Table of Contents

Mercado Indonesio (2019-)

Mercado Tailandes/SudAmerica (2019-)

Mercado Chino(2018-)

Mercado Indio (2019-)

 Table of Contents

Chapter 9 Engine/Propulsion
9.1 Engine Starting and Charging ............................ 7 (210561) 44
9.1.1 Specifications ................................. 7 9.2.3.5 DTCP042000 ............................... 48
9.1.1.1 Fastener Tightening Specifications 7 9.2.3.6 DTCP050000 ............................... 49
9.1.1.2 General Specifications ................... 8 9.2.3.8 DTCU007700 ............................... 52
9.1.2 Schematic and Routing Diagrams . 9 9.2.3.9 DTCU012200 ............................... 53
9.1.2.1 Starting and Charging .................... 9 9.2.3.10 DTCU011600 ............................... 53
9.1.3 Diagnostic Information and 9.2.3.11 DTCP032716 ............................... 54
Procedures 11 9.2.3.12 DTCU000100 ............................... 56
9.1.3.1 Battery Common Causes of 9.2.3.13 DTCP000A71, P000A77, P001013,
Malfunction (37571)................................................... 11 P001200, P001621, P001622, P001629, P034100,
9.1.3.2 Battery Electrical Drain/Parasitic P208811 or P208912 ................................................ 58
Load Test (37588) ..................................................... 11 9.2.3.14 DTCP000B71, P000B77, P001313,
9.1.3.3 Battery Inspection/Test (37781) ... 13 P001500, P001821, P001822, P001829, P034600,
9.1.3.4 Charging System Test (37782) .... 15 P209011 or P209112 ................................................ 60
9.1.3.5 Jump Starting in Case of 9.2.3.15 DTCP003013, P003111, P003212
Emergency (37522) ................................................... 15 or P00531E 63
9.1.3.6 Symptoms - Engine Electrical 9.2.3.16 DTCP003300, P003400, P003500
(37791) 17 or P226100 65
9.1.3.7 Battery Charging (37464) ............. 17 9.2.3.17 DTCP003613, P003711, P003812
or P00541E 67
9.1.4 Repair Instructions ....................... 20
9.2.3.18 DTCP009629, P009716, P009817,
9.1.4.3 Battery Negative Cable P023621, P023622, P023629, P02362A, P023711 or
Replacement (37760) ................................................ 21 P023815 69
9.1.4.4 Battery Positive Cable Replacement 9.2.3.19 DTCP010528, P010600, P010711,
(B15T - MT) 22 P010812, P011129, P011216 or P011317............... 72
9.1.4.7 Battery Replacement (37462) ...... 24 9.2.3.20 DTCP011629, P011716 or P011817
9.1.4.8 Battery Tray Replacement ........... 25 75
9.1.4.10 Generator Replacement - 1.5T 9.2.3.21 DTCP012129, P012216 or P012317
(37565) 26 77
9.2 Engine Controls and Fuel - 1.5L ...................... 28 9.2.3.22 DTCP013000, P013116, P013217,
9.2.1 Specifications ............................... 28 P013300, P013400, P219500 or P219600............... 79
9.2.1.1 Temperature Versus 9.2.3.23 DTCP013600, P013716, P013817,
Resistance—Engine Coolant Temperature Sensor P014000, P227000 or P227100 ............................... 82
(1.5T) (210513) 28 9.2.3.24 DTCP020113, P026111 or P026212
9.2.1.2 Fastener Tightening Specifications 84
(1.5T) 29 9.2.3.25 DTCP020213, P026411 or P026512
9.2.1.3 Temperature Versus Resistance 86
(1.5T) (210513) 30 9.2.3.26 DTCP020313, P026711 or P026812
9.2.2 Schematic and Routing Diagrams31 87
9.2.2.1 B15T Engine Controls Schematics 9.2.3.27 DTCP020413, P027011 or P027112
(209087) 31 89
9.2.3 Diagnostic Information and 9.2.3.28 DTCP022129, P022216 or P022317
Procedures 41 91
9.2.3.1 Fuel Injector Circuit Diagnosis (1.5T) 9.2.3.29 DTCP023400, P029900, P024300,
(226936) 41 P024500 or P024600 ................................................ 94
9.2.3.2 Crankcase Ventilation System 9.2.3.30 DTCP030021, P030022, P030029,
Inspection/Diagnosis ................................................. 42 P030121, P030122, P030129, P030221, P030222,
P030229, P030321, P030322, P030329, P030421,
9.2.3.3 Fuel System Diagnosis (210564) . 42
P030422 or P030429 ................................................ 95
9.2.3.4 Symptoms - Engine Controls (1.5T)
Table of Contents

