltage

ECM0061

At approx. 2,000 rpm Relatively lower than battery voltage

ECM0062

119 Power supply for C/U Ignition switch ON, engine running Battery voltage
120
104 Throttle control motor relay Ignition switch ON, engine running Approx. 1V
3 Throttle control motor relay power supply Always Battery voltage
5 Throttle control motor (Open) At idle after warming up Approx. 0.1 - 0.15V
At approx. 2,000 rpm
4 Throttle control motor (Close) At idle after warming up Approx. 2 - 2.5V
At approx. 2,000 rpm
11 LPG assistance injector Other than above (Ignition switch ON, Battery voltage
engine running)
32 Fuel changing switch 2 (Gasoline) Changing switch ON (At gasoline side) Approx. 5V
Changing switch ON (At LPG side or Approx. 0V
neutral)
49 Fuel changing switch power supply Changing switch ON Approx. 5V
Changing switch ON (At neutral) Approx. 0V
70 Fuel changing switch 1 (LPG) Changing switch ON (At LPG side) Approx. 5V
Changing switch ON (At Gas side or Approx. 0V
neutral)
112 LPG interception valve relay For approximately 10 seconds with Battery voltage
ignition switch ON and after ignition
switch OFF
Ignition switch OFF Approx. 0V

Numerical values are obtained using an analog circuit tester.

EC-41 K-Series Engines

 (8)Service Tool
DESCRIPTION
Service tool executes the following functions using the combination
of ECCS C/U data reception, instructions, and transmission from the
ECM via the communication line.
Diagnosis test mode Description

WORK SUPPORT • Reduces the preparation work necessary for inspecting.

• Displays input/output signal data related to the work.
• Allows setting control target values of idle speed or ignition timing.
• Allows performing "TAS Learning".
SELF-DIAGNOSTIC RESULTS • Displays names of suspect circuits stored in ECM.
• Erases DTCs recorded in memory.
DATA INDICATION • Provides useful data along with self-diagnosis results to determine the main cause.
• Displays input/output 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.

ECU PART NUMBER • Possible to display part numbers recorded on C/U.

OPERATION PROCEDURE
1. Turn ignition switch OFF.
2. Connect Service tool to diagnosing connector.
3. Turn on the Key switch.
4. Turn on the power of service tool.
5. Select “[Link] of Machine Trouble Diagnoses “ on “Main
menu“. And, press “YES“.
Refer to "Service tool Operation Manual" for further information.

WORK SUPPORT
Service tool assists with idle adjustment work. With Service tool, it
sends an operation command to ECCS C/U, 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 Learns the minimum idle air flow amount required for idle speed control when predetermined conditions
are specified following replacement of electric throttle control actuator and ECCS C/U.
AIR--FUEL RATIO LEARNING Clears air-fuel ratio feedback control correction coefficient.
TARGET IDLE TIM ADJ (*) Allows control target value for initial ignition timing (-10 to 0°).
Note: Inspectors must use timing light to make sure that ignition timing and actual timing are the same.
TARGET IDLE RPM ADJ (*) Sets a control target value for the idle speed (0 to 250 rpm).

*: This function is not necessary in the usual service procedure.

When it is necessary to change target value of idling speed or
ignition timing due to rough idling and others.

EC-42 K-Series Engines

 Service Tool (Cont’d)
SELF-DIAGNOSTIC RESULTS
When a malfunction occurs in ECCS C/U signal circuit, the
malfunctioning circuit is recorded and displayed. Also, the
malfunction item that is occurred is displayed.

Display sample [Example: When there is a malfunction in mass air

flow sensor]
Error code and error item are displayed on the alarm monitor
screen..

Display Item List

ENGINE
Code
Diagnosis item Malfunction Return Condition Warning Trip
No.
lamp

0000 No signal • No malfunction is detected in any of the circuits. — —

0102 Air flow sensor • When engine is stopped (ignition switch ON) and mass air On 1
0103 flow sensor output voltage has been 4.9V or more for
predetermined period.
• When engine is running and mass air flow sensor output
voltage has been 0.5V or less for predetermined period.
• When air flow meter output voltage remains
approximately 1V for a predetermined time while engine is
running.

0117 Engine coolant temperature • Engine coolant temperature sensor output voltage has On 2
0118 sensor been approximately 4.8V or more (open) or less than
0.06V (short) for predetermined period
0122 Throttle position sensor signal • Sensor power supply voltage has a malfunction. On* 1
0123 circuit • Throttle position sensor signal circuit is open or shorted.
0222 • A malfunction occurs in relation between throttle position
0223 sensors 1 and 2.
1225 • When the fully-closed position learning value was — 2
1226 unusually small or was not learning.
1229
2135
2122 Acceleration sensor signal circuit • Accelerator pedal position sensor signal circuit is open or On 1
2123 shorted.
2127 • A malfunction occurs in relation between accelerator
2128 pedal position sensors 1 and 2.
2138
0134 Oxygen sensor heater signal • Heated oxygen sensor signal circuit is open during travel On 2
circuit (open) after warm-up.
0132 Oxygen sensor heater signal • Oxygen sensor output voltage is higher than normal (2V On 2
circuit (short) or more). During travel after warm-up.
0031 Oxygen sensor heater signal • Oxygen sensor heater circuit is open On 2
0032 circuit
0335 POS sensor signal circuit • The crankshaft position sensor (POS) signal is not On 2
detected for a predetermined time at the engine start or
during engine running (during camshaft position sensor
(PHASE) signal input).
• A crankshaft position sensor (POS) signal irregular
waveform is detected for a predetermined time during
engine running (during camshaft position sensor (PHASE)
signal input).

EC-43 K-Series Engines

 Service Tool (Cont’d)
ENGINE
Code
Diagnosis item Malfunction Return Condition Warning Trip
No.
lamp

0340 PHASE sensor signal circuit • At start-up, no camshaft position sensor (PHASE) signal On 2
has been detected for more than a predetermined period.
• The camshaft position sensor (PHASE) signal is not
detected for a predetermined time during engine running
(during crankshaft position sensor (POS) signal input).
• A camshaft position sensor (PHASE) signal irregular
waveform is detected for a predetermined time during
engine running (during crankshaft position sensor (POS)
signal input).
0500 Vehicle speed signal circuit • During travel after warm-up, speed signal is not input On 2
more than specified time under specific conditions.
0605 ECCS C/U • Trouble in CPU circuits in ECCS C/U On 1 or 2
(Note)
1065 ECCS C/U (Power Source) • Power is not supplied to ECCS C/U for some time. On 2
circuit
1121 Electric throttle control actuator • Because of mechanical malfunction of electric throttle On* 1
control actuator, electric throttle control actuator does not
operate normally.
1122 Electric throttle control • When a malfunction occurred due to the correlation On* 1
(feedback) between the target throttle position and the actual throttle
position.
• Over current flows into throttle motor control circuit.
1124 Electric throttle control (motor • Throttle motor power source circuit is open or short. On* 1
1126 relay)
1128
1217 Overheat • Coolant temperature sensor output voltage has been On 1
approximately 0.35V or lower for a predetermined period
of time. (With the coolant temperature sensor normal)
0350 Ignition signal circuit • Ignition signal has not been continuously generated while On 2
the engine is running.
1805 Stop lamp switch signal circuit • Stop lamp switch has been continuously generated while On 1
the engine is running.
1218 Overhead step 1 • Coolant temperature sensor output voltage has been — 1
approximately 0.6V or lowers for a predetermined period
of time.
1240 LPG injector signal circuit • Abnormal current is applied on LPG injector On 1
1241
1245 LPG fuel pressure sensor circuit • LPG fuel pressure circuit is open On 1
(Open)
1249 LPG fuel pressure sensor circuit • LPG fuel pressure circuit is short. On 1
(Short) • Abnormally high pressure has been continued in VARO-
to-LPG injector line for a specified time period.

Note: Trip number differs according to the diagnosis number.

CAUTION:
Some items specified above may detect a malfunction related
in vehicle side self-diagnosis when the above detects some
malfunction. Therefor, carry out inspections except the engine
at this time.

EC-44 K-Series Engines

 Service tool (Cont’d)
Trip 1: If a malfunction is detected by self-diagnosis between the
time from the ignition switch is turned ON until it is turned OFF (this
is defined as "trip"), the 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 data code is to be remembered. If the
same malfunction is detected again by self-diagnosis in the next trip
(second trip), warning light is lit and the corresponding final data
record must be recorded.

Conditions to turn off 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, turning ignition switch to OFF
after normal operation is resumed shall erase self-diagnostic
results..

DATA MONITOR
• Allows determination and identification of the possible source of
a malfunction based on self-diagnosis test results.
• Displays ECCS C/U input/output signal data in real time.
• Records the data before and after engine stalls, falters or
refuses to start intentionally.

EC-45 K-Series Engines

 Service Tool (Cont’d)
Display Item List
Monitor item Unit Description

Engine speed rpm Engine speed computed from crankshaft angle sensor signal
Air flow meter bank 1 V Mass air flow sensor output voltage
Air-fuel ratio % Average of cycles for air-fuel ratio feedback correction coefficient
compensation bank 1
LPG Air-fuel ratio
compensation bank 1
Coolant temperature °C Value converted into temperature from the output voltage of the engine coolant temperature
sensor sensor.
O2 sensor bank 1 V Output voltage of heated oxygen sensor
O2 sensor Lean/Rich Air-fuel ratio is given as heated oxygen sensor output signal during air-fuel ratio feedback control.
monitor bank 1 Rich: Heated oxygen sensor output is high. Controlling to lower the value for leaner ratio.
Lean: Heated oxygen sensor output is low. Controlling to raise the value for richer ratio.
Battery voltage V Power source voltage for ECCS C/U
ETC acceleration V Value converted from the output voltage of accelerator pedal position sensor into acceleration
sensor 1 position.
ETC acceleration
sensor 2
ETC throttle sensor 1 V Value converted from the output voltage of throttle position sensor into throttle position.
ETC throttle sensor 2
Intake air temperature °C Value converted from the output power supply of intake air temperature sensor into intake air
sensor temperature.
Stater signal ON/OFF ON/OFF status as judged by each input signal
Idle SW
A/C signal
Neutral SW
Electric load signal
Fuel change SW1
Fuel change SW2
Ignition SW
Brake SW
Injection pulse width ms The value computed by ECCS C/U
bank 1
LPG fuel injection width
Ignition timing BTDC
Fuel pump relay ON/OFF Regulated status computed by ECCS C/U.
Throttle relay
LPG cutoff valve relay
Oxygen sensor heater
bank 1
TAS learning history Finished/ State of TAS learning.
Not finished
Machine speed sensor Km/h Value computed by machine speed signal.
Precise machine speed Km/h Precise valve computed by machine speed signal.
sensor
Speed limit value Km/h Value computed by ECCS C/U based upon speed limit input signal.
Oxygen sensor heater % Duty ratio of oxygen sensor heater
Real time DTC - Trouble code displayed in real time
Basic injection amount mS Value computed by ECCS C/U based upon air flow meter signal and engine speed

EC-46 K-Series Engines

 Monitor item Unit Description

LPG basic injection mS Value computed by ECCS C/U based upon air flow meter signal and engine speed
amount
Air conditioner relay ON/OFF Control status computed by ECCS C/U
Filling efficiency % Value converted to filling efficiency from aero-meter output voltage.
LPG filling efficiency
Fuel type 0/1/2 Position of fuel change switch
0: Gas 1: LPG 2: NEUT
LPG fuel pressure kPa Pressure converted from output voltage of LPG fuel pressure sensor.
sensor

EC-47 K-Series Engines

 Service tool (Cont’d)
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. Special tool, instead of the ECCS C/U on the
vehicle, sends a drive signal to actuators to check their operation.

Display Item List

Active test item Description

Fuel injection amount • Can increase or decrease the amount of fuel injection ( ±25%).
• Can reproduce conditions resulting from air-fuel ratio related malfunctions (e.g. hesitation, poor acceleration,
poor racing, etc.) and can help solve these malfunctions by pinpointing the causes.
Ignition timing • Allows setting a correction coefficient for retarding (-10 - 0°)
Power balance • Stops operation of specified injector. Also, displays the condition at that time.
• Mainly used to inspect for misfiring cylinders.
LPG fuel injection amount • Can increase or decrease the amount of fuel injection ( ±25%).
• Can reproduce conditions resulting from air-fuel ratio related malfunctions (e.g. hesitation, poor acceleration,
poor racing, etc.) and can help solve these malfunctions by pinpointing the causes.

Self-Diagnosis Function (Without Service

Tool)
DESCRIPTION
• In self-diagnosis, when any of the critical sensors or actuator
and exhaust gas control systems necessary for ECCS C/U
control returns a malfunction as well as self-diagnosis detection
conditions are satisfied, the suspect system is stored in the C/U
for easier trouble diagnosis. Self-diagnostic results can be
displayed on either service tool or the engine warning light of
the (combination) meter. The indication on the engine warning
light is explained in this section.
• The trouble shooting mode has two types: mode 1 and mode 2.
Mode 1 is normal mode and mode 2 is self-diagnosis or heated
oxygen sensor monitor function.

OPERATION PROCEDURE
• Refer to the following descriptions for how to activate self-
diagnosis mode or erase oxygen sensor monitor and self-
diagnostic results.

CAUTION:
When a malfunction occurs in accelerator pedal position
sensors, self-diagnosis (without using service tool) cannot be
activated. Thus, use service tool to perform self-diagnosis, and
repair malfunctioning part.

EC-48 K-Series Engines

 Self-Diagnosis Function (Without Service
Tool) (Cont’d)

ECM0078

DIAGNOSTIC TEST MODE 1 - BULB CHECK

• It should be turned on when the ignition switch is turned ON
(engine stopped), and turned off after the engine starts.

DIAGNOSTIC TEST MODE 1 - MALFUNCTION WARNING

• When a malfunction is detected by self-diagnosis, the system
goes into the malfunction warning mode and warns the driver by
blinking the engine warning light in the (combination) meter.
• There are two types of warning indications: items for which
warning is given by the warning light for the first trip and those
for which warning is given by the light for the second trip. For
the latter, the warning light will not light up for the first trip.

DIAGNOSTIC TEST MODE II - SELF-DIAGNOSTIC RESULTS

• In this mode, the light blinks (indicating the data number) to
identify the system that returned a malfunction.
• If no malfunction is detected, the code "0000" is displayed.

EC-49 K-Series Engines

 Self-diagnosis function (without Service
Tool) (Cont’d)
DIAGNOSTIC TEST MODE II - HEATED OXYGEN SENSOR
MONITOR
• In this mode, status of air-fuel ratio is displayed by blinking
of engine warning light.
• Make sure that engine warning light blinks at least 5 times
within 10 seconds after warming up engine and keeping
engine speed at approximately 2,000 rpm.
NOTE:
• Although air-fuel ratio feedback control is active at idle,
increase engine speed and check.
• During air-fuel ratio feedback control
ECM0080 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: Status of
immediately before clamping is maintained.

TROUBLE WARNING LIGHT

• If trouble is detected in self-diagnosis mode, it becomes
trouble-warning mode. In this mode, the engine warning
light (MIL) in the combination meter lights up (turns ON) to
infirm the operator of a problem.
• There are two types of displays: Trouble items being
turned ON for Trip 1 and items being turned ON for Trip 2.
The trouble items are turned on in either trip mode (Not in
both modes).

MALFUNCTION INDICATOR LIGHT (MIL) - BLINKING

• In this mode, the MIL blinks (indicating the DTC or Error
Code) to identify the system that returned a malfunction.
• If no DTC is detected, DTC (Error Code) “0000” is
displayed.