9.2.3.31 DTCP044413, P045816 or P045917 9.2.4.11 Camshaft Position Sensor

98 Replacement (1.5T) (208564) ................................ 157
9.2.3.32 DTCP046217 or P046316 ..........100 9.2.4.13 Accelerator Pedal Replacement
9.2.3.33 DTCP048013, P069111 or P069212 (1.5T) 160
102 9.2.4.14 Intake Air Pressure and
9.2.3.34 DTCP048113, P069311 or P069412 Temperature Sensor Replacement (1.5T low -
104 pressure) 161
9.2.3.35 DTCP050600, P050700, P154500, 9.2.4.15 Intake Air Pressure and
P154521, P154522 or P155900 ..............................106 Temperature Sensor Replacement (1.5T high -
pressure) 162
9.2.3.36DTCP053716 or P053817 ..........................108
9.2.4.16 Camshaft Position Actuator
9.2.3.37 DTCP056000, P056216 or P056317 Solenoid Valve Replacement (1.5T) (249903) ....... 163
110
9.2.4.17 Fuel Feed Pipe and Return Hose
9.2.3.38 DTCP05711C or P057129 .........112 Replacement (1.5T) ................................................ 164
9.2.3.39 DTCP062700, P062811 or P062915 9.2.4.18 Spark Plug Inspection (1.5T)
114 (208573) 165
9.2.3.40 DTCP064513, P064611 or P064712 9.2.4.19 Knock Sensor Replacement (1.5T)
116 (208565) 167
9.2.3.41 DTCP068891 or P068892 ..........118 9.2.4.20 Fuel Tank Filler Pipe Replacement
9.2.3.42 DTCP155929, P156400, P156500, (208550) 168
P156800, P157900, P210612, P210613, P210619, 9.2.4.21 Air Cleaner Outlet Duct
P210629 or P210692 ..............................................120 Replacement (1.5T) (208569) ................................ 169
9.2.3.43 DTCP212216, P212317, P212716, 9.2.4.22 Fuel Pressure Relief (1.5T) (208545)
P212817, P213800 or P213829 ..............................122 170
9.2.3.44 DTCP217700, P217800, P218700 9.2.4.23 Fuel System Cleaning (1.5T)
or P218800 126 (208554) 171
9.2.3.45 DTCU012900 or U041500 .........128 9.2.4.24 Fuel Tank Draining (1.5T) (208547)
9.2.3.46 DTCP012B21, P012B22, P012C11 172
or P012D15 130 9.2.4.25 Fuel Tank Fuel Pump Module
9.2.3.47 DTCP065000 or P070000 ..........132 Replacement (1.5T) (208552) ................................ 173
9.2.3.48 DTCP152300 or P168300 ..........133 9.2.4.27 Heated Oxygen Sensor
9.2.3.49 DTCP161000, P161100, P161200, Replacement - Sensor 1 (1.5T) (208541)............... 178
P161300, P161400, P161500, P161600, P161700, 9.2.4.28 Heated Oxygen Sensor
P161800, P161900 or P163000 ..............................134 Replacement - Sensor 2 (1.5T) (208541)............... 179
9.2.3.50 DTCU010100 .............................136 9.2.4.29 Ignition Coil Replacement (1.5T)
9.2.3.51 DTCU012800, U012900 or (208560) 180
U041500 140 9.2.4.30 Spark Plug Replacement (1.5T)
9.2.4 Repair Instructions .....................146 (208562) 181
9.2.4.1 Engine Control Module 9.2.5 Description and Operation ......... 182
Replacement (1.5 T) (208535) ................................146 9.2.5.1 Air Intake System Description (1.5T)
9.2.4.2 Engine Coolant Temperature (210571) 182
Sensor Replacement (1.5T) (208536) ....................147 9.2.5.2 Crankcase Ventilation System
9.2.4.3 Fuel Injector Replacement (1.5T) Description (1.5T) (210572) .................................... 182
(208556) 148 9.2.5.3 Engine Control Components
9.2.4.4 Evaporative Emission Canister Description (1.5T) 183
Replacement (1.5T) (208558) .................................150 9.2.5.4 Throttle Actuator Control (TAC)
9.2.4.6 Air Cleaner Element Replacement System Description ................................................. 183
(1.5T) (208570) 152 9.2.6 Special Tools and Equipment .... 184
9.2.4.9 Throttle Body Assembly 9.2.6.1 Special Tools (1.5T) (208572) ... 184
Replacement (1.5T) (208543) .................................155 9.4 Engine Cooling System ................................... 185
9.2.4.10 Crankshaft Position Sensor 9.4.1 Specifications............................. 185
Replacement (1.5T) (208563) .................................156
 Table of Contents

9.4.1.1 Fastener Tightening Specifications (1.5T) (208575) 220

185 9.5.1.4 Fastener Tightening Specifications
9.4.1.2 Approximate Fluid Capacities 224
(258271) 186 9.5.2 Component Locator ................... 228
9.4.1.3 Temperature Versus Resistance 9.5.2.1 Disassembled Views (Turbocharger
(210513) 187 Pipeline) (208602) .................................................. 228
9.4.2 Schematic and Routing Diagrams 9.5.2.2 Disassembled Views (Cylinder
188 Block LL5) (208602) ............................................... 229
9.4.3 Diagnostic Information and 9.5.2.3 Disassembled Views (Cylinder
Procedures 189 Head LL5) (208602)................................................ 231
9.4.3.1 Engine Fails to Reach Normal 9.5.2.4 Engine Number (1.5T) ............... 233
Operating Temperature (37221) .............................189
9.5.3 Diagnostic Information and
9.4.3.2 Engine Overheating (37218) ......190 Procedures 234
9.4.3.3 Loss of Coolant (37222) .............192 9.5.3.1 Base Engine Misfire with Abnormal
9.4.3.4 Symptoms - Engine Cooling (37429) Internal Lower Engine Noises (1.5T) (208580) ...... 234
194 9.5.3.2 Base Engine Misfire with Abnormal
9.4.4 Repair Instructions .....................196 Valve Train Noise (1.5T) (208581) ......................... 235
9.4.4.1 Engine Coolant Fan Replacement 9.5.3.3 Base Engine Misfire with Coolant
(B15T) (37302) 196 Consumption (208582) ........................................... 236
9.4.4.3 Radiator Air Side Baffle and 9.5.3.4 Base Engine Misfire with Excessive
Deflector Replacement (B15T) (69785) ..................197 Oil Consumption (208583) ...................................... 237
9.4.4.5 Radiator Surge Tank Overflow Hose 9.5.3.5 Base Engine Misfire without Internal
Replacement (B15T) ...............................................198 Engine Noises (208579) ......................................... 238
9.4.4.11 Engine Coolant Temperature 9.5.3.6 Coolant in Combustion Chamber
Sensor Replacement (1.5T) (208536) ....................201 (208589) 240
9.4.4.12 Radiator Inlet Hose Replacement 9.5.3.7 Coolant in Engine Oil (208590) . 241
(B15T) 202 9.5.3.8 Crankcase Ventilation System
9.4.4.18 Engine Coolant Thermostat Inspection/Diagnosis............................................... 241
Replacement (1.5T) (37212) ...................................204 9.5.3.9 Cylinder Leakage Test (208592) 241
9.4.4.19 Flushing ......................................205 9.5.3.10 Engine Compression Test (1.5T)
9.4.4.20 Radiator Replacement (37191) ..206 (208591) 242
9.4.4.21 Radiator Surge Tank Inlet Hose 9.5.3.11 Engine Noise Under Load (208587)
Replacement (B15T) (37409)..................................207 243
9.4.4.22 Radiator Surge Tank Outlet Hose 9.5.3.12 Engine Will Not Crank - Crankshaft
Replacement (B15T) (37410)..................................208 Will Not Rotate (208588) ........................................ 244
9.4.4.24 Radiator Surge Tank Replacement 9.5.3.13 Lower Engine Noise, Regardless of
(B15T) (37297) 209 Engine Speed (208586) .......................................... 245
9.4.4.26 Engine Oil Cooler Replacement 9.5.3.14 Oil Consumption Diagnosis (208593)
(1.5T) 211 245
9.4.4.30 Radiator Cleaning (37291) .........216 9.5.3.15 Oil Leak Diagnosis (208595) ..... 246
9.4.5 Description and Operation .........217 9.5.3.16 Oil Pressure Diagnosis and Testing
9.4.5.1 Cooling System Description and (208594) 248
Operation (37455) ...................................................217 9.5.3.17 Symptoms - Engine Mechanical
9.5 Engine Mechanical - 1.5L ............................... 219 (1.5T) (208578) 251
9.5.1 Specifications .............................219 9.5.3.18 Upper Engine Noise, Regardless of
Engine Speed (208585) .......................................... 256
9.5.1.1 Approximate Fluid Capacities
(258271) 219 9.5.3.19 Valve Clearance Testing ........... 257
9.5.1.2 Adhesives, Fluids, Lubricants, and 9.5.4 Repair Instructions - On Vehicle 259
Sealers (208576) 219 9.5.4.1 Engine Oil and Oil Filter
9.5.1.3 Engine Mechanical Specifications Replacement (1.5T) (208623) ................................ 259
Table of Contents