EC-50 K-Series Engines

 DISPLAY ITEM LIST

DTC
(code Diagnosis item Malfunction Return Condition MIL Trip
number)
0000 No trouble • No malfunction is detected in any of the circuits. - -
0102 Air flow sensor signal circuit • When engine is stopped (ignition switch ON) and mass air ON 1
0103 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.
0117 Coolant temperature sensor • Engine coolant temperature sensor output voltage has been ON 2
0118 signal circuit approximately 4.8V or more (open) or less than 0.04V
(short) for predetermined period.
0122 1225 Throttle position sensor signal • Sensor power supply voltage has a malfunction. ON* 1
0123 1226 circuit • Throttle position sensor signal circuit is open or shorted.
0222 1229 • A malfunction occurs in relation between throttle position
0223 2135 sensors 1 and 2.
• When the fully-closed position learning value was unusually - 2
small or was not able to learn.
2122 2138 Acceleration sensor signal • Accelerator pedal position sensor signal circuit is open or ON* 1
2123 2128 circuit shorted.
2127 • A malfunction occurs in relation between accelerator pedal
position sensors 1 and 2.
0134 Heated oxygen sensor (open • When traveling after warming up the engine, oxygen sensor ON 2
circuit) signal circuit is open.
0132 Heated oxygen sensor signal • When traveling after warming up the engine, oxygen sensor ON 2
(short circuit) output voltage is higher than normal (2V or more).
0031 Heated oxygen sensor heater
• Oxygen sensor signal circuit is open.
ON 2
0032 signal circuit
0335 Crankshaft position sensor 120 • The crankshaft position sensor (POS) signal is not detected ON 2
deg. (REF) signal circuit for a predetermined time at the engine start or during engine
running (when inputting (REF) signal).
• The crankshaft position sensor (POS) signal irregular
waveform is detected for a predetermined time during
engine running (when inputting (REF) signal).
0340 Camshaft position sensor • At start-up no (REF) signal has been detected for more than ON 2
1 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).
0500 Vehicle speed signal circuit • Vehicle sensor signal has not been input under specific ON 2
conditions for a predetermined time during driving after
warming up.
0605 ECCS C/U • CPU or circuits in ECCS have a malfunction. ON* 1 or 2
1065 ECCS C/U power supply circuit • When no power supplied to the ECCS C/U for more than ON 2
specified period.
1121 Electric throttle control, actuator • When electronic controlled throttle has malfunctions due to ON* 1
circuit the mechanical trouble in the throttle system.
1122 Electric throttle control, • Correlation between the target throttle opening angle and ON* 1
feedback circuit the actual opening angle has become abnormal.
• Excessive current in throttle motor control circuit.
1124 Electric throttle control, motor ON* 1
1126 relay circuit • Open or short in the throttle motor power supply circuit.
1128

EC-51 K-Series Engines

 DTC
(code Diagnosis item Malfunction Return Condition MIL Trip
number)
1217 Engine overheat • Normal status of coolant temperature circuit (Output voltage ON 1
of approx. 0.35V for more than specified period.)
0350 Ignition signal circuit • No continuous ignition signal while the engine is running. ON 2
1805 Stop lamp switch signal circuit • Stop lamp switch kept off more than specified time during ON 1
traveling.
1218 Engine overheat step #1 • Output voltage of coolant temperature sensor has been - 1
more than approx. 0.6V for specified time.
1240 1242 LPG injector signal circuit
• Abnormal current applied on the LPG injector.
ON 1
1241 1243
1245 LPG fuel pressure sensor
• LPG fuel pressure sensor circuit: OPEN
ON 1
signal, open-circuit
1249 LPG fuel pressure sensor • Short in the LPG fuel pressure sensor circuit. ON 1
signal, short-circuit • Pressure in fuel piping to the LPG injector has been raised
abnormally for the specified period.

(10)Service Tool Reference Value in Data

Monitor
• Values in the table are reference values.
• Values in the table are values detected in ECCS C/U or input/
output values sent from ECCS C/U. 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 C/U
using input signal from various sensors. They are crankshaft
position sensor (POS) and other ignition timing related
sensors.]
Monitor item Measurement condition Reference value

Engine speed • Tachometer: Connected Almost in accordance

• Start engine, and compare with the value displayed by tachometer.
Air flow meter bank 1 • After engine warming up At idle Approx. 1.8 - 2.0V
• A/C SW: OFF
At approx. 2,000 rpm Approx. 2.2 - 2.5V
• Selector lever: neutral or N
• No load
Air-fuel rate • After warming up engine At idle Approx. 90 - 110%
compensation bank 1
LPG Air-fuel rate
compensation bank 1
Coolant temperature • After warming up engine Approx. 80°C or above
sensor
Oxygen sensor bank 1 • After warming up engine At idle Approx. 0.1 - 0.4V⇔
Approx0.6 - 0.9V
Maintain speed approx. 2,000 rpm Approx. 0.1 - 0.4V⇔
Approx0.6 - 0.9V
Oxygen sensor • After warming up engine At idle Slowly repeat LEAN⇔RICH.
monitor bank 1
Maintain speed of approx. 2,000 rpm Repeat LEAN⇔RICH
operation, more than 5 times
for 10 seconds.

EC-52 K-Series Engines

 Service Tool Reference Value in Data Monitor
(Cont’d)
Monitor item Measurement condition Reference value

Battery voltage • Turn ignition switch: ON, not running engine Approx. 11 - 14V
ETC acceleration • After warming up engine At Idle Approx. 0.6 - 0.65V
sensor 1
Approx. 2,000 rpm Approx. 0.75 - 0.8V
Ignition switch ON with accelerator pedal Approx. 4.1 - 4.3V
depressed (With engine stopped)
ETC throttle sensor 1 • After warming up engine At idle speed Approx. 0.5 - 0.55V
Maintain Approx. 2,000 rpm Approx. 0.65 - 0.7V
Ignition ON, Full throttle with engine not Approx. 0.7 - 0.75V
running
Intake air temperature • After warming up engine Values in response to the
sensor intake air
Starter signal • Ignition switch: ON → START → ON OFF → ON → OFF
Idle switch • After warming up engine Accelerator closed fully ON
• Ignition switch: ON
Accelerator opened OFF
A/C signal • After warmed up engine, and at idle A/C switch OFF OFF
A/C switch: ON compressor ON ON
Neutral switch • Key switch: ON Neutral, or N ON
Other position than above OFF
Electric load signal • Ignition switch: ON Head light switch: ON ON
Head light switch: OFF OFF
Brake switch • Ignition switch: ON Depressing brake pedal ON
Not depressing brake pedal OFF
Injection pulse width • After warming up engine At idle Approx. 2 - 4 msec(Gasoline)
bank 1 • Shift lever in neutral Approx. 4 - 6 msec(LPG)
LPG fuel injection • No load At approx. 2,000 rpm
switch
Ignition timing • After warming up engine At idle Approx. 0° BTDC
• Shift lever in neutral At approx. 2,000 rpm Approx. 30° BTDC
• No load
Fuel pump relay • 1 second after turning on ignition switch ON
• During engine running or cranking
• Other cases than above OFF
Throttle relay • Ignition switch: ON → OFF ON → OFF
Oxygen sensor heater • After engine warmed up (at idle) ON
bank 1
TAS learning history • After engine warmed up (at idle) Learning completed Done
• All electrical load switches: OFF
Learning not yet completed Not done
• Selector lever: neutral or N
• Throttle valve closed position
Fuel change switch 1 • Ignition switch: ON Fuel changing switch: LPG ON
Fuel changing switch: Gasoline or OFF
neutral
Fuel change switch 2 • Ignition switch: ON Fuel changing switch: Gasoline ON
Fuel changing switch: LPG or neutral OFF

EC-53 K-Series Engines

 Service Tool Reference Value in Data Monitor
(Cont’d)
Monitor item Measurement condition Reference value

LPG relay • While engine is running and cranking ON

• Other than above OFF
Filling efficiency • After engine warming up At idle Approx. 30%
• Selector lever: neutral or N
At approx. 2,000 rpm Approx. 20%
• While engine is running on gasoline
• While engine is running on LPG. 0%
LPG filling efficiency • After engine warming up At idle Approx. 30%
• Selector lever: neutral or N
At approx. 2,000 rpm Approx. 20%
• While engine is running on LPG.
• While engine is running on LPG. 0%
LPG fuel pressure • Ignition switch: ON Approx. 0.3 kgf/cm2
sensor
TAS learning history • When carrying out TAS learning on Completed ON
active test
Not yet completed OFF

EC-54 K-Series Engines

 (11)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.
Related sensors Malfunction condition Fail-safe MIL

Air flow sensor Same as self-diagnosis • Selects fuel injection pulse width depending on engine speed and Engine
malfunction detection throttle position so the vehicle can be driven. However, fuel injection warning
conditions. will be adjusted (fuel cut off) when engine speed is in the range of light
800 to 1600 rpm. turns ON
• Idle speed is 800 rpm.
Engine coolant • Uses the estimated engine coolant temperature (varies with elapsed Engine
temperature sensor time after start) to perform controls so the vehicle can be driven. warning
light
turns ON
Accelerator pedal position • Fuel injection will be inhibited when 1 circuit is opened. Release Engine
sensor throttle valve mechanically until it can drive at low speed when warning
disconnecting connector. light
turns ON
Throttle position sensor • Fixes output to a preset value so the vehicle can be driven. However, Engine
fuel injection will be inhibited (fuel cut off) when engine speed warning
exceeds approximately 2,500 rpm. light
turns ON
Engine warning light • Fuel injector will be inhibited at approximately 2,500 rpm to prevent Engine
malfunctioning of engine warning light if exhaust performance and warning
driving performance malfunctions are occurring. light
turns ON

EC-55 K-Series Engines

 POWER SUPPLY AND GROUND SYSTEM

POWER SUPPLY AND (1)Control Unit Input/Output Signal

GROUND SYSTEM Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.

Terminal signal Signal name Measurement condition Measured value

111 ECCS & IGN coil relay For approximately 10 seconds with ignition switch Approx. 1V
ON and after ignition switch OFF
Approximately 10 seconds or more after turning Battery voltage
ignition switch OFF
109 Ignition switch Ignition switch ON
119 Power supply for ECCS
120
121 Power supply Always
115 Ground Approx. 0V
116
1

(2)Circuit Diagram

ECM0081

EC-56 K-Series Engines

 CRANKSHAFT POSITION SENSOR (POS) SYSTEM

CRANKSHAFT POSITION (1)Control Unit Input/Output Signal

SENSOR (POS) SYS- Specifications
TEM Check waveform between terminals shown below and ground using
an oscilloscope.
Terminal Signal name At cranking At idle after warming up At approx. 2,000 rpm

13 Crankshaft position Approx. 2.6V Approx. 3V Approx. 3V

sensor (POS)

ECM0082 ECM0083 ECM0084

Numerical values (reference values) are obtained using an analog

circuit tester.

(2)Circuit Diagram

ECM0085

(3)Component Parts Inspection

Crankshaft position sensor (POS)
Check resistance between terminals using an analog circuit tester.
At room temperature
(+) - (-) Resistance
3-1 : Not 0 Ω nor ∞ Ω
2-1 : Not 0 Ω nor ∞ Ω
3-2 : Not 0 Ω nor ∞ Ω

CAUTION:
Measurement values will vary depending on the measurement
range of circuit tester. Note that the higher the range is, the
larger the resistance is.
ECM0086

EC-57 K-Series Engines

 CAMSHAFT POSITION SENSOR (PHASE) SYSTEM

CAMSHAFT POSITION SEN- (1)Control Unit Input/Output Signal

SOR (PHASE) SYSTEM Specifications
Check waveform between terminals shown below and ground using
an oscilloscope.
Terminal Signal name At cranking At idle after warming up At approx. 2,000 rpm

14 Camshaft position Approx. 0.15V Fluctuates between approx. 1.5 - 2V. Approx. 2V
sensor (PHASE)

ECM0087 ECM0088 ECM0089

Numerical values (reference values) are obtained using an analog

circuit tester.

(2)Circuit Diagram

ECM0090

(3)Component Parts Inspection

Camshaft position sensor (PHASE)
Check resistance between terminals using an analog circuit tester.
At room temperature
(+) - (-) Resistance
3-1 : Not 0 Ω nor ∞ Ω
2-1 : Not 0 Ω nor ∞ Ω
3-2 : Not 0 Ω nor ∞ Ω

CAUTION:
Measurement values will vary depending on the measurement
range of circuit tester. Note that the higher the range is, the
ECM0091
larger the resistance is.

EC-58 K-Series Engines

 MASS AIR FLOW SENSOR SYSTEM

MASS AIR FLOW SENSOR SYSTEM (1)Special Tool Data Monitor Display
Monitor item At idle after warming up At approx. 2,000 rpm

Air flow meter bank 1 Approx. 1.8V-2.0V Approx. 2.2-2.5V

(2)Control Unit Input/Output Signal

Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal Signal name At cranking At idle after warming up At approx. 2,000 rpm

51 Mass air flow sensor Approx. 1.5V Approx. 1.8V-2.0V Approx. 2.2-2.5V
67 Mass air flow sensor ground Approx. 0V

(3)Circuit Diagram

ECM0092

(4)Component Parts Inspection

Mass air flow sensor
1. Remove mass air flow sensor.
2. Turn ignition switch to ON. While blowing air into the mass air
flow sensor from the air cleaner case side, check output voltage
between terminal 3 and ground.
No air blowing: Approx. 1V
With air blowing: Approx. 1.3V
(The more the air is blown, the higher the voltage is.)

CAUTION:
If air is blown from the air duct side, the voltage becomes lower.
ECM0093

EC-59 K-Series Engines

 ENGINE COOLANT TEMPERATURE SENSOR SYSTEM

ENGINE COOLANT TEMPERA- (1)Service Tool Data Monitor Display

TURE SENSOR SYSTEM
Monitor item At idle after warming up At approx. 2,000 rpm

Engine coolant temperature sensor After warming up engine: Approx. 80°C or more

(2)Control Unit Input/Output Signal

Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal Signal name At Idle At approx. 2,000 rpm

73 Engine coolant Engine coolant temperature at approx.

temperature sensor signal 20°C: Approx. 3.5V
Engine coolant temperature at approx.
80°C: Approx. 1.2V

NOTE:
ECM0094 • If engine coolant temperature sensor has a malfunction, the
value of engine coolant temperature signal is changed along
with start-up time by fail-safe to enable normal operation.

(3)Circuit Diagram

ECM0095

(4)Component Parts Inspection

Engine coolant temperature sensor
Check resistance between terminals 1 and 2 on the engine coolant
temperature sensor.
Resistance
Coolant temperature at approx. 20°C: Approx. 2.5 k Ω
Coolant temperature at approx. 80°C: Approx. 0.3 k Ω

ECM0096

EC-60 K-Series Engines

 HEATED OXYGEN SENSOR SYSTEM
HEATED OXYGEN SENSOR SYSTEM (1)Service Tool Data Monitor Display
Monitor item At idle after warming up At approx. 2,000 rpm

Oxygen sensor bank 1 Changes between approx. 0.1 - 0.4V⇔ approx. 0.6 - 0.9V
Oxygen sensor monitor Repeat Rich <-> Lean slowly. Repeat Rich <-> Lean at least 5 times in 10 seconds.
bank 1

(2)Control Unit Input/Output Signal

Specifications
Check waveform between terminals shown below and ground using
an oscilloscope.
Terminal Signal name At idle after warming up At approx. 2,000 rpm

35 Heated oxygen sensor Changes between approx. 0.1 - 0.4V⇔ approx. ←

signal 0.6 - 0.9V

ECM0097 ECM0098

Numerical values (reference values) are obtained using an analog

circuit tester.

(3)Circuit Diagram

ECM0099

EC-61 K-Series Engines

 THROTTLE POSITION SENSOR SYSTEM

THROTTLE POSITION SENSOR SYSTEM (1) Service Tool Data Monitor Display
Monitor item At idle after warming up At approx. 2,000 rpm

ETC Throttle sensor 1 Approx. 0.6V Approx. 0.7V

ETC Throttle sensor 2 Approx. 4.5V Approx. 4.4V

(2) Control Unit Input/Output Signal

Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal Signal name At idle after warming up At approx. 2,000 rpm

66 Sensor ground (Throttle position sensor) Approx. 0V

47 Sensor power supply (Throttle position sensor) Approx. 5V
50 Throttle position sensor 1 Approx. 0.6V Approx. 0.7V
69 Throttle position sensor 2 Approx. 4.5V Approx. 4.4V

(3) Circuit Diagram

ECM0100

(4) Component Parts Inspection

THROTTLE POSITION SENSOR 1, 2 (ELECTRIC THROTTLE
CONTROL ACTUATOR ASSEMBLY)
Check voltage between ECCS C/U terminal 50, 69 and ground.
Refer to (EC-36), "ECCS control unit Input/Output Signal
Specifications" for the voltage.

CAUTION:
• Make sure that there is no moisture around connector
when removing and installing throttle position sensor con-
nector. If there are any water drops, completely wipe them
off.
• Do not apply voltage to throttle position sensor terminal.
• Perform "Throttle Valve Closed Position Learning" if dis-
ECM0101
connecting connector. Perform "Throttle Valve Closed
Position Learning and Idle Air Volume Learning" if replac-
ing electric throttle control actuator. (Refer to (EC-12),
"Throttle Valve Closed Position Learning and TAS Learn-
ing".)
• Do not disassemble electric throttle control actuator.

EC-62 K-Series Engines

 ACCELERATOR PEDAL POSITION SENSOR SYSTEM

ACCELERATOR PEDAL POSITION SENSOR SYSTEM (1) Service Tool Data Monitor Display
Monitor item At idle after warming up At approx. 2,000 rpm

ETC Acceleration sensor 1 Approx. 0.6V Approx. 0.65V

ETC Acceleration sensor 2 Approx. 0.3V Approx. 0.35V

(2) Control Unit Input/Output Signal

Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal Signal name At Idle At approx. 2,000 rpm

90 Sensor power supply Approx. 5V

106 Accelerator pedal position sensor 1 Approx. 0.6V Approx. 0.65V
82 Sensor ground Approx. 0V
91 Accelerator pedal position sensor 2 power supply Approx. 2.5V
98 Accelerator pedal position sensor 2 Approx. 0.3V Approx. 0.35V
83 Accelerator pedal position sensor 2 ground Approx. 0V

NOTE:
• When the accelerator pedal is depressed slowly from the fully-
closed position, the voltage must increase in proportion to the
opening of the throttle. [Ignition switch ON (engine stopped)]
Ignition switch ON, engine stopped Ignition switch ON, engine stopped
Terminal Signal name
Accelerator pedal is fully released Accelerator pedal is fully depressed
106 Accelerator pedal position sensor 1signal Approx. 0.6V Approx. 4.2V
98 Accelerator pedal position sensor 2 signal Approx. 0.3V Approx. 2V

(3) Circuit Diagram

ECM0102

EC-63 K-Series Engines

ACCELERATOR PEDAL POSITION SENSOR SYSTEM

(4) Component Parts Inspection

ACCELERATOR PEDAL POSITION SENSORS 1, 2 (ACCELERA-
TOR WORK UNIT)
Check voltage between ECM terminal 106, 98 and ground.
Refer to (EC-36), "ECCS control unit Input/Output Signal
Specifications" for the voltage.

CAUTION:
• Do not apply voltage to accelerator pedal position sensor
terminal.
• Do not disassemble accelerator work unit.

ECM0103

EC-64 K-Series Engines

 INTAKE AIR TEMPERATURE SENSOR

INTAKE AIR TEMPERATURE SENSOR (1)Service Tool Data Monitor Display

Monitor item At Idle At approx. 2,000 rpm

Intake air temperature sensor Values according to intake air temperature

(2)Control Unit Input/Output Signal

Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal Signal name At Idle At approx. 2,000 rpm

34 Intake air temperature sensor signal Intake air temperature at 20°C: approx. 3.5V
Intake air temperature at 80°C: approx. 1.2V

(3)Circuit Diagram

ECM0092

(4)Component Parts Inspection

INTAKE AIR TEMPERATURE SENSOR (JOINED WITH MASS
AIR FLOW SENSOR)
Check resistance between intake air temperature sensor (mass air
flow sensor connector) terminals 3 and 5.
Resistance
Intake air temperature at approx. 20°C: Approx. 2.5 kΩ
Intake air temperature at approx. 80°C: Approx. 0.3 kΩ

ECM0105

EC-65 K-Series Engines

 PNP SWITCH SYSTEM

PNP SWITCH SYSTEM (1)Service Tool Data Monitor Display

Monitor item Neutral, or N position Other than the left

Neutral SW ON OFF

(2)Control Unit Input/Output Signal

Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal Signal name Neutral, or N position Other than the left

102 PNP switch Approx. 0V Battery voltage (A/T models)

Approx. 4.8V (M/T models)

(3)Circuit Diagram

ECM0106

(4)Component Parts Inspection

1. Inhibitor switch
Refer to “Inhibitor Switch”.

2. Neutral Switch
Refer to “Position Switch”.

EC-66 K-Series Engines

 STOP LAMP SWITCH SYSTEM

STOP LAMP SWITCH SYSTEM (1)Service Tool Data Monitor Display

Monitor item Brake pedal released Brake pedal depressed

Foot brake SW OFF ON

(2)Control Unit Input/Output Signal

Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal Signal name Brake pedal released Brake pedal depressed

101 Stop lamp switch Approx. 0V Battery voltage

(3)Circuit Diagram

ECM0107

(4)Component Parts Inspection

Stop lamp switch
Check continuity between stop lamp switch terminals 1 and 2.
Brake pedal released: Continuity should not exist.
Brake pedal depressed: Continuity should exist.

ECM0108

EC-67 K-Series Engines

 ELECTRIC LOAD SWITCH SYSTEM

ELECTRIC LOAD SWITCH SYSTEM (1)Service Tool Data Monitor Display

Monitor item Headlamp OFF Headlamp ON

Electric load signal OFF ON

(2)Control Unit Input/Output Signal

Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal Signal name Headlamp switch OFF Headlamp switch ON

84 Headlamp switch Approx. 0V Battery voltage

(3)Circuit Diagram

ECM0109

EC-68 K-Series Engines

 VEHICLE SPEED SENSOR SYSTEM

VEHICLE SPEED SENSOR (1)Service Tool Data Monitor Display

SYSTEM
Monitor item At idle During traveling

Vehicle speed sensor Almost same with speedometer indication

(2)Control Unit Input/Output Signal

Specifications
Using an oscilloscope, measure the voltage between the ground and
the terminals listed below.
Terminal Signal At idle Traveling at approx. 40km/h

33 Vehicle speed signal Approx. 4.6V or 0V Approx. 2.3V

(3)Circuit Diagram

EC-69 K-Series Engines

 IGNITION SYSTEM

IGNITION SYSTEM (1)Service Tool Data Monitor Display

Monitor item At idle after warming up

Ignition timing Approx. 0 deg

(2)Control Unit Input/Output Signal

Specifications
Check waveform between terminals shown below and ground using
an oscilloscope.
Terminal Signal name At cranking At idle after warming up At approx. 2,000 rpm

61 Ignition signal (power Approx. 0.2V Approx. 0.1V Approx. 0.1V

62 transmission drive signal)
80
81

ECM0113 ECM0114 ECM0115

Numerical values (reference values) are obtained using an analog

circuit tester.

(3)Circuit Diagram

ECM0116

(4)Component Parts Inspection

Spark plug
• Check electrode for dirt, damage, and wear, and check insulator
for damage.
• Replace spark plug if necessary.

CAUTION:
• Check terminals for looseness.
• Check insulator for cracks or damage.
• Check for contamination by oil, water, and dust.
• Make sure that the spark plug gap is normal, using a feeler
gauge.
Spark plug gap: 0.8 - 0.9 mm
ECM0117

EC-70 K-Series Engines

 IGNITION SYSTEM
Ignition coil
Check the resistance between terminals of the power transistor by
applying and exchanging (+ and -) the inspection rods of an analog
circuit tester.
(+) - (-) Resistance (at room temperature)
1-2 : Not 0 Ω nor ∞ Ω
2-1 : Not 0 Ω nor ∞ Ω
3-1 : Except 0 Ω
1-3 : Except 0 Ω
3-2 : Except 0 Ω
2-3 : Except 0 Ω
ECM0118
CAUTION:
Do not use a digital circuit tester because the standard is
different.

EC-71 K-Series Engines

 FUEL INJECTOR SYSTEM

FUEL INJECTOR SYSTEM (1)Service Tool Data Monitor Display

Monitor item At idle after warming up

Fuel injection pulse bank 1 Approx. 4-6 ms

(2)Control Unit Input/Output Signal

Specifications
Check waveform between terminals shown below and ground using
an oscilloscope.
Terminal Signal name At cranking At idle after warming up At approx. 2,000 rpm

22 Injector drive signal Approx. 10.5V Battery voltage Relatively lower than battery voltage
23
41
42

ECM0119 ECM0120 ECM0121

Numerical values (reference values) are obtained using an analog

circuit tester.

(3)Circuit Diagram

ECM0122

(4)Component Parts Inspection

Fuel Injector
• Check resistance between each cylinder injector terminals 1
and 2.
Standard resistance (all cylinders): Approx. 14.5 Ω
(at room temperature)

ECM0123

EC-72 K-Series Engines

 ENGINE WARNING LIGHT SYSTEM

ENGINE WARNING LIGHT (1)Control Unit Input/Output Signal

SYSTEM Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal Signal name Warning light ON Warning light OFF

30 Engine warning light Approx. 0.1V Power source voltage

(2)Circuit Diagram

EC-73 K-Series Engines

 FUEL PUMP SYSTEM

FUEL PUMP SYSTEM (1)Service Tool Data Monitor Display

Monitor item Fuel pump is not activated Fuel pump is operated

Fuel pump relay OFF ON

(2)Control Unit Input/Output Signal

Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal Signal name For approx. 1 second after ignition switch is turned ON At cranking, engine running

113 Fuel pump relay Approx. 1V (After approx. 1 second: Battery voltage) Approx. 1V

(3)Circuit Diagram

ECM0124

(4)Component Parts Inspection

Fuel pump
Check resistance between terminals 3 and 6.
Resistance: Approx. 1 Ω (at room temperature)

EC-74 K-Series Engines

 LPG INJECTOR SYSTEM

LPG INJECTOR SYSTEM (1)Control Unit Input/Output Specifications

Terminal Switching module

Signal name AT idle speed
signal terminal

8 2 LPG injector drive Approx. 3V

The time axis alters according to data setting and operating
conditions.

72 3 LPG injector drive check Slightly lower than battery voltage

The time axis alters according to data setting and operating
conditions.

- 6 LPG injector drive (L) Almost equal to battery voltage

The time axis alters according to data setting and operating
conditions.

EC-75 K-Series Engines

 LPG INJECTOR SYSTEM

Terminal Switching module

Signal name AT idle speed
signal terminal

44 8 LPG injector drive Approx. 5V

The time axis alters according to data setting and operating
conditions.

39 9 LPG injector drive retaining Approx. 5V

The time axis alters according to data setting and operating
conditions.

- 12 LPG injector drive (H) Battery voltage

The time axis alters according to data setting and operating
conditions.

EC-76 K-Series Engines

LPG INJECTOR SYSTEM

(2)Circuit Diagram

(3) Component Parts Inspection

LPG injector
Resistance: Approx. 1Ω (at room temperature)
Remove fuse cover to check if the fuse is broken.

CAUTION:
Do not apply voltage to the LPG injector.

EC-77 K-Series Engines

 LPG ASSIST INJECTOR SYSTEM

LPG ASSIST INJECTOR (1)Control Unit Input/Output Signal

SYSTEM Specifications
Using an oscilloscope, check resistance between following terminal
and ground.
Terminal Signal name At idle

71 LPG assist injector drive Battery voltage

(2)Circuit Diagram

(3)Component Parts Inspection

Check resistance between terminals 1 and 2.
Resistance: Approx. 27Ω (at room temperature)
Apply battery voltage between terminals 1 and 2 directly, to check
solenoid function.
With above voltage: conductivity
Without voltage: no conductivity

ECM0123

EC-78 K-Series Engines

 LPG FUEL PRESSURE SENSOR SYSTEM

LPG FUEL PRESSURE (1)Control Unit Input/Output Signal

SENSOR SYSTEM Specifications
Using an oscilloscope, check resistance between following terminal
and ground.
Terminal Signal name At idle

31 LPG fuel pressure sensor 2.5V

(2)Circuit Diagram

EC-79 K-Series Engines

 THROTTLE CONTROL MOTOR SYSTEM

THROTTLE CONTROL (1)Control Unit Input/Output Signal

MOTOR SYSTEM Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal Signal name At idle after warming up At approx. 2,000 rpm

5 Throttle control motor 1 (Open) Approx. 0.1 - 0.15V

4 Throttle control motor 2 (Close) Approx. 2 - 2.5V

(2)Circuit Diagram

ECM0100

(3)Component Parts Inspection

Electric throttle control motor (Electric throttle control actuator
assembly)
Check resistance between electric throttle control motor (throttle
position sensor connector) terminals 3 and 6.
Resistance: Approx. 1 -15 Ω (at 25°C)

CAUTION:
• Make sure that there is no moisture around connector
when removing and installing throttle position sensor con-
nector. Completely wipe off water drops if there are any.
• Do not apply voltage to electric throttle control motor ter-
minal.
• Perform "Throttle Valve Closed Position Learning" if dis-
ECM0126
connecting connector. Perform "Throttle Valve Closed
Position Learning and TAS Learning" if replacing electric
throttle control actuator. (Refer to (EC-12), "Throttle Valve
Closed Position Learning and TAS Learning".)
• Do not disassemble electric throttle control actuator.

EC-80 K-Series Engines

 HEATED OXYGEN SENSOR HEATER SYSTEM

HEATED OXYGEN SENSOR HEATER SYSTEM (1)Service Tool Data Monitor Display
Monitor item At idle after warming up

Oxygen sensor heater bank 1 ON

(2)Control Unit Input/Output Signal

Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.
Terminal Signal name At idle after warming up Approx. 3600 rpm or more

24 Heated oxygen sensor heater open signal Approx. 0.3V Battery voltage

(3)Circuit Diagram

ECM0099

(4)Component Parts Inspection

Oxygen Sensor Heater
Check resistance between heated oxygen sensor terminals 2 and 3.
Resistance: Approx. 3.3 - 3.5 Ω

EC-81 K-Series Engines

 BLOWBY GAS RECIRCULATION DEVICE

BLOWBY GAS RECIRCULATION (1) System Diagram

DEVICE

ECM0143

(2) Component Parts Inspection

Blowby control valve
1. At idle, remove blowby control valve together with hoses from
rocker cover.
2. Check if hissing sound is heard from the air passage when
blowby control valve is operating normally.

ECM0144

3. Check air flow through the blowby control valve and sucking air
to/from the INT end.
Blowing air: No air flow
Sucking air: Air flow exists

ECM0145

EC-82 K-Series Engines

 FUEL CUT FUNCTION

FUEL CUT FUNCTION (1) Inspection Procedure

With Service tool
1. Check "Injection pulse width" (gasoline) or "LPG fuel injection
width" (LPG) in the data display menu, and increase the engine
speed to approximately 2,500 rpm after warming up engine.
2. Make sure that "Injection pulse width" (gasoline) or "LPG fuel
injection width2 (LPG) instantly drops when accelerator pedal is
released.

Without Service Tool

1. Warm up the engine sufficiently.
2. Disconnect harness connector of the injector and connect a test
lamp.
3. Release the accelerator pedal at the engine speed of
approximately 2,500 rpm or more, and confirm test lamp goes
off for a moment.

ECM0147

EC-83 K-Series Engines

 REMOVAL AND INSTALLATION OF ECCS COMPONENTS

REMOVAL AND INSTALLATION OF ECCS COMPO- (1) Removal and Installation of ECCS control
NENTS unit
1. Disconnect ECCS C/U connector.
2. Remove ECCS C/U..
3. Install in the reverse order of removal.

CAUTION:
Perform "Throttle Valve Closed Position Learning and TAS
Learning" after installation if replacing ECCS C/U. (Refer to (EC-
12), "Throttle Valve Closed Position Learning and TAS
Learning".)

CAUTION:
ECM0148 Check for damage or bending of pin when installing ECCS C/U

(2) Removal and Installation of Crankshaft

Position Sensor (POS)
Removal
1. Remove fan.
2. Remove harness connector.
3. Remove crankshaft position sensor (POS).

Installation
NOTE:
• Make sure that there is no foreign material on sensor flange, O-
rings, and cylinder block.
• Keep away from magnetized objects.
ECM0149 • Make sure that the sensor is inserted securely into chain hous-
ing before tightening bolts.

(3) Removal and Installation of Camshaft

Position Sensor (PHASE)
Removal
1. Remove fan.
2. Remove harness connector.
3. Remove camshaft position sensor (PHASE).

Installation
NOTE:
• Make sure that there is no foreign material on sensor flange, O-
rings, and cylinder head.
• Keep away from magnetized objects.
ECM0150 • Make sure that the sensor is inserted securely into cylinder
head front cover before tightening bolts.

EC-84 K-Series Engines

REMOVAL AND INSTALLATION OF ECCS COMPONENTS

(4) Removal and Installation of Mass Air

Flow Sensor
1. Remove harness connector.
2. Remove mass air flow sensor assembly from air horn.

ECM0151

(5) Removal and Installation of Engine

Coolant Temperature Sensor.
1. Disconnect radiator drain plug, and drain coolant.

CAUTION:
Make sure to drain when the coolant temperature is cold.
2. Remove harness connector.
3. Remove coolant temperature sensor using a socket specially
designed for removing and installing coolant temperature
sensors [commercially available: Thermosensor Socket
manufactured by KTC (part No.: B20T-19)] and similar parts.

ECM0152
(6) Removal and Installation of Oxygen
Sensor (with Oxygen Sensor Heater)
1. Remove harness connector from hearted oxygen sensor.
2. Remove heated oxygen sensor using a socket designed for
heated oxygen sensor removal and installation (Special Tool).

ECM0153

3. Remove heated oxygen sensor using a socket designed for

heated oxygen sensor removal and installation (SST).

CAUTION:
Handle it carefully and avoid impacts.

EC-85 K-Series Engines

REMOVAL AND INSTALLATION OF ECCS COMPONENTS

(7) Removal and Installation of Throttle

Position Sensor (Electric Throttle Control
Assembly)
Refer to "Removal and Installation" in EF section.

(8) Removal and Installation of Accelerator

Pedal Position Sensor (Accelerator Pedal
Assembly)
CAUTION:
Do not disassemble accelerator pedal assembly and remove
sensors and switches.

(9) Removal and Installation of Intake Air

Temperature Sensor (with Air Flow Sensor)
• Refer to (EC-76), "Removal and Installation of Mass Air Flow
Sensor" because intake air temperature sensor is joined with
mass air flow sensor.

(10) Removal and Installation of Ignition Coil

(with Power Transistor)

(11) Removal and Installation of Fuel Injector

Refer to "Removal and Installation" in EF section.

(12) Removal and Installation of Fuel Pump

(13) Removal and Installation of Throttle

Control Motor (Electric Throttle Control
Actuator Assembly)
Refer to "Removal and installation of throttle position sensor (electric
throttle control actuator assembly)" in EF section.

(14) Removal and Installation of LPG Injector

Holder
Removal
1. Remove air duct from air horn.
2. Remove harness connectors of mass air flow sensor, LPG
injector, and LPG fuel pressure sensor.
3. Loosen air horn bolts and remove air horn.
4. Loosen and remove LPG injector holder bolt.

Installation
NOTE:
• Uniformly tighten bolts diagonally in several steps.

EC-86 K-Series Engines

REMOVAL AND INSTALLATION OF ECCS COMPONENTS

CAUTION:
• Make sure that there is no moisture around connector
when removing and installing each connector. Completely
wipe off water drops if there are any.
• Do not apply voltage to each terminal.