9.5.4.2 Air Conditioning Compressor Replacement (1.5T) ................................................ 311

Bracket Replacement (1.5T) (48303)......................261 9.5.4.32 Turbocharger Oil Feed Pipe
9.5.4.4 Vacuum Pump Assembly Replacement (1.5T) ................................................ 312
Replacement (1.5T).................................................263 9.5.4.33 Crankshaft Front Oil Seal
9.5.4.5 Piston Oil Nozzle Removal (1.5T) Replacement (1.5T) (208614) ................................ 313
263 9.5.4.34 Engine Replacement (1.5T)
9.5.4.6 Piston Oil Nozzle Installation (1.5T) (208622) 316
264 9.5.4.35 Valve Lifter Replacement (1.5T)
9.5.4.7 Drive Belt Tensioner Replacement (208609) 325
(1.5T) (208598) 265 9.5.5 Repair Instructions - Off Vehicle 327
9.5.4.9 Cylinder Head Replacement (1.5T) 9.5.5.1 Engine Flywheel Removal (1.5T)
(208610) 271 (208642) 327
9.5.4.10 Engine Flywheel Replacement (1.5T) 9.5.5.2 Exhaust Manifold Removal (1.5T)
(208612) 272 (208651) 327
9.5.4.12 Engine Front Cover with Oil Pump 9.5.5.3 Engine Flywheel Removal (1.5T)
Replacement (1.5T) (208617) .................................275 (208642) 328
9.5.4.13 Oil Level Indicator Tube 9.5.5.4 Draining Fluids and Oil Filter
Replacement (1.5T) (208621) .................................279 Removal (1.5T) (208635)........................................ 329
9.5.4.14 Oil Pressure Relief Valve 9.5.5.5 Water Pump Pulley Removal (1.5T)
Replacement (1.5T) (208624) .................................280 (208638) 329
9.5.4.15 Camshaft Cover Replacement (1.5T) 9.5.5.6 Water Pump Removal (1.5T)
(208627) 281 (208640) 330
9.5.4.16 Camshaft Replacement (1.5T) 9.5.5.7 Ignition Coil Removal (1.5T)
(208628) 283 (208643) 330
9.5.4.18 Valve Stem Oil Seal and Valve 9.5.5.8 Camshaft Cover Removal (1.5T)
Spring Replacement (1.5T) (208630) .....................288 (208644) 330
9.5.4.19 Valve Spring Inspection and 9.5.5.9 Camshaft Timing Chain Removal
Measurement (208632) ...........................................291 (1.5T) (208647) 331
9.5.4.20 Oil Pan Replacement (1.5T) 9.5.5.10 Timing Chain Guide Removal (1.5T)
(208730) 292 (208648) 331
9.5.4.21 Ignition Coil Cover Replacement 9.5.5.11 Timing Chain Tensioner Removal
(1.5T) (212125) 295 (1.5T) (208649) 332
9.5.4.22 Oil Filler Cap Replacement (1.5T) 9.5.5.12 Camshaft Sprocket Removal (1.5T)
296 (208650) 332
9.5.4.23 Engine Mount Bracket Replacement 9.5.5.13 Cylinder Head Removal (1.5T)
(1.5T) 297 (208652) 333
9.5.4.24 Crankshaft Pulley Replacement 9.5.5.14 Piston, Connecting Rod, and
(1.5T) (212375) 299 Bearing Removal (1.5T) (208653) .......................... 333
9.5.4.25 Camshaft Timing Chain, Sprocket, 9.5.5.15 Crankshaft and Bearing Removal
and Tensioner Replacement (1.5T) (212378).........300 (1.5T) (208655) 334
9.5.4.26 Engine Mount Replacement (1.5T) 9.5.5.16 Cylinder Head Disassemble (1.5T)
304 335
9.5.4.27 Engine Oil Pressure Indicator 9.5.5.17 Cylinder Head Cleaning and
Switch Replacement (1.5T)(212700) ......................305 Inspection (1.5T) (208657) ..................................... 336
9.5.4.28 Turbocharger Heat Shield 9.5.5.18 Cylinder Head Assemble (1.5T)
Replacement (1.5T).................................................306 (208658) 337
9.5.4.29 Turbocharger Replacement (1.5T) 9.5.5.19 Engine Block Disassemble ........ 339
307
9.5.5.20 Engine Block Assemble ............. 341
9.5.4.30 Turbocharger Oil Return Pipe
Replacement (1.5T).................................................310 9.5.5.21 Piston and Connecting Rod
Disassemble (1.5T) (208663) ................................. 343
9.5.4.31 Intake Manifold Support
9.5.5.22 Piston, Connecting Rod, and
 Table of Contents

Bearing Cleaning and Inspection (1.5T) (208664) ..344 (1.5T) (212380) 364
9.5.5.23 Piston and Connecting Rod 9.5.5.50 Engine Water Outlet Adapter
Assemble (1.5T) (208665) ......................................346 Installation (1.5T) (205010)..................................... 364
9.5.5.24 Intake Manifold Cleaning and 9.5.5.51 Exhaust Manifold Heat Shield
Inspection (1.5T) (208667) ......................................347 Removal (1.5T) (205206)........................................ 365
9.5.5.25 Crankshaft and Bearing Cleaning 9.5.5.52 Exhaust Manifold Heat Shield
and Inspection (1.5T) (208669) ...............................348 Installation (1.5T) (205207)..................................... 365
9.5.5.26 Oil Pump Disassemble (1.5T) ....350 9.5.5.53 Turbocharger Removal (1.5T) ... 366
9.5.5.27 Oil Pan Cleaning and Inspection 9.5.5.54 Turbocharger Installation (1.5T) 367
(1.5T) (208671) 351 9.5.5.55 Crankshaft Position Sensor
9.5.5.28 Crankshaft and Bearing Installation Removal (1.5T) 367
(1.5T) (208672) 352 9.5.5.56 Crankshaft Position Sensor
9.5.5.29 Piston, Connecting Rod, and Installation (1.5T) 368
Bearing Installation (1.5T) (208673) .......................353 9.5.5.57 Crankshaft Pulley Removal (1.5T)
9.5.5.30 Cylinder Head Installation (1.5T) (257930) 368
(208674) 354 9.5.5.58 Starter Removal (1.5T) .............. 368
9.5.5.31 Camshaft Sprocket Installation 9.5.5.59 Crankshaft Pulley Installation (1.5T)
(1.5T) 355 (257935) 369
9.5.5.32 Timing Chain Tensioner Installation 9.5.5.60 Timing Chain Cleaning and
(1.5T) (208676) 355 Inspection (1.5T) (257940) ..................................... 369
9.5.5.33 Camshaft Timing Chain Installation 9.5.5.61 Engine Installation to Stand (1.5T)
(1.5T) (208677) 356 370
9.5.5.34 Camshaft Cover Installation (1.5T) 9.5.5.62 Engine Pre - lubrication (1.5T) .. 371
(208681) 356
9.5.5.63 Generator Installation (1.5T) ..... 372
9.5.5.35 Ignition Coil Installation (1.5T)
(208682) 357 9.5.5.64 Generator Removal (1.5T)......... 372
9.5.5.36 Water Pump Installation (1.5T) 9.5.5.65 Positive Crankcase Ventilation Pipe
(208685) 357 Installation (1.5T) 373
9.5.5.37 Water Pump Pulley Installation 9.5.5.66 Positive Crankcase Ventilation Pipe
(1.5T) (208687) 358 Removal (1.5T) 373
9.5.5.38 Drive Belt Tensioner Installation 9.5.5.67 Starter Installation (1.5T) ........... 373
(1.5T) 358 9.5.5.68 Engine Coolant Thermostat Housing
9.5.5.39 Exhaust Manifold Installation (1.5T) Removal (1.5T) (208637)........................................ 374
(208692) 358 9.5.5.69 Engine Coolant Thermostat Housing
9.5.5.40 Drive Belt Tensioner Removal (1.5T) Installation (1.5T) (208691)..................................... 374
(208598) 359 9.5.5.70 Intake Manifold Removal (1.5T)
9.5.5.42 Throttle Body Assembly Removal (208641) 375
(1.5T) (208700) 360 9.5.5.71 Intake Manifold Installation (1.5T)
9.5.5.43 Engine Block Cleaning and (208684) 375
Inspection (1.5T) (208704) ......................................360 9.5.5.72 Camshaft Cleaning and Inspection
9.5.5.44 Throttle Body Assembly Installation (1.5T) (208717) 376
(1.5T) (208711) 361 9.5.5.73 Crankshaft Front Oil Seal
9.5.5.45 Crankshaft Sprocket Installation Installation (1.5T) (208720)..................................... 377
(1.5T) (208713) 361 9.5.5.74 Crankshaft Front Oil Seal Removal
9.5.5.46 Crankshaft Rear Oil Seal Removal (1.5T) (208715) 377
(1.5T) (208716) 362 9.5.5.75 Engine Front Cover and Oil Pump
9.5.5.47 Timing Chain Guide Installation Installation (1.5T) (208679)..................................... 378
(1.5T) (208718) 362 9.5.5.76 Engine Front Cover and Oil Pump
9.5.5.48 Crankshaft Rear Oil Seal Installation Removal (1.5T) (208646)........................................ 379
(1.5T) (208719) 363 9.5.5.77 Oil Pan Installation (1.5T) (208680)
9.5.5.49 Camshaft Timing Chain Adjustment 379
Table of Contents

9.5.5.78 Oil Pan Removal (1.5T) (208645)

381
9.5.5.79 Valve Lifter Installation (1.5T)
(208710) 381
9.5.5.80 Valve Lifter Removal (1.5T) (208701)
382
9.5.5.81 Oil Level Indicator and Tube
Removal (1.5T) (208698) ........................................382
9.5.5.82 Oil Level Indicator and Tube
Installation (1.5T) (208709) .....................................383
9.5.6 Description and Operation .........384
9.5.6.1 Cleaning and Maintenance ........384
9.5.6.2 Crankcase Ventilation System
Description (210572) ...............................................384
9.5.6.3 Engine Component Description
(208722) 384
9.5.6.4 Separating Parts (208725) .........385
9.5.6.5 Tools and Equipment .................385
9.7 Exhaust.............................................................. 389
9.7.1 Specifications .............................389
9.7.1.1 Fastener Tightening Specifications
389
9.7.2 Diagnostic Information and
Procedures 390
9.7.2.1 Exhaust Leakage (37907) ..........390
9.7.2.2 Exhaust Noise (37853)...............391
9.7.2.3 Symptoms - Engine Exhaust (37994)
391
9.7.3 Repair Instructions .....................392
9.7.3.2 Exhaust Manifold Replacement
(1.5T) (37850) 393
9.7.3.4 Exhaust Manifold Heat Shield
Replacement (1.5L Turbocharged Engine) (64786)
394
9.7.3.5 Exhaust Muffler Heat Shield
Replacement 395
9.7.3.6 Intermediate Pipe Replacement.396
9.7.3.8 Rear Exhaust Muffler Replacement
398
9.7.3.9 Turbocharger Heat Shield
Replacement (1.5T).................................................399
9.7.3.11 Catalytic Converter Replacement
(1.5T) (37817) 401
9.7.4 Description and Operation .........403
9.7.4.1 Exhaust System Description (37949)
403
9-7 Engine/Propulsion

9.1 Engine Starting and Charging

9.1.1 Specifications
9.1.1.1 Fastener Tightening Specifications
Fastener Specifications
Specification
Application
Metric
Battery tray bolt 20±3 N·m
Battery retaining nut 3±1 N·m
Generator bolt (1.5L) 40±5 N·m
Generator - mounted battery positive cable nut (1.5L) 13±2 N·m
Starter bolt (1.5L) 25±4 N·m
Starter - mounted ignition switch wire nut M6 (1.5L) 7 N·m
Battery negative pole fastening nut 6±1 N·m
Battery negative cable ground bolt 9±1.5 N·m
Battery positive cable clamp nut (B15T) 9±1.5 N·m
Generator mounting bolt (1.5L turbocharged engine) 40±5 N·m
Starter mounting bolt (1.5L turbocharged engine) 25±4 N·m
Starter starting end nut (1.5L turbocharged engine) 6.5±1 N·m
Starter battery end nut (1.5L turbocharged engine) 13±2 N·m
 9-8 Engine/Propulsion

9.1.1.2 General Specifications

Electrical
Engine
Item
1.5 Turbocharged engine (LL5)
Battery 12V/55Ah
Generator 14V/90A
Starter 12V/1.2Kw
9-9 Engine/Propulsion