(15) Removal and Installation of LPG Injector

Drive Unit
Removing Connector of LPG injector drive unit
1. Strongly pull the center of lever to remove the lever from pawl.
2. Raise the lever until click sound is made to fully raise it toward
drive unit body.
3. Pull the connector to remove it from the unit body.

Connecting Connector of LPG Injector drive unit.

1. With the lever inclined toward the connector side, push it into
the drive unit.
2. Push the lever until click sound is heard.
3. Bring up the lever until click sound is made and hook it on the
pawl behind the connector. Then, confirm that they are securely
connected.

EC-87 K-Series Engines

 SERVICE DATA

SERVICE DATA (1)Standard, Repair Limit

Fuel pressure [kPa (bar, kg/cm2, psi)] 0.35{3.6}

Idle speed (rpm) M/T model (at neutral) 750±50

A/T model (at N position) 750±50
Ignition timing (°BTDC/rpm) M/T model (at neutral) 0±2/750
A/T model (at N position) 0±2/750
Firing order 1-3-4-2
Spark plug Manufacturer/type/gap (mm) NGK/FR2A-D/0.8 - 0.9
Ignition advance device Electronically controlled ignition advance
Density of CO at idle speed (%) /Density of HC at idle speed (ppm) 0.1/50 or less

EC-88 K-Series Engines

 TB45 ENGINE CONTROL

SECTION EC
CONTENTS EC

PRECAUTIONS .................................................. EC-3 CRANKSHAFT POSITION SENSOR 120° (REF)

General Precautions for Service Operations .. EC-3 SIGNAL CIRCUIT ............................................. EC-59
PREPARATION ................................................... EC-4 Control Unit Input/Output 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 Input/Output Signal Specifications
Inspection of Idle 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 Input/Output 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 Input/Output Signal Specifications .... EC-39 Service Tool Data Monitor Display ............... EC-62
Service Tool ................................................. EC-45 Control Unit Input/Output 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 Input/Output Signal Specifications
POWER SUPPLY AND GROUND SYSTEM .... EC-57 EC-63
Control Unit Input/Output Signal Specifications THROTTLE POSITION SENSOR SYSTEM ..... EC-64
...................................................................... EC-57 Service Tool Data Monitor Display ............... EC-64
Circuit Diagram ............................................. EC-57 Control Unit Input/Output Signal Specifications
CRANKSHAFT POSITION SENSOR 1° (POS) EC-58 EC-64
Control Unit Input/Output 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 Input/Output Signal Specifications Component Parts Inspection ........................ EC-76
EC-65 LPG INJECTOR SYSTEM ................................ EC-77
Circuit Diagram ............................................ EC-65 Control Unit Input/Output 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 Input/Output Signal Specifications Control Unit Input/Output 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 Input/Output Signal Specifications Control Unit Input/Output 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 Input/Output 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 Installation of Crankshaft Position
ECM Input/Output Signal Specifications ...... EC-69 Sensor (Integrated Into the Distributor) ........ EC-83
Circuit Diagram ............................................ EC-69 Removal and Installation of Mass Air Flow
IGNITION SYSTEM ........................................... EC-70 Sensor .......................................................... EC-83
Service Tool Data Monitor Display ............... EC-70 Removal and Installation of Engine Coolant
Control Unit Input/Output Signal Specifications Temperature Sensor .................................... EC-83
EC-70 Removal and Installation 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 Installation of Throttle Position
Service Tool Data Monitor Display ............... EC-72 Sensor (Electric Throttle Control Actuator
Control Unit Input/Output Signal Specifications Assembly) .................................................... EC-84
EC-72 Removal and Installation 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 Installation of Intake Air
Service Tool Data Monitor Display ............... EC-73 Temperature Sensor
Control Unit Input/Output Signal Specifications (With Mass Air Flow Sensor) ........................ EC-85
EC-73 Removal and Installation 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 Input/Output Signal Specifications Removal and Installation of Throttle Control
EC-74 Motor (Electric Throttle Control Actuator
Circuit Diagram ............................................ EC-74 Assembly) .................................................... EC-85
Component Parts Inspection ........................ EC-74 Removal and Installation of LPG Injector
ENGINE WARNING LIGHT SYSTEM .............. EC-75 Holder .......................................................... EC-86
Control Unit Input/Output Signal Specifications LPG Injector Drive Unit ................................ EC-86
EC-75 SERVICE DATA AND SPECIFICATIONS
Circuit Diagram ............................................ EC-75 (SDS) ................................................................ EC-87
HEATED OXYGEN SENSOR HEATER Standard, Repair Limit ................................. EC-87
SYSTEM ............................................................ EC-76
Service Tool Data Monitor Display ............... EC-76
Control Unit Input/Output Signal Specifications
EC-76
 PRECAUTIONS
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.

ECM0215

• Be careful not to damage connector terminals when connecting

and disconnecting. Check the terminals for bend or breakage
before connecting.
• Check the input/output signal of terminal before replacing
control unit. Confirm that it operates normally.
Refer to EC section, "ECCS control unit
• Input/Output Signal Specifications".

ECM0216

• 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.

EGM0063

EC-3 TB45 ENGINE

 PREPARATION
PREPARATION

(1) Special Tools

Description Application

EGI fuel pressure indicator For measuring fuel pressure

ST1959 0000 gauge

EGM00217

Heated oxygen sensor wrench Removing and installing heated

KV101 13700 oxygen sensor

EGM00218

Maintenance tool For system inspection and

diagnosis

For molding coil Checking engine speed

Adapter harness
EG101 17500

EGM00219

EC-4 TB45 ENGINE

 ENGINE CONTROL SYSTEM
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 valve opening
optimally according to driving conditions or to improve safety and operability by electronically controlled governor.
Fuel injection control • With SOFIS 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 • Performs maximum regulation of engine speed for oil pressure pump protection by engine speed signal.
Maximum speed regulation • Performs maximum speed regulation by vehicle speed sensor signal. Also, performs variable control of maximum
control
speed by changeover switch as an option.
Idling area torque up control • 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).
Soft 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 ON/OFF depending on engine speed signal.
(gasoline)

LPG interception valve control • Turns interception valve relay ON/OFF depending on engine speed signal and fuel pressure sensor signal.
Fail-safe function • 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.
Diagnostic system • Adopts self-diagnosis system for easier trouble diagnosis.

EC-5 TB45 ENGINE

ENGINE CONTROL SYSTEM

(1) System Diagram

1. GASOLINE

ECM0218

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. DUAL-FUEL

ECM0220

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 std std std std Combined std std
Fuel
LPG std std std – std std std std Combined std std

Control Item Fuel injection control

Fuel change (Gasoline-LPG) control

Maximum machine speed control
Maximum engine speed control
Fuel pump drive control
Air-fuel rate feedback

Ignition timing control

Fuel injection control

Idle speed control

Self diagnosis

Fail safe
Fuel cut
⊕ : Significant impact to control
♦ : Impact to control
Crankshaft position sensor (POS, REF) ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ♦
Mass air flow sensor ⊕ ⊕ ♦ ⊕ ♦ ♦
Intake air temperature sensor ♦ ♦
Engine coolant temperature sensor ♦ ⊕ ♦ ♦ ♦ ♦ ♦
Heated oxygen sensor ⊕ ♦ ♦
Vehicle speed sensor & sensor unit ♦ ♦ ♦ ♦ ⊕ ♦
Sensor System

Throttle position sensor ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦

Accelerator pedal position sensor ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
Ignition switch IGN ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕
PNP switch ♦ ♦ ♦ ♦ ♦
Stop lamp switch ♦
Headlamp (electrical load) switch ♦
Battery voltage ♦ ♦ ♦ ♦ ♦
LPG fuel pressure sensor ♦ ⊕ ♦
LPG injector drive unit check signal ♦
Fuel changing switch ⊕ ⊕ ⊕ ⊕ ⊕
Gasoline injector ⊕ ⊕ ⊕
Ignition system Power transistor ⊕ ♦
Ignition coil ⊕
Throttle control motor relay ⊕ ♦
Throttle control motor ⊕ ♦ ♦
Actuator System

Gasoline fuel pump relay ⊕ ⊕

Gasoline fuel pump ⊕ ♦
Ignition relay ⊕
ECM relay ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕
LPG injector drive unit ⊕ ⊕ ⊕
LPG injector ⊕ ⊕ ⊕ ♦
LPG assistance injector ⊕ ⊕ ⊕ ♦
LPG interception valve relay ⊕ ⊕ ♦
LPG interception valve ⊕ ♦

EC-9 TB45 ENGINE

BASIC INSPECTION
BASIC INSPECTION

(1) Inspection of Idle Speed, Ignition Timing,

and Air-Fuel Ratio

1. STANDARD AT IDLE
Idle speed [N position] (rpm) 675 ± 50
Ignition timing (BTDC/rpm) 10 ± 2/675
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 ± 50 rpm.
CAUTION:
• Perform "Idle 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 ± 50 rpm.
CAUTION:
• Perform "TAS Learning" (EC section) when idle speed is
outside the standard.

3. CO/HC 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 CO/HC density adjustment is necessary.
• Warm up engine to normal operating temperature. Confirm idle
speed and ignition timing are within the standards. Then, check
CO/HC density with a CO/HC 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 Bank1" 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

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.)

ECM0221

+
• Make sure that ignition timing and base idle speed is BTDC 10°
± 2°/675 rpm.

ECM0222

EC-11 TB45 ENGINE

 BASIC INSPECTION

Inspection of Idle 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° ± 2°/675 rpm.
• Clockwise rotation of the distributor advances the ignition Make
sure that ignition timing advances synchronously when racing
the engine.

(2) Throttle Valve Closed Position Learning

ECM0223
and Idle Air Volume Learning
1. DESCRIPTION
When electric throttle control actuator or ECCS C/U 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.
Idle 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 - 194°F)]
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-14 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 kg/cm2, 51 psi)

• If the vehicle shows poor starting, check fuel pressure with fuel
pump operating for approximately 1 second 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 kg/cm2, 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
TROUBLE SHOOTING

(1) How to Proceed with Trouble Shooting

1. The most important point in performing trouble diagnosis of
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 his/her 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".

ECM0234

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.
ECM0235
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 input/output signals.
When checking the ECCS input/output 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 input/output data (guideline) in this
manual in order to judge the ECCS input/output 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.

ECM0236

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.

ECM0237

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
the customer and collect information about their concerns.
• Ask the customer about what symptoms are present under what
conditions. Use the information to clarify the symptom.
• Use the trouble diagnosis sheet to be certain not to miss any
vital information.

ECM0238

EC-18 TB45 ENGINE

TROUBLE SHOOTING

How to Proceed with Trouble Shooting (Cont'd)

Trouble Shooting Information Memo

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.

Im-

Check that symptoms are detected with self-diagnosis.

Check that symptoms are in fail-safe condition.
possi- Poor
Symptoms Poor idle Poor driving control Engine stall Other
ble to start
start

Poor fuel
Initial combustion

When engine is warming up

Inconsistent idle when warming up

Poor acceleration
Engine rpm does not increase smoothly.

Surge at constant speed travel

After-burn
No initial combustion

Poor power output

Surge during acceleration

Knocking
Backfire

At Idle
Driving
During deceleration
During a heavy load
When engine is cold

High idle rpm

Low idle rpm

Overheat
Fast idle is not effective

Inconsistent idle when engine is cold.

Description/notable characteristics of
the symptom

Actuator malfunction
⊕ : Highly possible
♦ : 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.

Momentarily • The symptom depends on the

open duration of momentarily open circuit
and the operating conditions. Slight
♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ⊕ ♦ ♦ ♦ ♦
shocks and surges may be sensed
during driving, while engine stall
may be caused during idle.

Mass air flow OPEN • It will be fail-safe condition, and

sensor ♦ ♦ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ vehicle runs at an engine speed of
800 rpm or less.

High • The air-fuel ratio becomes rich.

output Black smoke may accompany. Poor
Signal ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
connection of grounding may be a
possible cause.

Low output • The air-fuel ratio becomes lean.

♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ Contaminated hot wire or suction of
air may be suspected.

Ground OPEN ⊕ ⊕ ⊕ ⊕ ⊕ ♦ • It will be over-rich.

OPEN • It will be fail-safe condition, and

Power
♦ ♦ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ vehicle runs at an engine speed of
supply
800 rpm or less.

Intake air temperature OPEN/

♦ ♦
sensor SHORT

Engine coolant temperature OPEN/ • It will be fail-safe condition, and

sensor SHORT then Engine warning light turns with
overheat step #1 ON. This
♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
malfunction tends to occur when
engine is cold or when the engine
coolant temperature is high.

Resistanc • The engine coolant temperature is

e is large. ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ judged as low. This malfunction
tends to occur after warming up.

Resistance • The engine coolant temperature is

is small. ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ judged as high. This malfunction
tends to occur when engine is cold.

Heated oxygen sensor OPEN/

♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • It will be base air-fuel ratio.
SHORT

Vehicle speed sensor OPEN/ • Duration of fuel cut becomes

♦ ♦ ♦ ♦ ♦
SHORT shorter or fuel may not be cut.

EC-20 TB45 ENGINE

 TROUBLE SHOOTING

Im-

Check that symptoms are in fail-safe condition.

Check that symptoms are detected with self-diagnosis.
possi- Poor
Symptoms Poor idle Poor driving control Engine stall Other
ble to start
start

Surge at constant speed travel

When engine is cold
When engine is warming up

Inconsistent idle when engine is cold.

Inconsistent idle when warming up

Poor fuel
Poor acceleration
Engine rpm does not increase smoothly.
Surge during acceleration
No initial combustion
Initial combustion

After-burn
At Idle
High idle rpm

Knocking
Low idle rpm

Backfire

Driving
During deceleration
During a heavy load
Poor power output

Overheat
Fast idle is not effective
Description/notable characteristics of
the symptom

Actuator malfunction
⊕ : Highly possible
♦ : Possible

Throttle position sensor OPEN/ • Idle will be base rpm. No addition

♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
SHORT for acceleration.

Output • Possible interruption by

fluctuation unnecessary fuel injection. Poor
♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
ground or control unit connection
may be the cause.

Poor • Idling is judged as OFF during idle.

adjustment Turning ignition switch repeatedly
♦
to ON and OFF will set the system
to normal.

Accelerator pedal position OPEN/

♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
sensor SHORT

Output
♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
fluctuation

Ignition switch (IGN) OPEN • Impossible to start without outputs

⊕ ⊕ ⊕ ⊕ ⊕
for fuel and ignition systems.

Neutral switch OPEN • PNP switch is judged as OFF, and

♦ ⊕ ♦ ⊕ ♦ ♦ ♦ the target cold engine speed in N/P
position is lowered.

SHORT • PNP switch is judged as ON, and

fast idle is effective for cold engine
in positions other than N/P position,
making the creep larger.

Stop lamp switch OPEN/

SHORT

Headlamp (electrical load) OPEN/

♦ ⊕ ♦ ♦
switch SHORT

Power supply for C/U OPEN • Impossible to start without outputs

⊕ ⊕ ⊕ ⊕ ⊕ ♦
for fuel and ignition systems.

Sensor ground (coolant OPEN/

• The same as the open circuit in the
temperature sensor, throttle SHORT ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
applicable sensor.
position sensor)

Control unit and connector Poor • A slightly raised connector often

connection, results in poor connection. Entry of
water entry water causes engine stall and
♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ afterwards it is momentarily
impossible to restart engine. In some
cases, restarting is possible after a
short wait.

LPG fuel pressure sensor OPEN/ • Upon short-circuit, LPG cutoff valve
⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ OFF. Starting not possible.
SHORT

LPG injector Check OPEN ♦

drive unit signal
line SHORT ♦

Fuel changing switch OPEN ♦

LPG fuel pressure sensor OPEN ♦ ♦

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.

Check that symptoms are in fail-safe condition.

Im-

Check that symptoms are detected with self-diagnosis.

possi- poor
Symptoms Poor idle Poor driving control Engine stall Other
ble to start
start

Surge at constant speed travel

When engine is cold
When engine is warming up

Inconsistent idle when warming up

Poor fuel
No initial combustion
Initial combustion

At Idle
Poor acceleration

Surge during acceleration

Knocking
Backfire
After-burn

Driving

During a heavy load

Fast idle is not effective
High idle rpm
Low idle rpm
Inconsistent idle when engine is cold.

During deceleration
Poor power output

Engine rpm does not increase smoothly.

Overheat
Description/notable characteristics of
the symptom

Actuator malfunction
⊕ : Highly possible
♦ : Possible

Gasoline injector Power OPEN ♦ ♦ ♦ ♦ ⊕ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • No fuel injection to cylinder with open

supply circuit, resulting in LEAN output of
circuit Momentarily
♦ ♦ ♦ ♦ heated oxygen sensors.
open • Starting engine is impossible when
Coil OPEN ♦ ♦ ♦ ♦ ⊕ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ the circuits for all the cylinders are
open.
Momentarily
♦ ♦ ♦ ♦
open
Drive OPEN ♦ ♦ ♦ ♦ ♦ ⊕ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
circuit (C/
U side) Momentarily
♦
open
SHORT • Continuous fuel injection to cylinder
with short circuit, resulting in OVER-
RICH and misfiring.
♦ ♦ ♦ ♦ ⊕ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
• Starting engine is impossible when
the circuits for all the cylinders are
open.

Nozzle Foreign • The cylinder with foreign material will

hole material ♦ ♦ ♦ ♦ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ keep injecting.
intrusion
Clogging • The symptom depends on clogging
♦ ♦ ♦ ♦ ⊕ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ status. The correction factor of air-
fuel ratio becomes larger.

Ground OPEN ♦ ♦ ♦ ♦
circuit (C/
U) Momentarily
♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
open

Ignition signal circuit OPEN ⊕ ♦ ⊕ ⊕ ⊕ ⊕ ♦ • OPEN

• Immediately engine stalls during
Momentarily
♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ engine running, and then does not
open
restart.
Ignition coil Power OPEN ⊕ ♦ ⊕ ⊕ ⊕ ⊕ ♦ • Injects fuel toward spark plug during
supply cranking.
circuit Momentarily • MOMENTARILY OPEN
♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • Slight shocks and surges may be
open
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 & IGN relay circuit OPEN ⊕ ♦ ⊕ ⊕ ⊕ ⊕

Throttle control motor circuit OPEN/

♦ ♦ ♦ ♦ ♦ ♦
SHORT
Throttle control motor relay OPEN • The same malfunction may occur as
circuit ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ power supply open of throttle control
motor and throttle position sensor.

Heated oxygen sensor heater OPEN

circuit

EC-22 TB45 ENGINE

 TROUBLE SHOOTING

Im-

Check that symptoms are in fail-safe condition.

Check that symptoms are detected with self-diagnosis.
possi- poor
Symptoms Poor idle Poor driving control Engine stall Other
ble to start
start

When engine is warming up

Poor acceleration
Initial combustion

At Idle

During a heavy load

Inconsistent idle when engine is cold.

Backfire
After-burn
No initial combustion

When engine is cold

Engine rpm does not increase smoothly.

Surge during acceleration

Knocking

Driving
During deceleration
Inconsistent idle when warming up
Poor power output

Surge at constant speed travel

Overheat
Poor fuel
High idle rpm
Low idle rpm
Fast idle is not effective
Description/notable characteristics of
the symptom

Actuator malfunction
⊕ : Highly possible
♦ : Possible

Fuel pump relay circuit OPEN ⊕ ⊕ ⊕ ⊕ • Impossible to start

Fuel pump circuit
Ignition relay circuit Momentarily • Surge may occur.
♦ ♦ ♦ ♦ ♦
open
Fuel pump pressure regulator Stuck ♦ ♦ ♦ ♦

LPG injector drive Ti circuit OPEN ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦

unit
SHORT ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦

Tip circuit OPEN ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦

SHORT ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦

PWM OPEN ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦
circuit
SHORT ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦

Power OPEN
⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦
supply

Ground OPEN ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦

LPG injector HI side OPEN • When self-diagnosis NG, LPG

circuit ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦
interception OFF.

SHORT • When self-diagnosis NG, LPG

⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦
interception OFF.

Coil OPEN • When self-diagnosis NG, LPG

⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦
interception OFF.

LO side OPEN • When self-diagnosis NG, LPG

circuit ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦
interception OFF.

SHORT • When self-diagnosis NG, LPG

⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦
interception OFF.

LPG assistance injector OPEN ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦

Control unit
♦ ♦ ♦ ♦ ♦
side short
LPG interception valve relay OPEN ⊕ ⊕ ⊕ ⊕ ⊕

Control unit
side short
LPG interception valve OPEN

Engine warning light OPEN ♦ ♦

Improper TAS learning ♦ ♦ ♦ ♦ ♦ ♦

Also check the following items other than the above:

• Check harness tension. • Check each connector connection. • Check ground wire for looseness. • Check battery connection for looseness or corrosion.
• Check water and oil condition. • Check fan belts for looseness.

EC-23 TB45 ENGINE

 TROUBLE SHOOTING

Diagnosis Chart by Symptom (Cont'd)

TB45 ENGINE RELATIONSHIP BETWEEN MALFUNCTIONING
SYMPTOM AND THE ENGINE MAIN BODY/AUXILIARY
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.

Im- Im-
possi- possi-
Symptoms Poor idle Poor driving control Engine stall Other
ble to ble to
start start
Inconsistent idle when engine is cold.

Engine rpm does not increase smoothly.

Low idle rpm

During a heavy load

Overheat

Oil pressure warning lamp ON

When engine is cold
When engine is warming up

High idle rpm

Poor power output

Overcool
Poor fuel
Poor acceleration
Initial combustion

Surge during acceleration

Surge at constant speed travel
Knocking
Backfire
After-burn
At Idle
Driving
During deceleration

High oil consume

Mechanical noise
No initial combustion

Inconsistent idle when warming up

Fast idle is not effective

Description/notable characteristics of
the symptom

Main unit symptom

⊕ : Highly possible
♦ : Possible
∇ : Not very possible

Fuel Air sucked from oil level gauge ♦ ∇ ♦ ♦ ∇ ∇ ∇ • Air-fuel ratio becomes LEAN.
mixture • High air-fuel correction factor.
Air sucked from oil filler cap ♦ ∇ ♦ ♦ ∇ ∇ ∇ • Low suction power (vacuum pressure) of
intake manifold.
Air sucked from PCV hose Check the suction using a pressure gauge.
♦ ∇ ♦ ∇ ♦ ♦ ♦ ♦ ♦ ∇ ∇ ♦ ♦ ♦ ∇
(downstream of PCV) Generally applicable to air suction in air
Air sucked from intake manifold intake system
♦ ∇ ♦ ∇ ♦ ♦ ♦ ♦ ♦ ∇ ∇ ♦ ♦ ♦ ∇
and gasket

PCV kept open ♦ ♦ ∇ ♦ ♦ ♦ ♦ ♦ • Noise (high hissing tone)

Clogged fuel strainer ♦ ∇ ♦ ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ∇ ♦ ♦ • Symptom depends on clogging status. This

tends to happen during high-speed or high
Clogged air cleaner element ♦ ♦ ♦ ♦ ♦ ♦ load operation.
Malfunctioning gasoline pressure • Symptom varies depending on oil quality.
∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
regulator
Poor quality gasoline ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ∇ ♦ ♦ ♦ ♦ ∇ • Symptom varies depending on oil quality.

Improper LPG fuel (cold area and • Starting ability in cold area is changed
propane ratio) ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ∇ ♦ ♦ ♦ ♦ depending on propane ratio.
• Use LPG with proper propane ratio.
Malfunctioning LPG vaporizer • If the pressure is low, it is caused by poor
pressure adjusting valve output during high-speed or high load
∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ operation.
• If the pressure is excessively high, relief
valve operates and engine stalls at rich.
Clogged LPG vaporizer hot water • Symptom depends on fuel temperature.
circuit This tends to happen during engine stall
♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
and is impossible to restart during engine
warming up.
Clogged LPG interception valve • Symptom depends on clogging status. This
filter ♦ ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ∇ ♦ ♦ tends to happen during high-speed or high
load operation.
Valve deposit • The malfunction tends to happen during
♦ ♦ ♦ ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ∇ high-speed or high load operation (low
vacuum).

EC-24 TB45 ENGINE

 TROUBLE SHOOTING

Im- Im-
possi- possi-
Symptoms Poor idle Poor driving control Engine stall Other
ble to ble to
start start

Inconsistent idle when warming up

Surge at constant speed travel

Poor fuel
No initial combustion
Initial combustion

When engine is warming up

When engine is cold

Fast idle is not effective

Engine rpm does not increase smoothly.

During a heavy load

Overcool

Mechanical noise
Low idle rpm
Inconsistent idle when engine is cold.

Poor acceleration

Surge during acceleration

Knocking

After-burn
At Idle
Backfire

Driving
During deceleration

High oil consume

High idle rpm

Overheat
Poor power output

Oil pressure warning lamp ON

Description/notable characteristics of
the symptom

Main unit symptom

⊕ : Highly possible
♦ : Possible
∇ : Not very possible

Spark- Improper high-tension cord • Check the igniting sequence.

⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕
ing connection
Improper ignition timing
♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ∇ ♦ ♦ ♦ –
adjustment
Malfunctioning spark plug • Check that the gap is proper. Check plug
♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ∇ ∇ ∇
for soil (smoking).
Leakage from high-tension cord • Symptom varies depending on the level of
∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
leakage.
Leakage from distributor cap. ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ –

Loose or open of primary wire

–
connection
Com- Improper bulb contact ∇ ♦ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ ♦ ♦ ♦ • The symptom occurs depending on
pres- malfunctioning grade and the number of
sion Worn, stuck, broken piston ring ∇ ♦ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ ♦ ♦ ♦ malfunctioning cylinders.
pres-
sure Blow out from head gasket • The symptom occurs depending on
malfunctioning grade and the number of
∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
malfunctioning cylinders. Precautions for
head bolt tightening torque.

Broken or deterioration valve • The symptom occurs depending on

spring ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ malfunctioning grade and the number of
malfunctioning cylinders.

Stuck and upthrust valve stem • The symptom occurs depending on

∇ ♦ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ ♦ ♦ malfunctioning grade and the number of
malfunctioning cylinders.
Pressure leakage from spark plug ⊕ • Check gasket and tightening condition.

Other Low idle base speed • Engine stall may occur by power steering
∇ ∇ ∇ ∇ ♦ ♦ ♦ ♦ load and cargo load during deceleration or
at idling.
Crack and water leakage on
♦
cylinder block

Excessive crankshaft end

♦
play

Crankshaft and connecting • Oil leakage around front or rear crankshaft.

♦ ♦
rod bearing clearance task

Broken crankshaft front/rear • Oil leakage around front or rear crankshaft.

♦
oil seal
Main motor system

Excessive clearance • Whitish exhaust gas. Worn piston or

♦ ♦
between piston and cylinder cylinder.
Excessive piston pin
♦
clearance

Improper piston ring • Whitish exhaust gas. Improper location of

installation ♦ connecting end and assemble it upside
down.
Excessive piston ring • Whitish exhaust gas. Worn piston ring
♦
clearance glove or piston ring.

Worn torque converter pilot

♦
bushing
Crack and water leakage on
♦
cylinder block
Carbon deposit in
Heads

♦
combustion chamber
Worn valve stem or guide ♦ • Whitish exhaust gas

Deterioration of valve oil seal

♦
lip

EC-25 TB45 ENGINE

 TROUBLE SHOOTING

Im- Im-
possi- possi-
Symptoms Poor idle Poor driving control Engine stall Other
ble to ble to
start start

Inconsistent idle when engine is cold.

Engine rpm does not increase smoothly.

Oil pressure warning lamp ON

Low idle rpm

Poor power output

Overheat
When engine is cold

High idle rpm

During a heavy load

Overcool
Poor fuel
Initial combustion

Poor acceleration

Surge during acceleration

Surge at constant speed travel
Knocking
Backfire
After-burn
At Idle
Driving
During deceleration
No initial combustion

High oil consume

Mechanical noise
When engine is warming up

Inconsistent idle when warming up

Fast idle is not effective
Description/notable characteristics of
the symptom

Main unit symptom

⊕ : Highly possible
♦ : Possible
∇ : Not very possible

Others Excessive or clogged valve • Excessive clearance:

clearance Chattering noise at idling
♦ ♦ ♦ ♦ ♦ ♦
• Clogged clearance:
Valves

Engine leakage at idling

Rocker cover gasket oil • Loose or broken gasket
♦
leakage

Slack of timing chain • Worn chain tensioner shoe

♦
• Dropped chain guide
Chains

Improper valve timing • Check timing mark related to timing chain

♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
for dislocation.
Front cover oil leakage ♦ • Loose or broken gasket

Improper engine oil • Insufficient oil amount, improper grade,

♦ ♦ deterioration
• Refill full recommended oil.

Malfunctioning oil pump • Worn or broken rotor

♦ ♦ • Operation malfunction or oil leakage of
regulator

Oil leakage around oil pan • Loose or broken oil pan gasket
Lubrication

♦
• Loose oil pan drain plug
Clogged/restricted oil • Dirt or entry of foreign material in engine oil
♦
strainer

Oil leakage of oil filter • Loose or broken gasket

⊕
• Apply oil to gasket when replacing oil filter.
Clogged/restricted oil filter ♦ • Dirt or entry of foreign material in engine oil

Loose or malfunctioning oil

♦ ♦
pressure switch

Foreign material in fuel tank • With low fuel, this may easily occur.
∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
Fuels

(such as dust)

Oil leakage from fuel system ♦ • Check LPG leakage by applying snoop.

Rotation malfunction of fan • Slip or worn belt caused by belt looseness

♦
or water pump

Malfunctioning water pump • Worn or broken bearing. Coolant leakage

♦ ♦
from axle seal.

Malfunctioning thermostat ♦ ♦

Malfunctioning engine
♦ ♦
coolant temperature gauge
Coolant

Coolant leakage from engine

♦
coolant temperature sensor

Radiator related malfunction • Deterioration of radiator cap pressure, and

water leakage
♦
• Clogged/restricted radiator and condenser,
and water leakage

Contamination and
♦
insufficient amount of coolant
Water leakage from coolant
♦
piping
Engine drive belt tension too high
♦ ♦ ♦ ♦ ♦
(excessive tension)
Clogged three-way catalytic • In some cases, after engine stall, restarting
∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
converter /exhaust system is possible.
Dragging of brakes ♦ ♦ ♦ ♦ • Tires/wheels are hot.

EC-26 TB45 ENGINE

 TROUBLE SHOOTING

Im- Im-
possi- possi-
Symptoms Poor idle Poor driving control Engine stall Other
ble to ble to
start start

Inconsistent idle when engine is cold.

Engine rpm does not increase smoothly.

Oil pressure warning lamp ON

Low idle rpm

Poor power output

During a heavy load

Overheat
High idle rpm
When engine is cold

Poor acceleration

Overcool
Poor fuel
Fast idle is not effective

Surge during acceleration

After-burn
Surge at constant speed travel

Backfire

At Idle
Initial combustion

When engine is warming up

Knocking

Driving
During deceleration

High oil consume

Mechanical noise
No initial combustion

Inconsistent idle when warming up

Description/notable characteristics of
the symptom

Main unit symptom

⊕ : Highly possible
♦ : Possible
∇ : Not very possible

Other High A / T load • Insufficient ATF amount, improper oil

∇ ∇ ♦ ∇ ♦ specification (This symptom may
especially occur in the cold.)
High HYD PUMP load ([Link]) • Malfunctioning oil pressure relief valve,
∇ ∇ ∇ ♦ ♦ ∇ improper oil specification (This symptom
may especially occur in the cold.)

Clogged condenser ♦

Also check the following items other than the above:

• Check harness tension. • Check ground for looseness. • Check each connector connection. • Check battery connection for looseness or corrosion.
• Check engine drive belt for looseness. • Check water and oil condition.

EC-27 TB45 ENGINE

 (2)Component Parts Location
Specifications
Main component part Type Location
Gasoline LPG Combined

Gasoline injector High resistance Intake manifold { {

LPG injector Gas injection Integrated in injector holder (on {
intake manifold)
Actuators

Fuel pump Electric motor/turbine Integrated in fuel tank { {

Fuel pressure regulator Diaphragm { {
Throttle control motor Electric DC motor (DC motor) Integrated in electronic throttle { { {
control actuator
Ignition coil Molded Integrated in distributor { { {
Power transistor 1-channel
Crankshaft position sensor Photoelectric Integrated in distributor { { {
Mass air flow sensor Hot wire Air horn { { {
Accelerator pedal position Variable resistance Integrated in accelerator work { { {
sensors 1 and 2 unit (accelerator pedal assembly)
Throttle position sensors 1 and Integrated in electronic throttle { { {
Sensors

2 control actuator
Engine coolant temperature Thermistor Thermostat housing { { {
sensor
Intake air temperature sensor With air flow meter { { {
Heated oxygen sensor Zirconia (with heater) Front tube { { {
Vehicle speed sensor Electromagnetic power Body side { { {
generation
ECCS C/U 121-pin digital control Body side { { {
ECCS relay Compact general relay (2M) Body side { { {

EC-28 TB45 ENGINE

 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 { { {
LPG injector Integrated in injector holder (on intake { { {
manifold)

Throttle control motor Integrated in electronic throttle control { { { {

actuator

Throttle position sensors 1 and 2 Integrated in electronic throttle control { { { {

actuator

Ignition coil Integrated in distributor { { { {

Crankshaft position sensor { { { {
Power transistor { { { {
Mass air flow sensor Air horn { { { {
Intake air temperature sensor With air flow meter { { { {
Engine coolant temperature sensor Thermostat housing { { { {
Accelerator pedal position sensors 1 and 2 Integrated in accelerator work unit { { { {
(accelerator pedal assembly)

Fuel pump Integrated in fuel tank { { {

Fuel pressure regulator { { {
Heated oxygen sensor (Vehicle side) { { { {
Vehicle speed sensor (Vehicle side) { { { {
ECCS C/U (Vehicle side) { { {
ECCS & IGN coil relay (Vehicle side) { { {
Stop lamp switch (Vehicle side) { { { {
Throttle control motor relay (Vehicle side) { { { {
Fuel pump relay (Vehicle side) { {
Vaporizer (Vehicle side) { { {
LPG interception valve (Vehicle side) { { {

EC-29 TB45 ENGINE

 Component Parts Location (Cont'd)

EC-30 TB45 ENGINE

 Component Parts Location (Cont'd)

EC-31 TB45 ENGINE

 Component Parts Location (Cont'd)

EC-32 TB45 ENGINE

 (4) Circuit Diagram - ECCS
1. GASOLINE

ECM01

EC-33 TB45 ENGINE

 Circuit Diagram (Cont'd)
2. LPG

ECM02

EC-34 TB45 ENGINE

 Circuit Diagram (Cont'd)
3. DUAL-FUEL SPECIFICATION

EC-35 TB45 ENGINE

 (5) Control Unit Terminal Layout

ECM01

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

connector.