9.1.2 Schematic and Routing Diagrams

9.1.2.1 Starting and Charging
9-10 Engine/Propulsion
9-11 Engine/Propulsion
9.1.3 Diagnostic Information and
Procedures
9.1.3.1 Battery Common Causes of Malfunction
(37571)
The battery cannot be used forever. However, if
maintained properly, it can work normally for many
years. If the battery is tested normal but cannot work
normally, the causes are generally the followings:
• Vehicle accessories are kept on overnight.
• Many electrical accessories are used, especially
the air conditioning system, headlamp, wiper, rear
windshield heater, on - board telephone, etc.; the
vehicle runs at a low speed; the vehicle stops
frequently (run for a while and then stop for many
times).
• The electrical load exceeds the generator output
power, especially when an aftermarket device is
installed additionally.
• A charging system fault occurs and the causes
can be:
– Drive belt slipping
– Generator damage
• The battery is not maintained normally, including
the battery pressing device is too loose or the
battery insulator is missing (if used).
• The electrical system has a mechanical fault,
such as wire short circuit or binding. Refer to
“11.3.4.18 General Electrical Diagnosis” under
“Wiring System”.
Electrolyte Freezing
Freezing point of the electrolyte depends on its
specific gravity. A fully charged battery can freeze only
when the ambient temperature is lower than - 54°C
(−65°F). However, if the battery is not charged fully, it
can freeze when the ambient temperature is just -
7°C (20°F). Freezing can damage the battery, so
please keep the battery charged properly to prevent
freezing. Freezing point of the battery is always lower
than - 32°C ( - 25°F) as long as the green point on
the specific gravity hydrometer is noticeable.
Battery Protection during Vehicle Storage
Certain vehicle devices can cause the battery to leak a
little continuously, for example, parasitic load. A
battery that is left unused for a long time can discharge.
This can lead to permanent battery damage. A
discharged battery can also freeze in cold weather.
Refer to “9.1.3.3 Battery Inspection/Test”.
To keep the battery charged during vehicle storage for
over 30 days:
1. Ensure that the green point on the specific gravity
hydrometer is noticeable.
Caution: Unless directed otherwise, the ignition
switch must be in “OFF (disconnected)” or “LOCK
(locked)” position, and all electrical loads must be
“OFF (disconnected)” before servicing any
electrical component. If the tool or equipment to
be used is likely to contact any live and bare
electric terminal, the battery negative cable
should be disconnected in advance. Violation of
all these safety instructions will cause personal
injury/damage to the vehicle or vehicle
components.
2. Disconnect the battery ground cable to prevent
discharging due to parasitic load.
In case that the battery cannot be disconnected:
1. Keep the battery fully charged.
2. Make a charging schedule to charge the battery
every 20~45 days.
If the battery is in a discharging state for a long time,
charging can be difficult and permanent battery
damage can occur.
9.1.3.2 Battery Electrical Drain/Parasitic Load
Test (37588)
Special Tools
J38758 parasitic current test switch
Diagnostic Aids
• Eliminate all obvious influence factors, such as
misoperation by the customer or an aftermarket
device.
• Check the customer’s driving habit, for example,
driving for frequent short trips. In this case, time
for normal battery charging is insufficient. Refer to
“Battery Description and Operation”.
• Check and confirm that the battery and the
charging system can work normally. Refer to
“9.1.3.7 Battery Charging” and “9.1.3.4
Charging System Test”.
• If unexpected battery discharging happens as the
vehicle is parked and the reason cannot be found,
the cause can be intermittent current
consumption (for example, module wakeup) or
continuous current consumption (for example,
roof lamp or relay binding).
 9-12 Engine/Propulsion

• Some systems and modules, for example, switch knob is turned to ON (connected) position, the
OnStar ? and regulating voltage control (RVC) will circuit closes and current passes the switch. When the
be waken up to perform tasks and then enter switch knob is turned to OFF (disconnected) position,
dormancy after a specified time interval. For the circuit disconnects and no current passes the
description and operation about the systems and switch.
modules, refer to “6.1.1.1 Control Module 1. Before connecting J38758, remove the
References”. underhood fuse block cover.
• Some systems and modules, for example, the 2. Disconnect the battery negative cable from the
theft deterrent and the remote keyless entry (RKE) battery negative terminal.
can be waken up under external output. For
description and operation about the systems and 3. Connect terminal end on J38758 female joint top
modules, refer to “6.1.1.1 Control Module to the battery ground terminal.
References”. 4. Turn J38758 knob to OFF (disconnected)
• The battery discharging time changes as the cold position.
cranking ampere (CCA) and the reserve capacity 5. Install the battery negative cable to J38758 male
(RC) change. The higher the cold cranking joint end.
ampere and the reserve capacity, the longer the 6. Turn J38758 knob to ON (connected) position.
battery discharging time. The lower the cold
7. Start the engine and turn on all accessories,
cranking ampere and the reserve capacity, the
including radio and air conditioning (A/C).
shorter the battery discharging time. The table
below lists in brief the number of days taken for a 8. Turn the ignition switch to OFF (disconnected)
battery with a cold cranking ampere of 690 and a position and pull out the ignition key.
reserve capacity of 60.5 Ah to change from an 9. Disconnect the scan tool if it has been connected
initially 80% charged state to 50% charged state to the vehicle.
at a constant discharge current and on a regular 10. Connect one 10 A fused jumper wire to tool
110 - minute daily usage. These results can be terminal of the test switch.
affected by rated value and temperature of the
battery. 11. Wait for one minute and then turn J38758 knob to
OFF (disconnected) position so that current
Note: The battery in the table below is of general passes the jumper wire. If the fuse blows, connect
specifications. Refer to this table during battery test. the inductive ammeter and go to Step 19.2.
Discharge Current Number of Days
25 mA 30.5
50 mA 16.5
75 mA 11
100 mA 8.25
250 mA 3.3
500 mA 1.65
750 mA 1
1A 0.8
2A 0.4
Load Test
Warnings: Refer to “0.2.1.42 Battery Disconnect
Warning”.
Caution: Never turn the parasitic current test switch to
OFF position while the engine is running, otherwise
the vehicle electrical system can be damaged.
Caution: Do turn the test switch to ON (connected)
position when removing the fuse so as to keep
electrical system continuity. In this way, damage to the
digital multimeter due to unexpected load (for example,
when the door is opened for fuse removal) can be
avoided.
Note: J38758 switch knob is marked with “ON
(connected)” and “OFF (disconnected)”. When the
9-13 Engine/Propulsion