Terminal Description

1 C/U ground
2 –
3 Throttle control motor relay power supply
4 Throttle control motor (Close)
5 Throttle control motor (Open)
6 –
7 –
8 LPG injector 1
9 LPG injector 2
10 –
11 LPG assistance injector
12 Soft mode
13 Crankshaft position sensor 1° (POS) signal
14 Crankshaft position sensor 120° (REF) signal
15 –
16 –
17 –
18 –
19 –
20 –
21 Injector No. 5
22 Injector No. 3
23 Injector No. 1
24 Heated oxygen sensor heater
25 –
26 –
27 –
28 –
29 –
30 Warning light
31 LPG fuel pressure sensor
32 Fuel changing switch 2 (Gasoline)
33 Vehicle speed
34 Intake air temperature sensor

EC-36 TB45 ENGINE

 Terminal Description

35 Heated oxygen sensor

36 –
37 –
38 –
39 LPG injector drive keeping
40 Injector No. 6
41 Injector No. 4
42 Injector No. 2
43 –
44 LPG injector drive intake signal #1
45 –
46 –
47 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
55 –
56 –
57 –
58 –
59 Inching switch
60 –
62 Ignition signal (power transmission drive signal)
63 LPG injector drive intake 2
64 –
65 –
66 Sensor ground (Throttle position sensor)
67 Sensor ground
68 –
69 Throttle position sensor #2
70 Fuel changing switch 1 (LPG)
71 –
72 LPG injector check #1
73 Engine coolant temperature sensor
74 –
75 –
76 –
77 –
78 Sensor ground (Heated oxygen sensor)
79 –
82 Sensor ground (Accelerator pedal position sensor 1)
83 Sensor ground (Accelerator pedal position sensor 2)
84 Headlamp switch
85 (K LINE) K-line (C/U data transmit/receive)

EC-37 TB45 ENGINE

 Terminal Description

86 –
87 –
88 –
89 –
90 Accelerator pedal position sensor 1 power supply
91 Accelerator pedal position sensor 2 power supply
92 –
93 –
94 –
95 –
96 –
97 –
98 Accelerator pedal position sensor 2
99 –
100 –
101 Stop lamp switch
102 PNP switch
103 –
104 Throttle control motor relay
105 –
106 Accelerator pedal position sensor 1
107 –
108 –
109 (IGN) Ignition switch
110 –
111 ECCS & IGN coil relay
112 LPG interception valve relay
113 Fuel pump relay
114 –
115 (–) C/U ground
116 (–) C/U ground
117 –
118 –
119 Power supply for C/U
120 Power supply for C/U
121 Power supply for C/U (Back-up)

EC-38 TB45 ENGINE

 (6) ECCS Input/Output 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 instrument/method,
etc. Data shown below are reference values.

ECM02

ECM03

Terminal Signal name Condition Data (DC value)

24 Heated oxygen sensor heater At idle after warming up Approx. 0.3V

Approx. 3600 rpm or more Battery voltage
113 Fuel pump relay For approximately 1 second after Approx. 1V
ignition switch ON
After that Battery voltage
At cranking, engine running Approx. 1V
111 ECCS & IGN coil relay control For approximately 10 seconds when Approx. 1V
ignition switch ON and after ignition
switch OFF
Ignition switch OFF Battery voltage

EC-39 TB45 ENGINE

 Terminal Signal name Condition Data (DC value)

62 Ignition signal (power transmission At cranking At cranking: Approx. 0.5V

drive signal)

ECM04

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

ECM05

At approx. 2,000 rpm Approx. 0.9V

ECM06

101 Stop lamp switch Brake pedal released Approx. 0V

Brake pedal depressed Battery voltage
109 (IGN) Ignition switch Ignition switch OFF Approx. 0V
Ignition switch ON Battery voltage
102 PNP switch N position Approx. 0V
Other than above Battery voltage (A/T models)
Approx. 4.8V (M/T models)
85 (K LINE) K-line (ECM data transmit/receive) When connected to SST Approx. 6.6 - Battery voltage
When not connected to SST Approx. 6V
84 Headlamp switch Lighting switch OFF Approx. 0V
Lighting switch ON Battery voltage
67 Sensor ground Always Approx. 0V
115 C/U ground Always Approx. 0V
116
1

EC-40 TB45 ENGINE

 Terminal Signal name Condition Data (DC value)

13 Crankshaft position sensor 1° (POS) At cranking At cranking: Approx. 2.6V

ECM07

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

ECM08

At approx. 2,000 rpm Approx. 2.5V

ECM09

91 Accelerator pedal position sensor 2 Ignition switch ON, engine running Approx. 2.5V
power supply
48 Sensor power supply Ignition switch ON, engine running Approx. 5V
121 Power supply for ECM (Buck-up) Always Battery voltage
47 Electric throttle control actuator power Ignition switch ON, engine running Approx. 5V
supply
78 Heated oxygen sensor ground Always Approx. 0V
82 Accelerator pedal position sensor 1 Always Approx. 0V
ground
90 Accelerator pedal position sensor 1 Ignition switch ON, engine running Approx. 5V
power supply

EC-41 TB45 ENGINE

 Terminal Signal name Condition Data (DC value)

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

ECM010

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

ECM011

At approx. 2,000 rpm Approx. 0.5V

ECM012

51 Mass air flow sensor Ignition switch ON Approx. 1V

At cranking Approx. 1.5V
At idle after warming up Approx. 1.8 - 2.0V
At approx. 2,000 rpm Approx. 2.2 - 2.5V
50 Throttle position sensor 1 At idle after warming up Approx. 0.6V
Ignition switch ON with engine stopped Approx. 0.75V
Accelerator pedal is released.
Ignition switch ON with engine stopped Approx. 0.75V
Accelerator pedal is fully depressed
At approx. 2,000 rpm Approx. 0.7V
69 Throttle position sensor 2 At idle after warming up Approx. 4.5V
Ignition switch ON with engine stopped Approx. 4.35V
Accelerator pedal is released.
Ignition switch ON with engine stopped Approx. 4.35V
Accelerator pedal is fully depressed.
At approx. 2,000 rpm Approx. 4.4V
106 Accelerator pedal position sensor 1 At Idle Approx. 0.6V
Ignition switch ON with engine stopped Approx. 0.6V
Accelerator pedal is released.
Ignition switch ON with engine stopped Approx. 4.2V
Accelerator pedal is fully depressed
At approx. 2,000 rpm Approx. 0.65V
98 Accelerator pedal position sensor 2 At Idle Approx. 0.3V
Ignition switch ON with engine stopped Approx. 0.3V
Accelerator pedal is released.
Ignition switch ON with engine stopped Approx. 2V
Accelerator pedal is fully depressed
At approx. 2,000 rpm Approx. 0.35V

EC-42 TB45 ENGINE

 Terminal Signal name Condition Data (DC value)

34 Intake air temperature sensor Intake air temperature is approx. 20°C Approx. 3.5V
(68°F).
Intake air temperature is approx. 80°C Approx. 1.2V
(176°F).
83 Accelerator pedal position sensor 2 Always Approx. 0V
ground
35 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 1
approx. 0.5 - 1.0V

ECM013

At approx. 2,000 rpm Changes between approx. 0 - 0.3V 1

approx. 0.5 - 1.0V

ECM014

73 Engine coolant temperature sensor Engine coolant temperature is approx. Approx. 3.5V
20°C.
Engine coolant temperature is approx. Approx. 1.2V
80°C.
21 Injector drive signal At cranking Approx. 10.5V
22
23
40
41
42

ECM015

At idle after warming up Battery voltage

ECM016

At approx. 2,000 rpm Relatively lower than battery voltage

ECM017

EC-43 TB45 ENGINE

 Terminal Signal name Condition Data (DC value)

119 Power supply for C/U Ignition switch ON, engine running Battery voltage
120
104 Throttle control motor relay Ignition switch ON, engine running Approx. 1V
3 Throttle control motor relay power Always Battery voltage
supply
5 Throttle control motor (Open) At idle after warming up Approx. 0.1 to 0.15V
At approx. 2000 rpm
4 Throttle control motor (Close) At idle after warming up Approx. 2 - 2.5V
At approx. 2000 rpm
32 Fuel changing switch 2 (Gasoline) Changing switch ON (At gasoline side) Approx. 5V
Changing switch ON (At LPG side or Approx. 0V
neutral)
49 Fuel changing switch power supply Changing switch ON Approx. 5V
Changing switch OFF (At neutral) Approx. 0V
70 Fuel changing switch 1 (LPG) Changing switch ON (At LPG side) Approx. 5V
Changing switch OFF (At LPG side or Approx. 0V
neutral)
112 LPG interception valve relay For approximately 1 second after Battery voltage
ignition switch ON , and for
approximately 10 seconds after ignition
switch is OFF
Ignition switch OFF Approx. 0V
52 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. 0V
volume learning
54 Maximum speed shifting It varies depending on setting
condition.
33 Vehicle speed sensor signal Vehicle stopped Approx. 11V or approx. 1V

EC-44 TB45 ENGINE

 (7) Service Tool
1. DESCRIPTION
• The service tool executes the following functions using the
combination of data reception, instructions, and transmission
from the ECCS C/U via the communication line.

Diagnosis test mode Function

WORK SUPPORT • Reduces the preparation work necessary for inspecting.

• Displays input/output 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 input/output 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.
C/U PART NUMBER • Displays part number memorized by C/U

2. OPERATION PROCEDURE
1. Turn ignition switch OFF.
2. Connect service tool to data link connector.
3. Turn ignition switch ON.
4. Turn on power supply for the service tool.
5. With main menu, select “1. Trouble Diagnosis of Vehicle“, and
press YES.
6. 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 C/U, 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 C/U, 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 (0 to 250 rpm)
SPEED (*)

*: This function is not necessary in the usual service [Link] is used to change target value due to rough idle or similar reasons.

EC-45 TB45 ENGINE

 Service Tool (Cont'd)
4. SELF-DIAGNOSTIC RESULTS 丂
When a malfunction occurs in ECCS 丂 C/U 丂 input/output signal
circuit, the malfunctioning circuit is recorded. Then, that particular
system name and basic inspection items are displayed. Also,
malfunction data recorded is displayed.

[DISPLAY 丂 EXAMPLE] 丂 MALFUNCTION IN AIR FLOW METER

SYSTEM

The error code one error items are displayed in the alarm monitor
screen.

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 1), timing "1t" 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.

EC-46 TB45 ENGINE

 DISPLAY ITEM LIST

Stored data item Unit Description

FUEL SYS-B1 - 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 °C Displays engine coolant temperature at the time a malfunction is detected.
S-FUEL TRIM-B1(*) % Displays air-fuel ratio feedback learned value at the time a malfunction is
L-FUEL TRIM-B2 detected.
S-FUEL TRIM-B1 Displays air-fuel ratio feedback corrected value at the time a malfunction is
S-FUEL TRIM-B2 detected.
ENGINE SPEED rpm Displays engine speed at the time a malfunction is detected.
VEHICLE SPEED km/h Displays vehicle speed at the time a malfunction is detected.
PULSE WIDTH msec DIsplays pulse width at the time a malfunction is detected.
INTAKE AIR TEMP °C Displays intake air temperature at the time a malfunction is detected.

Show B1: No. 1 and 4 cylinders, B2: No. 2 and 3 cylinders.

EC-47 TB45 ENGINE

 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 C/U input/output 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 rpm Engine speed computed from crankshaft angle sensor signal
Air flow meter bank 1 V 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 1
Coolant emperature sensor °C Value converted into temperature calculated from the output voltage of the engine
coolant temperature sensor
Oxygen sensor bank 1 V Output voltage of heated oxygen sensor
Oxygen sensor monitor bank 1 Lean/Rich 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 V Battery voltage for ECCS C/U
ETC accelerator sensor 1 V Value converted to the accelerator opening angle from output voltage of the
accelerator sensor.
ETC accelerator sensor 2
ETC throttle sensor 1 V Value converted to the throttle opening angle from output voltage of the throttle
ETC throttle sensor 2 sensor.

Intake air temperature sensor °C Value converted to the intake air temperature from the output of air temperature
sensor.
Idle SW ON/OFF ON/OFF status as judged by each input signal
A/C signal
Neutral SW
Electric load signal
Fuel changing SW 1
Fuel changing SW 2
Ignition SW
Brake SW
Injection pulse width bank 1 ms Value calculated by ECCS C/U
LPG injection width
Ignition timing BTDC
Fuel pump relay ON/OFF Status of each control as calculated by ECCS C/U
Throttle relay
LPG fuel injection relay
Oxygen sensor heater bank 1
TAS learning history Done/Not done Status of TAS leaning
Vehicle speed sensor km/h Value calculated from the vehicle speed sensor signal
Precise vehicle speed km/h Precise value calculated from the vehicle speed sensor signal
Speed limit value km/h Value calculated from the speed limit input signal (by ECCS C/U)
Oxygen sensor heater % Duty ratio of oxygen sensor heater
Real time DTC - Real time display of trouble code
Basic injection amount ms Value calculated from the air flow meter signal and engine speed (by ECCS C/U)

EC-48 TB45 ENGINE

 Monitor item Unit Description

LPG basic injection amount ms Value calculated from the air flow meter signal and engine speed (by ECCS C/U)
Filling efficiency % Value converted to filling efficiency from aerometer output voltage
LPG filling efficiency
Fuel type 0/1/2 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)

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

ECM0365

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 C/U 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 • Allows setting a correction coefficient for retarding (-10 - 0°)
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

 Service Tool (Cont'd)
8. CONTROL UNIT PART NUMBER
Displays part number of ECCS C/U 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 with 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.

EC-50 TB45 ENGINE

 Self-diagnosis Function (without Service Tool)
(Cont'd)

ECM0282

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).

EC-51 TB45 ENGINE

 Self-diagnosis Function (without Service tool)
(Cont'd)

• 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.

ECM0284

DISPLAY ITEM LIST

DTC
(code Diagnosis item Malfunction Return Condition MIL Trip
number)
0000 No trouble • No malfunction is detected in any of the circuits. - -
0102 Air flow sensor signal circuit • When engine is stopped (ignition switch ON) and mass air ON 1
0103 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.
0117 Coolant temperature sensor • Engine coolant temperature sensor output voltage has been ON 2
0118 signal circuit approximately 4.8V or more (open) or less than 0.04V
(short) for predetermined period.
0122 1225 Throttle position sensor signal • Sensor power supply voltage has a malfunction. ON* 1
0123 1226 circuit • Throttle position sensor signal circuit is open or shorted.
0222 1229 • A malfunction occurs in relation between throttle position
0223 2135 sensors 1 and 2.
• When the fully-closed position learning value was unusually - 2
small or was not able to learn.
2122 2138 Acceleration sensor signal • Accelerator pedal position sensor signal circuit is open or ON* 1
2123 2128 circuit shorted.
2127 • A malfunction occurs in relation between accelerator pedal
position sensors 1 and 2.
0134 Heated oxygen sensor (open • When traveling after warming up the engine, oxygen sensor ON 2
circuit) signal circuit is open.
0132 Heated oxygen sensor signal • When traveling after warming up the engine, oxygen sensor ON 2
(short circuit) output voltage is higher than normal (2V or more).
0031 Heated oxygen sensor heater
• Oxygen sensor signal circuit is open.
ON 2
0032 signal circuit
0335 Crankshaft position sensor 120 • The crankshaft position sensor (POS) signal is not detected ON 2
deg. (REF) signal circuit for a predetermined time at the engine start or during engine
running (when inputting (REF) signal).
• The crankshaft position sensor (POS) signal irregular
waveform is detected for a predetermined time during
engine running (when inputting (REF) signal).

EC-52 TB45 ENGINE

 DTC
(code Diagnosis item Malfunction Return Condition MIL Trip
number)
0340 Crankshaft position sensor 1 • At start-up no (REF) signal has been detected for more than ON 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).
0500 Vehicle speed signal circuit • Vehicle sensor signal has not been input under specific ON 2
conditions for a predetermined time during driving after
warming up.
0605 ECCS C/U • CPU or circuits in ECCS have a malfunction. ON* 1 or 2
1065 ECCS C/U power supply circuit • When no power supplied to the ECCS C/U for more than ON 2
specified period.
1121 Electric throttle control, actuator • When electronic controlled throttle has malfunctions due to ON* 1
circuit the mechanical trouble in the throttle system.
1122 Electric throttle control, • Correlation between the target throttle opening angle and ON* 1
feedback circuit the actual opening angle has become abnormal.
• Excessive current in throttle motor control circuit.
1124 Electric throttle control, motor ON* 1
1126 relay circuit • Open or short in the throttle motor power supply circuit.
1128
1217 Engine overheat • Normal status of coolant temperature circuit (Output voltage ON 1
of approx. 0.35V for more than specified period.)
0350 Ignition signal circuit • No continuous ignition signal while the engine is running. ON 2
1805 Stop lamp switch signal circuit • Stop lamp switch kept off more than specified time during ON 1
traveling.
1218 Engine overheat step #1 • Output voltage of coolant temperature sensor has been - 1
more than approx. 0.6V for specified time.
1240 1242 LPG injector signal circuit
• Abnormal current applied on the LPG injector.
ON 1
1241 1243
1245 LPG fuel pressure sensor
• LPG fuel pressure sensor circuit: OPEN
ON 1
signal, open-circuit
1249 LPG fuel pressure sensor • Short in the LPG fuel pressure sensor circuit. ON 1
signal, short-circuit • Pressure in fuel piping to the LPG injector has been raised
abnormally for the specified period.

EC-53 TB45 ENGINE

 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
after warming up engine and keeping engine speed at
approximately 2,000 rpm.
NOTE:
• Although air-fuel ratio feedback control is active at idle, increase
engine speed and check.

• During air-fuel ratio feedback control

ECM0285
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 C/U or input/
output values sent from ECCS C/U. 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

 Service Tool Reference Value in Data Monitor
(Cont'd)

Monitor item Measuring condition Reference value

Engine rpm Almost in accordance

Airflow meter bank 1 • After engine warming up At Idle Approx. 1.8 - 2.0V
• Selector lever: N
At approx. 2,000 rpm Approx. 2.5 - 2.8V
• No load
Basic fuel injection amount • After engine warming up At Idle Approx. 2.5 - 4 msec
• Selector lever: N
At approx. 2,000 rpm
• No load
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 -
0.4VÙ0.6 - 0.9V
Maintain at approx. 2,000 rpm Changes between approx. 0.1 -
0.4VÙ0.6 - 0.9V
Oxygen sensor monitor • After engine warming up At Idle Switches slowly between
bank 1 LEANÙRICH.
Maintain at approx. 2,000 rpm Switches between LEANÙRICH 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 • After 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 - 0.7V
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
sensor • Ignition switch: ON (Engine not
Other than above OFF
running)
Idle SW • Ignition switch: ON Accelerator pedal: released ON
Accelerator pedal: fully depressed OFF
Neutral SW • Ignition switch: ON N range ON
Other than above OFF
Electric load signal • Ignition switch: ON Head light switch: ON ON
Head light switch: OFF OFF
Ignition SW • Ignition switch: ON / OFF ON / 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
Ignition timing • After engine warming up At Idle Approx. 10°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
• Other than above OFF

EC-55 TB45 ENGINE

 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 completed.
• Selector lever: N
Idle 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.

Malfunction
Related sensors Fail-safe Warning light
condition

Mass air flow sensor Same as self- • Selects fuel injection pulse width depending on engine speed ON
diagnosis and throttle position so the vehicle can be driven. However, fuel
malfunction detection injection will be inhibited (fuel cut-off) when engine speed
conditions. exceeds approximately 800 rpm.
• Idle 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

 POWER SUPPLY AND GROUND SYSTEM
POWER SUPPLY AND GROUND SYSTEM

(1) Control Unit Input/Output Signal

Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.

Terminal Signal name Measurement condition Measured value

111 ECCS & IGN coil relay For approximately 10 seconds with Approx. 1V
ignition switch ON and after ignition
switch OFF
Approximately 10 seconds or more after Battery voltage
ignition switch OFF
109 Ignition switch Ignition switch ON
119 Power supply for ECM
120
121 Power supply for ECM (Back-up) Always
1 Ground Approx. 0V
115
116

(2) Circuit Diagram

ECM0286

EC-57 TB45 ENGINE

 CRANKSHAFT POSITION SENSOR 1° (POS)
CRANKSHAFT POSITION SENSOR 1° (POS)

(1) Control Unit Input/Output Signal

Specifications
Check waveform between terminals shown below and ground using
an oscilloscope.

Terminal Signal name At cranking At idle after warming up At approx. 2,000 rpm

13 Crankshaft position At cranking: Approx. 2.6V At idling: Approx. 2.5V Approx. 2.5V
sensor 1° (POS)

ECM0287 ECM0288 ECM0289

Numerical values (reference values) are obtained using an analog

circuit tester.

(2) Circuit Diagram

ECM0290

(3) Component Parts Inspection

1. CRANKSHAFT POSITION SENSOR
• Remove distributor (with the harness connector connected)
from the engine.
• Turn ignition switch ON.
• Slowly turn the crankshaft position sensor shaft by hand and
check voltage between terminal 3 and ground.
3 - Ground (1° signal):
Approx. 0.2 or 5V
CAUTION:
• Check voltage after disconnecting the injector fuse to
inhibit injector operation.
ECM0291
Malfunctions may or may not be accurately detected by
self-diagnosis depending on how the shaft is turned. Note
that there is no malfunction in this case.

EC-58 TB45 ENGINE

 CRANKSHAFT POSITION SENSOR 120° (REF) SIGNAL CIRCUIT
CRANKSHAFT POSITION SENSOR 120° (REF) SIGNAL CIRCUIT

(1) Control Unit

Input/Output Signal Specifications
Check waveform between terminals shown below and ground using
an oscilloscope.
Numerical values (reference values) are obtained using an analog
circuit tester.

Terminal Signal name At cranking At idle after warming up At approx. 2,000 rpm

14 Crankshaft position At cranking: Approx. 0.5V At idling: Approx. 0.5V Approx. 0.5V
sensor 120° (REF)

ECM0292 ECM0293 ECM0294

(2)Circuit Diagram

ECM0295

(3) Component Parts Inspection

1. CRANKSHAFT POSITION SENSOR
• Remove distributor (with the harness connector connected)
from the engine.
• Turn ignition switch ON.
• Slowly turn the crankshaft position sensor shaft by hand and
check voltage between terminal 4 and ground.
4 - Ground (120° signal): Approx. 0.2 or 5V
CAUTION:
• Check voltage after disconnecting the injector fuse to
inhibit injector operation.
Malfunctions may or may not be accurately detected by
ECM0296
self-diagnosis depending on how the shaft is turned. Note
that there is no malfunction in this case.

EC-59 TB45 ENGINE

 MASS AIR FLOW SENSOR SYSTEM
MASS AIR FLOW SENSOR SYSTEM

(1) Service Tool Data Monitor Display

Monitor item At idle after warming up At approx. 2,000 rpm

Airflow meter bank 1 Approx. 1.8 - 2.0V Approx. 2.2 - 2.5V

(2) Control Unit Input/Output Signal

Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.

Terminal Signal name At cranking At idle after warming up At approx. 2,000 rpm

51 Mass air flow sensor Approx. 1.5V Approx. 1.8 - 2.0V Approx. 2.2 - 2.5V
67 Mass air flow sensor
Approx. 0V
ground

(3) Circuit Diagram

ECM0297

(4) Component Parts Inspection

1. MASS AIR FLOW SENSOR
1. Remove mass air flow sensor.
2. Turn ignition switch to ON. While blowing air into the mass air
flow sensor from the air cleaner case side, check output voltage
between terminal 3 and ground.
No air blowing:
Approx. 1V
With air blowing:
Approx. 1.3V
(The more the air is blown, the higher the voltage is.)
NOTE:
ECM0298
• If air is blown from the air duct side, the voltage becomes lower.

EC-60 TB45 ENGINE

 ENGINE COOLANT TEMPERATURE SENSOR SYSTEM
ENGINE COOLANT TEMPERATURE SENSOR SYSTEM

(1) Service Tool data monitor display

Monitor item At Idle At approx. 2,000 rpm

COOLANT TEMP/S After warming up engine: Approx. 80°C (176°F) or more

(2) Control Unit Input/Output Signal

Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.
At approx. 2,000
Terminal Signal name At Idle
rpm

73 Engine coolant Engine coolant temperature at approx. 20°C

temperature sensor (68°F): Approx. 3.5V
Engine coolant temperature at approx. 80°C
(176°F): Approx. 1.2V

NOTE:
• If engine coolant temperature sensor has a malfunction, the
value of engine coolant temperature signal is changed along
with start-up time by fail-safe to enable normal operation.

(3) Circuit Diagram

ECM0300

(4) Component Parts Inspection

1. ENGINE COOLANT TEMPERATURE SENSOR
Check resistance between terminals 1 and 2 on the engine coolant
temperature sensor.
Resistance
Coolant temperature at approx. 20°C (68°F):
Approx. 2.5 kΩ
Coolant temperature at approx. 80°C (176°F):
Approx. 0.3 kΩ

EC-61 TB45 ENGINE

 HEATED OXYGEN SENSOR SYSTEM
HEATED OXYGEN SENSOR SYSTEM

(1) Service Tool Data Monitor Display

Monitor item At idle after warming up At approx. 2,000 rpm

Oxygen sensor bank 1 Changes between approx. 0.1 - 0.4VÙapprox. 0.6 - 0.9V
Oxygen sensor monitor bank 1 RICH and LEAN alternate slowly. RICH and LEAN alternate at least 5 times in
10 seconds.

(2) Control Unit Input/Output Signal

Specifications
Check waveform between terminals shown below and ground using
an oscilloscope.

Terminal Signal name At idle after warming up At approx. 2,000 rpm

35 Heated oxygen sensor Air conditioner OFF Changes between approx. 0 - 0.3V"
: Clamps between approx. 0 - 0.7V. approx. 0.5 - 1.0V
Air conditioner ON
: Changes between approx. 0 - 0.3V"
approx. 0.5 - 1.0V

ECM0302 ECM0303

Numerical values (reference values) are obtained using an analog

circuit tester.

(3) Circuit Diagram

ECM0304

EC-62 TB45 ENGINE

 VEHICLE SPEED SENSOR SYSTEM
VEHICLE SPEED SENSOR SYSTEM

(1) Service Tool Data Monitor Display

Monitor item At Idle Driving

Vehicle speed sensor Almost in accordance with the speedometer display

(2) Control Unit Input/Output Signal

Specifications
Check waveform between terminals shown below and ground using
an oscilloscope.

Terminal Signal name At Idle Vehicle running at approx. 40 km/h

33 Vehicle speed signal Approx. 4.6V or 0V Approx. 2.3V

ECM0305

3) Circuit Diagram

EC-63 TB45 ENGINE

 THROTTLE POSITION SENSOR SYSTEM
THROTTLE POSITION SENSOR SYSTEM

(1) Service Tool Data Monitor Display

Monitor item At idle after warming up At approx. 2,000 rpm

ETC throttle sensor 1 Approx. 0.6V Approx. 0.7V

ETC throttle sensor 2 Approx. 4.5V Approx. 4.4V

(2) Control Unit Input/Output Signal

Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.

Terminal Signal name At idle after warming up At approx. 2,000 rpm

47 Sensor power supply (Throttle position sensor) Approx. 5V

66 Sensor ground (Throttle position sensor) Approx. 0V
50 Throttle position sensor 1 Approx. 0.6V Approx. 0.7V
69 Throttle position sensor 2 Approx. 4.5V Approx. 4.4V

(3) Circuit Diagram

ECM0307

(4) Component Parts Inspection

1. THROTTLE POSITION SENSOR 1, 2 (ELECTRIC
THROTTLE CONTROL ACTUATOR ASSEMBLY)
Check voltage between ECCS C/U terminal 50, 69 and ground.
Refer to EC section, "Control Unit Input/Output Signal
Specifications" for the voltage.
CAUTION:
• Make sure that there is no moisture around connector
when removing and installing throttle position sensor
connector. If there are any water drops, completely wipe
ECM0308
them off.
• Do not apply voltage to throttle position sensor terminal.
• Perform "Throttle Valve Closed Position Learning" if
disconnecting connector. Perform if replacing electric
throttle control actuator. (Refer to EC section, "Throttle
Valve Closed Position Learning and Idle Air Volume
Learning".)
• Do not disassemble electric throttle control actuator.

EC-64 TB45 ENGINE

 ACCELERATOR PEDAL POSITION SENSOR SYSTEM
ACCELERATOR PEDAL POSITION SENSOR SYSTEM

(1) Service Tool Data Monitor Display

Monitor item At Idle At approx. 2,000 rpm

ETC accelerator sensor 1 Approx. 0.6V Approx. 0.65V

ETC accelerator sensor 2 Approx. 0.3V approx. 0.35V

(2) Control Unit Input/Output Signal

Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.

Terminal Signal name At Idle At approx. 2,000 rpm

82 Sensor ground Approx. 0V

83 Accelerator pedal position sensor 2 ground Approx. 0V
90 Sensor power supply Approx. 5V
91 Accelerator pedal position sensor 2 power supply Approx. 2.5V
98 Accelerator pedal position sensor 2 Approx. 0.3V Approx. 0.35V
106 Accelerator pedal position sensor 1 Approx. 0.6V Approx. 0.65V

NOTE:
• When the accelerator pedal is depressed slowly from the fully-
closed position, the voltage must increase in proportion to the
opening of the throttle. [Ignition switch ON (engine stopped)]

Ignition switch ON with engine Ignition switch ON with engine

Terminal Signal name stopped Accelerator pedal is fully stopped Accelerator pedal is fully
depressed released

98 Accelerator pedal position sensor 2 Approx. 0.3V Approx. 2V

106 Accelerator pedal position sensor 1 Approx. 0.6V Approx. 4.2V

(3) Circuit Diagram

ECM0309

EC-65 TB45 ENGINE

ACCELERATOR PEDAL POSITION SENSOR / INTAKE AIR TEMPERATURE
ACCELERATOR PEDAL POSITION SENSOR / INTAKE AIR TEMPERATURE SENSOR

(4) Component Parts Inspection

1. ACCELERATOR PEDAL POSITION SENSORS 1, 2
(ACCELERATOR WORK UNIT)
Check voltage between ECCS C/U terminal 98, 106 and ground.
Refer to EC section, "Control unit Input/Output Signal Specifications"
for the voltage.
CAUTION:
• Do not apply voltage to accelerator pedal position sensor
terminal.
• Do not disassemble accelerator work unit.
ECM0310

(1)Service Tool Data Monitor Display

Monitor item Engine at Idle Approx. 2,000 rpm

Intake air temperature sensor Similar to ambient air temperature

(2)Control Unit Input/Output Signal

Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.

Terminal Signal name Engine at Idle Approx. 2,000 rpm

34 Intake air temperature Similar to ambient air temperature

(3)Circuit Diagram

(4)Component Parts Inspection

1. Air Intake temperature sensor (with airflow meter)
Measure the resistance between terminal 3 and terminal 5 on the
sensor (airflow meter connector)

Resistance:
Air intake temperature - approx. 20°C: approx 2.5KΩ
Air intake temperature - approx. 80°C: approx 0.3KΩ

EC-66 TB45 ENGINE

 PNP SWITCH SYSTEM
PNP SWITCH SYSTEM

(1) Service Tool Data Monitor Display

Monitor item Neutral or N/P position Other than the left

Neutral SW ON OFF

(2) Control Unit Input/Output Signal

Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.

Terminal Signal name Neutral or N/P position Other than the left

102 PNP switch Approx. 0V Battery voltage (A/T models)

Approx. 4.8V (M/T models)

(3) Circuit Diagram

ECM0313

(4) Component Parts Inspection

1. INHIBITOR SWITCH
Refer to “INHIBITOR SWITCH".

2. NEUTRAL SWITCH
Refer to "POSITION SWITCH".

EC-67 TB45 ENGINE

 STOP LAMP SWITCH SYSTEM
STOP LAMP SWITCH SYSTEM

(1) Service Tool Data Monitor Display

Monitor item Brake pedal released Brake pedal depressed

BRAKE SW OFF ON

(2) Control Unit Input/Output Signal

Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.

Terminal Signal name Brake pedal released Brake pedal depressed

101 Stop lamp switch Approx. 0V Battery voltage

(3) Circuit Diagram

ECM0314

(4) Component Parts Inspection

1. STOP LAMP SWITCH
Check continuity between stop lamp switch terminals 1 and 2.
Brake pedal released:
Continuity should not exist.
Brake pedal depressed:
Continuity should exist.

ECM0315

EC-68 TB45 ENGINE

 ELECTRIC LOAD SWITCH SYSTEM
ELECTRIC LOAD SWITCH SYSTEM

(1) Special Tool Data Monitor Display

Monitor item Headlamp switch OFF Headlamp switch ON

Electric load signal OFF ON

(2) Control Unit Input/Output Signal

Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.

Terminal Signal name Headlamp switch OFF Headlamp switch ON

84 Headlamp switch Approx. 0V Battery voltage

(3) Circuit Diagram

ECM0316

EC-69 TB45 ENGINE

 IGNITION SYSTEM
IGNITION SYSTEM

(1) Service Tool Data Monitor Display

Monitor item At idle after warming up At approx. 2,000 rpm

Ignition timing Approx. 10°BTDC Approx. 35 - 45°BTDC

(2) Control Unit Input/Output Signal

Specifications
Check waveform between terminals shown below and ground using
an oscilloscope.