12. Turn the knob to ON position and then remove the Warnings: Refer to “0.2.1.42 Battery Disconnect
fused jumper wire. Warning”.
13. Set the digital multimeter at Range 10 A. Notes:
14. Connect the digital multimeter to tool terminal of • To use EL42000 battery tester for battery test,
the test switch. connection to battery terminals must be correct. If
15. Turn J38758 knob to OFF (disconnected) position. the connection is incorrect, an intact battery may
Current passes the digital multimeter. fail the test as well.
16. Record the current reading. The reading should • For a vehicle equipped with two batteries, test
be less than 250 mA. each battery outside the vehicle.
17. Wait for 20 minutes. The reading should be less To avoid wrong diagnosis due to connection problems,
than 80 mA. please operate as instructed below:
18. Remove IBCM1 fuse 20 of 30 A from the • If the battery test is to be conducted with the
underhood fuse block. The reading should read battery cable connected, turn EL42000 clamp on
less than 30 mA. the terminal bolt. In this way, the coating or oxides
on the bolt can be penetrated. Even a bolt has a
19. If no excessively large discharge current or other protective coating which may provide insulation or
obvious faults are found, complete the following generate resistance in the test circuit.
steps:
• If connection of battery terminal bolt is suspected
19.4 Set the digital multimeter at “MIN/MAX” and use it to be wrong, carry out the following steps:
to monitor parasitic discharge overnight or for a whole
day. Confirm whether any component is activated Disconnect the battery negative cable. Disconnect the
during this period. battery positive cable.
Caution: Do turn the test switch to ON (connected) Install the tester adapter to the terminal.
position when removing the fuse so as to keep Test the removed battery as instructed below:
electrical system continuity. In this way, damage to the • During the battery test with the battery cable
digital multimeter due to unexpected load (for example, connected to the vehicle, if the result shown on
when the door is opened for fuse removal) can be the tester is “REPLACEBATTERY” or
avoided. “BADCELLREPLACE”, carry out the following
Note: Remove the fuse, relay and connector to confirm steps:
the fault location of the module that may be waken up. Disconnect the battery negative cable.
Wait until these modules return to dormancy or use
sleep mode of the scan tool. Disconnect the battery positive cable.
19.2 If the parasitic discharge current is excessively
large, remove the fuses one by one until the discharge
current drops to the acceptable level. The circuit which
causes discharge can be determined in this way. Refer
to “Power Distribution Schematics” to correctly locate
the parasitic discharge position in the suspected circuit.
In some cases, it is a not fused circuit or component
that causes excessively large parasitic discharge
current, for example, relay.
19.3 Repeat the parasitic discharge current test
procedure after completing any repair to ensure that
the parasitic discharge current is at the acceptable
level.
9.1.3.3 Battery Inspection/Test (37781)
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category.
Diagnostic Aids
 9-14 Engine/Propulsion

Install the tester adapter. C1 battery.

Note: For the convenience of warranty, please do 2. Check and confirm that the cold cranking ampere
record in the repair order the test code shown on the (CCA) and reserve capacity (RC) of the battery
tester. This number is the only code corresponding to conform to specifications of the original battery or
the test data generated in a specified time. When the original equipment (OE). Refer to “Battery
same battery is tested again, the test code may repeat Usage”.
occasionally. However, generally a separate test code – If C1 battery falls below or goes beyond the
will be generated for each test. Use the second - time specifications, replace it.
test code or the code for outside test.
3. Check and confirm that the battery cable is clean
Test the removed battery as instructed below: and firm. The battery terminal bolt should be
Battery replacement is required only when the result tightened to the torque specified in “Fastener
for the second - time test is shown as Tightening Specifications”.
“REPLACEBATTERY” or “BADCELLREPLACE”. For – If it is necessary to clean the battery, clean it
the convenience of warranty, please use the second - as required and tighten it to the specification.
time test code.
– If the battery cable has been damaged,
• Use the correct terminal adapter. During battery replace the cable and tighten it to the
test, never use any common bolt or a cluster of specification.
bolt, nut and washer as the adapter. Use the
tester adapter provided together with EL42000 or 4. Install EL42000 and operate as per the tester
GM terminal adapter (PN: 12303040). If it is instructions.
necessary to replace the adapter provided – If battery charging is required as directed in
together with EL42000, use GM part (PN: the tester instructions, refer to “9.1.3.7
12303040) instead. Any other adapter may fail to Battery Charging”.
fully and correctly contact the battery terminal, Scan Tool Reference
and resistance thus caused may lead to invalid
Refer to “6.1.1.1 Control Module References” for
battery test result.
scan tool information.
Reference Information
Schematic Reference
9.1.2.1
Connector End View Reference
Component Connector End Views
Description and Operation
Starting system description and operation
Electrical Information Reference
• 11.3.4.12 Circuit Testing
• 11.3.4.7 Testing for Intermittent Conditions
and Poor Connections
Special Tools
For the regional tool equivalent to EL42000 battery
tester, refer to “Special Tools”.
Circuit/System Testing
Warning: Unless directed otherwise in the operation
procedure, the ignition and start switch must be in OFF
or LOCK position, and all electrical loads must be OFF
before servicing any electrical component. Disconnect
the battery negative cable tto prevent the tool or
equipment from contacting the bare electric terminal
and causing electric sparks. Violation of all these
safety instructions can cause personal injury/damage
to the vehicle or vehicle components.
1. Check C1 battery for cracks, breakage or damage
which would allow electrolyte leakage.
– If no obvious damage is discovered, replace
9-15 Engine/Propulsion
Repair Instructions
Perform the “6.2.2.8 Diagnostic Repair Verification”
after completing the diagnostic procedure.
• Battery Positive Cable Replacement
• 9.1.4.3 Battery Negative Cable Replacement
• 9.1.4.7 Battery Replacement
9.1.3.4 Charging System Test (37782)
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category.
Reference Information
Schematic Reference
9.1.2.1
Connector End View Reference
Component Connector End Views
Description and Operation
Charging system description and operation
Electrical Information Reference
• 11.3.4.12 Circuit Testing
• 11.3.4.7 Testing for Intermittent Conditions
and Poor Connections
Circuit/System Verification
With the engine started, observe the charge indicator
on the instrument panel cluster (IPC) or the
information shown on the driver information center
(DIC). The charge indicator on the instrument panel
cluster should go out and no charging information
should appear on the driver information center.
– If the charge indicator is not on the instrument
panel cluster and no charging system information
appears on the driver information center, refer to
“11.3.4.7 Testing for Intermittent Conditions
and Poor Connections”.
– If the charge indicator on the instrument panel
cluster illuminates or charging system information
appears on the driver information center, refer to
“Circuit/System Testing”.
Circuit/System Testing
1. Turn the ignition switch to ON position and then
check and confirm no generator or battery current
sensor DTC which can cause a charging system
fault is set.
– If a DTC is set, refer to “6.2.2.3 Diagnostic
Trouble Code (DTC) List - Vehicle”.
2. Turn the ignition switch to OFF position and
measure the battery terminal voltage. The voltage
reading should read 12 V or higher under room
temperature.
– If the value is not within the specification,
refer to “9.1.3.3 Battery Inspection/Test”.
3. Connect the carbon pile tester to the battery.
4. Start the engine and increase the speed to 2,500
r/m. Observe the voltage reading on the tester.
The voltage reading should read between 12.6 -
15.0 V.
– If the reading is not within the specified range,
replace the generator.
5. Adjust the carbon pile tester to the specified
load test output value. Refer to “Generator
Usage”.
– If it is not within the specified value, replace
the generator.
Repair Instructions
Perform the “6.2.2.8 Diagnostic Repair Verification”
after completing the diagnostic procedure.
• Generator Replacement
9.1.3.5 Jump Starting in Case of Emergency
(37522)
Caution: Batteries produce explosive gases. Batteries
contain corrosive acid. Current generated by the
battery can be as strong as to cause burns. Therefore,
to reduce the risk of personal injuries during operation
near the battery, please do observe the following
instructions:
• Always wear protective goggles properly.
• Avoid leaning over the battery whenever possible.
• Do not expose the battery to open flames or
sparks.
• Do not allow battery acid to contact the eyes or
the skin.
– Flush any contacted areas with water
immediately and thoroughly.
– Get medical help.