Terminal Signal name At cranking At idle after warming up At approx. 2,000 rpm

62 Ignition signal (power Approx. 0.5V Approx. 0.5V Approx. 0.9V

transmission drive
signal)

ECM0317 ECM0318 ECM0319

Numerical values (reference values) are obtained using an analog

circuit tester.

(3) Circuit Diagram

ECM0320

(4) Component Parts Inspection

1. SPARK PLUG
• Check electrode for dirt, damage, and wear and insulator for
damage.
• Replace spark plug if necessary.
CAUTION:
• Check terminals for looseness.
• Check insulator for cracks or damage.
• Check for contamination by oil, water, and dust.
• Make sure that the spark plug gap is normal, using a feeler
gauge.
ECM0321
Spark plug gap:
0.8 - 0.9 mm (0.031 - 0.035 in)

EC-70 TB45 ENGINE

 IGNITION SYSTEM

Component Parts Inspection (Cont'd)

2. POWER TRANSISTOR
• Check resistance between terminals of the power transistor by
applying and exchanging (+ and -) the inspection rods of an
analog circuit tester.
Inspection Terminals and Results (at room temperature)
Positive probe to 8 and negative probe to 7:
Except 0 or ∞Ω
Positive probe to 7 and negative probe to 8:
Except 0 or ∞Ω
Positive probe to 5 and negative probe to 8:
ECM0322 Except 0 or ∞Ω
Positive probe to 8 and negative probe 5:
∞Ω
Positive probe to 7 and negative probe 5:
∞Ω
Positive probe to 5 and negative probe to 7:
Except 0 or ∞Ω
CAUTION:
• Do not use a digital circuit tester because the standard is
different.

• Check distribution functions (rotor and distributor cap) of the

distributor.
3. IGNITION COIL
• Check resistance of the following:
Primary coil resistance (5 - 6):
Approx. 2.2 kΩ
Secondary coil resistance:
Approx. 11.5 kΩ
(Between coil tower tip metal and 6 with the distributor
cap removed.)

ECM0323

4. HIGH-TENSION CABLE
1. Removal and installation
1) Remove intake manifold cover.
2) Disconnect spark plug side.
3) Disconnect distributor side and remove high-tension cable.

CAUTION FOR INSTALLATION

• Securely install distributor cap and high-tension code when
matching both cylinder numbers.

2. Inspection
• Check resistance of high-tension cable.
For No. 1 cylinder: Approx. 2.7 kΩ
For No. 2 cylinder: Approx. 2.8 kΩ
For No. 3 cylinder: Approx. 4 kΩ
For No. 4 cylinder: Approx. 5 kΩ
For No. 5 cylinder: Approx. 5.2 kΩ
For No. 6 cylinder: Approx. 6.1 kΩ

EC-71 TB45 ENGINE

 FUEL INJECTOR SYSTEM
FUEL INJECTOR SYSTEM

(1) Service Tool Data Monitor Display

Monitor item At idle after warming up At approx. 2,000 rpm

Injection pulse width bank 1 Approx. 4 - 6 msec

(2) Control Unit Input/Output Signal

Specifications
Check waveform between terminals shown below and ground using
an oscilloscope.

Terminal Signal name At cranking At idle after warming up At approx. 2,000 rpm

21 Injector drive signal Approx. 10.5V Battery voltage Relatively lower than battery
22 voltage
23
40
41
42

ECM0324 ECM0325
ECM0326

Numerical values (reference values) are obtained using an analog

circuit tester.

(3) Circuit Diagram

ECM0327

(4) Component Parts Inspection

1. FUEL INJECTOR
• Check resistance between each cylinder injector terminals 1
and 2.
Standard resistance (all cylinders):
Approx. 14.5Ω; (at room temperature)

ECM0328

EC-72 TB45 ENGINE

 FUEL PUMP SYSTEM
FUEL PUMP SYSTEM

(1) Service Tool Data Monitor Display

Monitor item Fuel pump is not activated Fuel pump is operated

Fuel pump relay OFF ON

(2) Control Unit Input/Output Signal

Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.

For approx. 1 second after ignition

Terminal Signal name At cranking, engine running
switch is turned ON

113 Fuel pump relay Approx. 1V Approx. 1V

(After approx. 1 second: Battery voltage)

(3) Circuit Diagram

ECM0329

(4) Component Parts Inspection

1. FUEL PUMP
Check resistance between terminals 3 and 6.
Resistance: Approx. 1Ω (at room temperature)

EC-73 TB45 ENGINE

 ENGINE WARNING LIGHT SYSTEM
ENGINE WARNING LIGHT SYSTEM

(1) Control Unit Input/Output Signal

Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.

Terminal Signal name Warning lamp ON Warning lamp OFF

30 Engine warning light Approx. 0.1V Battery voltage

Circuit Diagram

ECM01

EC-74 TB45 ENGINE

 HEATED OXYGEN SENSOR HEATER SYSTEM
HEATED OXYGEN SENSOR HEATER SYSTEM

(1) Service Tool Data Monitor Display

Monitor item At idle after warming up

Oxygen sensor heater bank 1 ON

(2) Control Unit Input/Output Signal

Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.

Terminal Signal name At idle after warming up Approx. 3,600 rpm or more

24 Heated oxygen sensor heater open signal Approx. 0.3V Battery voltage

(3) Circuit Diagram

ECM01

(4) Component Parts Inspection

1. HEATED OXYGEN SENSOR HEATER
Check resistance between heated oxygen sensor terminals 2 and 3.
Resistance: Approx. 3.3 - 3.5Ω

ECM02

EC-75 TB45 ENGINE

 LPG INJECTOR SYSTEM
LPG INJECTOR SYSTEM

(1)Control Unit Input/Output Signal

specifications
Check waveform between terminals shown below and ground using
an oscilloscope.

ECCU C/U Switching

Terminal module Signal name At idling
Terminal
8 2 LPG injector drive Approx. 3V
9 The time axis may be
altered according to the data
setting and/or operating
conditions.

72 3 LPG injector check Slightly lower than battery voltage

53 The time axis may be altered
according to the data setting
and/or operating conditions.

- 6 LPG injector drive (L) Similar to battery voltage

The time axis may be altered
according to the data setting
and/or operating conditions.

44 8 LPG injector drive absorbing Approx. 5V

63 The time axis may be altered
according to the data setting
and/or operating conditions.

39 9 LPG injector drive retaining Approx. 5V

The time axis may be altered
according to the data setting
and/or operating conditions.

- 12 LPG injector drive (H) Battery voltage

The time axis may be altered
according to the data setting
and/or operating conditions.

EC-76 TB45 ENGINE

LPG INJECTOR SYSTEM

(2)Circuit Diagram

(3)Component Parts Inspection

LPG injector
• Check resistance between terminal 1 and terminal 2.
Resistance: approx. 1Ω (at normal temperature)
• Check the fuse for open by removing fuse cover.
CAUTION:
• Do not apply voltage to the LPG injector.

EC-77 TB45 ENGINE

 THROTTLE CONTROL MOTOR SYSTEM
THROTTLE CONTROL MOTOR SYSTEM

(1) Control Unit Input/Output Signal

Specifications
Measure voltage between terminals shown below and ground using
a circuit tester.

Terminal Signal name At idle after warming up At approx. 2,000 rpm

5 Throttle control motor 2 (Close) Approx. 2 - 2.5V

4 Throttle control motor 1 (Open) Approx. 0.1 - 0.15V

(2) Circuit Diagram

ECM0330

(3) Component Parts Inspection

1. ELECTRIC THROTTLE CONTROL MOTOR
(ELECTRIC THROTTLE CONTROL ACTUATOR
ASSEMBLY)
Check resistance between electric throttle control motor (throttle
position sensor connector) terminals 3 and 6.
Resistance: Approx. 1 -15Ω; [at 25°C (77°F)]
CAUTION:
• Make sure that there is no moisture around connector
when removing and installing throttle position sensor
ECM0332 connector. If there are any water drops, completely wipe
them off.
• Do not apply voltage to electric throttle control motor
terminal.
• Perform "Throttle Valve Closed Position Learning" if
disconnecting connector. Perform "Throttle Valve Closed
Position Learning" and “TAS learning” if replacing electric
throttle control actuator. (Refer to EC section), "Throttle
Valve Closed Position Learning and TAS Learning".)
• Do not disassemble electric throttle control actuator.

EC-78 TB45 ENGINE

LPG FUEL PRESSURE SENSOR SYSTEM
LPG FUEL PRESSURE SENSOR SYSTEM

(1)Control Unit Input/Output Signal

Reference
Check wave form between following terminal and ground, using an
oscilloscope.

Terminal Signal name At Idle

31 LPG fuel pressure sensor 2.5V

(2)Circuit Diagram

EC-79 TB45 ENGINE

LPG ASSISTANCE INJECTOR SYSTEM
LPG ASSISTANCE INJECTOR SYSTEM

(1)Control Unit Input/Output Signal

Specifications
Check waveform between following terminal and ground using an
oscilloscope.

Terminal Signal name At Idle

11 LPG assistance injector Battery voltage

(2)Circuit Diagram

ECM0349

(3)Component Parts Inspection

• Check resistance between terminal 1 and terminal 2.

Resistance: approx. 27Ω (at normal temperature)
• Directly apply battery voltage between terminal 1 and terminal
2, and check function of the solenoid..

Battery voltage between 1 and 2 terminals: Continuity

No voltage between 1 and 2 terminals: No continuity

EC-80 TB45 ENGINE

BLOWBY GAS RESTORATION DEVICE
BLOWBY GAS RESTORATION DEVICE

(1) System Diagram

ECM0350

(2) Removal and Installation of Blowby

Control Valve
1. Remove and install blowby control hose.
2. Remove and install Blowby control valve.

(3) Blowby Control Valve Inspection

• Hissing noises should be heard from the air passage of the
valve.
• Check continuity when blowing/sucking air to/from Blowby
control valve rocker cover side.
Blowing air: Air flow exists
Sucking air: No air flow

ECM0353

EC-81 TB45 ENGINE

 FUEL CUT FUNCTION
FUEL CUT FUNCTION

Inspection Procedure
WITH SERVICE TOOL
1. Check "injection pulse width bank 1" (Gasoline) or “LPG fuel
injection width” (LPG spec.) in Data Display menu and increase
the engine speed to approximately 2,400 rpm after warming up
engine.
2. Make sure that "injection pulse width bank 1" (Gasoline) or
“LPG fuel injection width” (LPG spec.) instantly drops when
accelerator pedal is released.
WITHOUT SERVICE TOOL
1. Warm up the engine sufficiently.
2. Disconnect harness connector of the injector and connect a test
lamp.
3. Release the accelerator pedal at the engine speed of
approximately 2,400 rpm or more, and confirm test lamp goes
out for a moment.

ECM0354

EC-82 TB45 ENGINE

REMOVAL AND INSTALLATION OF ECCS COMPONENTS
REMOVAL AND INSTALLATION OF ECCS COMPONENTS

(1) Removal and Installation of ECCS Control

Unit
1. Disconnect ECCS connector.
2. Remove ECCS C/U..
3. Install in the reverse order of removal.
CAUTION:
• Perform "Throttle Valve Closed Position Learning and TAS
Learning" after installation if replacing ECCS control unit.
(Refer to EC section, "Throttle Valve Closed Position
Learning and TAS Learning".)
CAUTION:
ECM0355 • When installing ECCS C/U, confirm that pin is not damaged
nor bent.

(2) Removal and Installation of Crankshaft

Position Sensor (Integrated Into the
Distributor)
Refer to EM section, "Removal and Installation".

(3) Removal and Installation of Mass Air

Flow Sensor
1. Remove harness connector.
2. Remove mass air flow sensor assembly from air horn.

ECM0391

(4) Removal and Installation of Engine

Coolant Temperature Sensor
1. Disconnect radiator drain plug, and drain coolant.
CAUTION:
• Make sure to drain when the coolant temperature is cold.

2. Remove harness connector.

3. Remove coolant temperature sensor using a socket specially
designed for removing and installing coolant temperature
sensors [commercially available: thermosensor socket
manufactured by KTC (part No.: B20T-19)] and similar parts.

ECM0392

EC-83 TB45 ENGINE

 REMOVAL AND INSTALLATION OF ECCS COMPONENTS

(5) Removal and Installation of Heated

Oxygen Sensor (With Heated Oxygen Sensor
Heater)
1. Remove harness connector from hearted oxygen sensor.
2. Remove heated oxygen sensor using a socket designed for
heated oxygen sensor removal and installation (Service Tool).
CAUTION:
• Handle it carefully and avoid impacts.

(6) Removal and Installation of Throttle

Position Sensor (Electric Throttle Control
Actuator Assembly)
1. REMOVAL
Screw 1. Remove air duct from air horn.
Bolt 2. Remove harness connector.
Mass air flow
senso CAUTION:
• Also, remove harness connectors of mass air flow sensor,
LPG injector, and LPG fuel pressure sensor so that when
Air horn removing and installing air horn, LPG injection holder (LPG
and Combined) is performed at the same time.

3. Loosen bolts diagonally, remove air horn, LPG injection holder

(LPG or Combined) or air horn spacer (Gasoline), and then
remove electric throttle control actuator.

LPG injector holder

(LPG and combined use)

Electric throttle
control actuator

ECM0374

2. INSTALLATION
1) CAUTION FOR INSTALLATION
• Uniformly tighten bolts diagonally in several steps.
CAUTION:
• Make sure that there is no moisture around connector
when removing and installing throttle position sensor
connector. If there are any water drops, completely wipe
them off.
• Do not apply voltage to throttle position sensor terminal.
• Perform "Throttle Valve Closed Position Learning" if
disconnecting connector. Perform “Throttle Valve Closed
Position Learning and TAS learning" if replacing electric
throttle control actuator. (Refer to EC section, "Throttle
Valve Closed Position Learning and TAS Learning".)
• Do not disassemble electric throttle control actuator.

EC-84 TB45 ENGINE

REMOVAL AND INSTALLATION OF ECCS COMPONENTS

(7) Removal and Installation of Accelerator

Pedal Position Sensor (Accelerator Pedal
Assembly)
Refer to "Removal and Installation".
CAUTION:
• Do not disassemble accelerator pedal assembly and
remove sensors and switches.

(8) Removal and Installation of Intake Air

Temperature Sensor (With Mass Air Flow
Sensor)
• Refer to EC section, "Removal and Installation of Mass Air Flow
Sensor" because intake air temperature sensor is joined with
mass air flow sensor.

(9) Removal and Installation of Ignition Coil

(Integrated in Distributor)
Refer to EM section, "Removal and Installation".

(10) Removal and Installation of Fuel Injector

Refer to EF section, "Removal and Installation".

(11) Removal and Installation of Fuel Pump

Refer to FL section, "Fuel Gauge, Fuel Filter, and Fuel Pump
Assembly".

(12) Removal and Installation of Throttle

Control Motor (Electric Throttle Control
Actuator Assembly)
Refer to EF section, "Removal and installation of throttle position
sensor (electric throttle control actuator assembly)".

EC-85 TB45 ENGINE

 REMOVAL AND INSTALLATION OF ECCS COMPONENTS

(13) Removal and Installation of LPG Injector

Holder
1. REMOVAL
Screw
1.0 - 2.0 1. Remove air duct from air horn.
Bolt (0.1 - 0.2, 2. Remove harness connectors of mass air flow sensor, LPG
22 - 37 9 - 17)
Mass air flow
injector, and LPG fuel pressure sensor.
(2.2 - 3.8,
16 - 27) sensor 3. Loosen bolts in turn, remove air horn, and then remove injector
holder.
Air horn
2. INSTALLATION
1. Caution for installation
• Uniformly tighten bolts diagonally in several steps.
CAUTION:
• Make sure that there is no moisture around connector
when removing and installing each connector. If there are
LPG injector holder any water drops, completely wipe them off.
(LPG and combined use)
• Do not apply voltage to each terminal.

Electric throttle
control actuator

N m (kg-m, ft-lb)
N m (kg-m, in-lb)
ECM0375

(14) LPG Injector Drive Unit

1. HOW TO DISCONNECT LPG INJECTOR DRIVE
UNIT CONNECTOR
1. Pull center of lever forward, and then disconnect tab from lever
and lift it up.
2. Raise the lever until it clicks, and fully press the lever to drive
unit side.
3. Pull connector forward, and then disconnect it from unit.

2. HOW TO CONNECT LPG INJECTOR DRIVE UNIT

CONNECTOR
1. Press the lever in drive unit connector while pressing it to
connector end.
ECM0363
2. Press in the lever until it clicks.
3. Raise the lever until it clicks, engage the tabs to the back of the
lever and connector, and then securely connect them.

EC-86 TB45 ENGINE

 SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)

(1) Standard, Repair Limit

Fuel pressure [MPa (bar, kg/cm2, psi)] 0.35 (3.53, 3.6, 51)

Idle speed (rpm) N position 675±50

Ignition timing (°BTDC/rpm) N position 10±2/675
Firing order 1-5-3-6-2-4
Spark plug Manufacturer/type/gap [mm (in)] BPR4ES [0.8 - 0.9 (0.31 - 0.35)]
Ignition advance device Electronically controlled ignition advance
Density of CO at idle speed (%) /Density of HC at idle speed (ppm) 0.1/50 or less

EC-87 TB45 ENGINE