Note: The vehicle has a 12 V electrical system with the
negative electrode grounded. Ensure that the vehicle
or equipment to be used for jump starting is also a
system of 12 V with the negative electrode grounded.
If any other type of system is used, damage to the
vehicle electrical component can result. The vehicle
has an electrical system with a 12 V positive electrode
and a grounded negative electrode. If you are not sure
about the positive voltage or grounding position of any
other vehicle, do not use it for jump starting. If a
jumper cable is used, please handle the battery
(charged) on the auxiliary vehicle and the drained
battery carefully.
1. Park the auxiliary vehicle with the charged battery
in a place where it is convenient to connect the
jumper wire to the battery on the other vehicle.
○ Do not allow the two vehicles to contact.
○ Ensure that the jumper wire is free of defects
such as loose clamp or insulating layer
chipping.
2. Carry out the following steps on the two vehicles:
(1) Engage the automatic transmission at the
parking gear or the manual transmission at
the neutral gear.
(2) Block the wheels.
(3) Apply the park brake.
(4) Turn off all unnecessary electrical loads
(keep the hazard flasher illuminated).
(5) Disconnect the ignition switch.
Note: Batteries on some vehicles have a far - end
positive terminal. Do use the battery far - end positive
terminal to provide or receive jump starting.
3. Connect the red positive (+) cable to positive (+)
terminal (1) of the charged battery on the auxiliary
vehicle. Use the far - end positive (+) terminal (if
any).
4. Connect the red positive (+) cable to positive (+)
terminal of the drained battery. Use the far - end
positive (+) terminal (if any).
9-16 Engine/Propulsion
5. Connect the black negative ( - ) cable to negative
( - ) terminal (3) of the charged battery on the
auxiliary vehicle.
Connect the black negative ( - ) cable to negative
( - ) terminal (3) of the charged battery on the
auxiliary vehicle to prevent sparks and the hazard
of battery gas explosion.
6. Finally, connect the black negative jumper wire to
a large metal unpainted engine component (4) on
the vehicle with the drained battery. This final
connection point must be 46 cm (18”) or further
from the drained battery.
7. Start the engine of the vehicle which provides the
jumper current and turn off all electrical
accessories. Increase the engine speed to
approximately 1,500 r/m. Note: The starter motor
cannot run continuously for over 15s. Keep an
interval of 2 minutes as minimum to wait for the
starter to cool down. Overheating can damage
the starter motor.
8. Start the engine of the vehicle with the drained
battery. If the engine fails to start or starts slowly,
carry out the following steps:
(1) Turn off the ignition switch.
(2) Keep the engine of the auxiliary vehicle
running at approximately 1,500 r/m for 5
minutes.
(3) Try to start the engine of the vehicle with the
drained battery.
9-17 Engine/Propulsion
9. Disconnect the black negative ( - ) cable (1) from
the vehicle with the drained battery.
10. Disconnect the black negative ( - ) cable from
negative ( - ) terminal (2) of the charged battery
on the auxiliary vehicle.
11. Disconnect the red positive (+) cable from positive
(+) terminal (3) of the charged battery on the
auxiliary vehicle.
12. Disconnect the red positive (+) cable from positive
(+) terminal (4) of the vehicle with the drained
battery.
9.1.3.6 Symptoms - Engine Electrical (37791)
The following steps must be completed before using
the symptom diagnostic procedures:
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” before using the symptom diagnostic
procedures in order to verify that all of the
following conditions are true:
– No DTCs are set.
– The control modules can communicate via
the serial data link.
• Review the system descriptions and operations in
order to familiarize yourself with the system
functions. Refer to one of the following system
operations:
– Battery Description and Operation
– Charging System Description and Operation
– Electrical Power Management Description
and Operation
– Starting System Description and Operation
Visual/Physical Inspection
• Inspect for aftermarket devices which could
affect the operation of the starting and charging
systems. Refer to “11.3.4.15 Checking
Aftermarket Accessories”.
• Inspect the easily accessible or visible system
components for obvious damage or conditions
which could cause the symptom.
Intermittent
Faulty electrical connections or wiring may be the
cause of intermittent conditions. Refer to “11.3.4.7
Testing for Intermittent Conditions and Poor
Connections”.
Symptom List
Refer to a symptom diagnostic procedure from the
following list in order to diagnose the symptom:
• Battery Inspection/Test
• Battery Electrical Drain/Parasitic Load Test
• Charging System Test
9.1.3.7 Battery Charging (37464)
Special Tools
EL42000 battery tester
Refer to “Special Tools” for locally equivalent tools.
Diagnostic Aids
• To achieve the best, use an automatic constant -
voltage altering - current battery charger of 16 V
voltage capacity.
• The charging area should be well - ventilated.
• Do not charge the battery if it has frozen. Warm
the battery up to the room temperature before
charging and use EL42000 to test.
Battery State of Charge
Note: Using voltage to determine the battery state of
charge is only accurate after the battery has been at
rest for 24 hours. This is enough time for the acid in
each cell to equalize. If the battery has been charged
or discharged in the past 24 hours, the battery state of
charge will only be an estimate.
For maintenance - free batteries, state of charge is
estimated by reading the voltage of the battery across
the battery terminals. Because the voltage is affected
by current flow into or out of the battery, when
checking the voltage the engine must be stopped and
all electrical loads turned OFF, including parasitic
loads. The voltage can also be affected if the battery
has just been charged or discharged, so it is important
to consider what has happened to the battery in the
time just before testing. Use the following procedure to
determine the battery state of charge.

1. Be sure all electrical loads are turned off.
2. Determine whether the battery has been used in
a vehicle or charged within the past 12 hours.
○ If the answer is no, the terminal voltage will
be stabilized and no action is necessary
before reading the voltage. Go to Step 3.
○ If the answer is yes, terminal voltage will not
be stabilized. Wait for 12 hours since the last
time the battery was used/charged before
continuing.
3. Estimate the battery temperature by determining
the average temperature to which the battery has
been exposed for the past 12 hours.
Note: For the convenience of warranty, please do
record in the repair order the test code shown on the
tester. This number is the only code corresponding to
the test data for a specified code generated in a
specified time. When the same battery is tested again,
the test code may repeat occasionally. However,
generally a separate test code will be generated for
each test. Use the second - time test code or the code
for outside test.
The state of charge table is accurate to 10 percent
only after the battery has been at rest for 12 hours.
4. Measure the voltage across the battery terminals.
Refer to the following table to determine the state
of charge according to the estimated battery
temperature:
% Charged
% Charged
Battery - Voltage under 25°C
under 0°C (32°F)
(75°F)
12.75 V 100% 100%
12.7 V 100% 90%
12.6 V 90% 75%
12.45 V 75% 65%
12.2 V 65% 45%
12.0 V 40% 20%
Use the state of charge information as follows:
• A battery with a state of charge that is below 65
percent must always be recharged before
returning it for repair or continuing storage.
• A battery with a state of charge that is 65 percent
or greater is generally considered to be charged
enough to be returned for normal usage or
continuing storage. However, if the battery is
being used in slow traffic or with short drive times
or if the temperature is very hot or very cold, the
battery should be charged for the required
charging time, before returning it for usage again
or continuing storage.
The time required to charge a battery will vary
depending upon the following factors:
• Battery charger capacity—The higher the charger
9-18 Engine/Propulsion
amperage, the less time it will take to charge the
battery.
• Battery stage of charge—A completely
discharged battery requires more than twice as
much charging time as a half charged battery. In a
discharged battery with a voltage below 11 V, the
battery has a very high internal resistance and
may only accept a very low current at first. Later,
as the charging current causes the acid content to
increase in the electrolyte, the charging current
will increase. Extremely discharged batteries may
not activate the reversed voltage protection in
some chargers. Refer to the manufacturer
instructions for operating this circuitry.
• Battery temperature—The colder the battery is
the more time it takes to recharge the battery. The
charging current accepted by a cold battery is
very low at first. As the battery temperature
increases the charging current will increase.
Charging Procedure
Caution: Turn off the ignition switch when connecting
or disconnecting the battery cables, the battery
charger or the jumper cables. Failure to do so may
damage the engine control module/powertrain control
module or other electronic elements.
Caution: Refer to “0.2.1.30 Fastener Caution”. For
side terminal battery charging with the battery cable
connected, connect the charger to the positive cable
bolt and the ground away from the battery respectively.
For side terminal battery charging with the battery
cable disconnected, install the battery side terminal
adapter and connect the charger to the adapter.
Tighten
Tighten the battery side terminal adapter to 15 N·m
(11 lb in). Use the following procedure to charge the
battery:
1. Turn off the charger.
2. Be sure that all battery terminal connections are
clean and firm.
3. Connect the battery positive wire to the battery
positive terminal, or to the underhood split jumper
double - end bolt.
Never connect the battery negative cable to other
vehicle electrical accessory or any device shell.
The battery charger can damage these devices.
9-19 Engine/Propulsion

4. Connect the charger negative wire to the engine

ground or ground double - end bolt in the engine
compartment. The engine ground or ground
double - end bolt should be directly connected to
the battery negative terminal and be away from
the battery. If the battery negative cable has been
disconnected and a terminal adapter is used,
connect directly to the adapter.
5. Turn on the charger and set to the maximum for
normal charging.
6. Check the battery on a half - hour basis after the
charger is turned on.
○ Charge the battery until the constant -
voltage altering - current charger indicates
that the battery is fully charged.
○ Touch the battery side to estimate the battery
temperature. If the side is felt hot or the
temperature exceeds 45°C (125°F), interrupt
charging first to allow the battery to cool
down and then resume charging.
7. Preform battery test after charging. Refer to
“9.1.3.3 Battery Inspection/Test”.
 9-20 Engine/Propulsion

9.1.4 Repair Instructions

9.1.4.2 Battery Negative Cable Disconnection and Connection (37733)

Battery Negative Cable Disconnection and Connection

Callout Component Name
Preliminary Procedure
Warnings: Refer to “0.2.1.42 Battery Disconnect Warning”.
1. Turn the ignition switch to the OFF position.
2. Remove the cover plate assembly at left side of engine compartment. Refer to “2.1.2.17 Engine Compartment
Side Cover Replacement”.
Battery negative pole fastening nut (Qty.: 1)
Caution: Refer to “0.2.1.30 Fastener Caution”.
1
Tighten
6±1 N·m
2 Battery negative cable
9-21 Engine/Propulsion

9.1.4.3 Battery Negative Cable Replacement (37760)

Battery Negative Cable Replacement

Callout Component Name
Preliminary Procedure
Warnings: Refer to “0.2.1.42 Battery Disconnect Warning”.
1. Turn the ignition switch to the OFF position.
2. Remove the cover plate assembly at left side of engine compartment. Refer to “2.1.2.17 Engine Compartment
Side Cover Replacement”.
Battery negative cable retaining clip nut (Qty.: 1)
Caution: Refer to “0.2.1.30 Fastener Caution”.
1
Tighten
6±1 N·m
Front harness and battery negative cable connecting nut (Qty.: 1)
2 Tighten
6±1 N·m
3 Battery negative cable clip (Qty.: 1)
Battery negative cable ground bolt (Qty.: 1)
4 Tighten
9±1.5 N·m
5 Battery negative cable
 9-22 Engine/Propulsion

9.1.4.4 Battery Positive Cable Replacement (B15T - MT)

Battery Positive Cable Replacement (B15T - MT)

Callout Component Name
Preliminary Procedure
Warnings: Refer to “0.2.1.42 Battery Disconnect Warning”.
1. Remove the cover plate assembly at left side of engine compartment. Refer to “2.1.2.17 Engine Compartment
Side Cover Replacement”.
2. Disconnect the battery negative pole. Refer to “9.1.4.2 Battery Negative Cable Disconnection and
Connection”.
3. Lift the vehicle. Refer to “1.1.1.4 Lifting and Jacking the Vehicle”.
1 Battery positive cable trim cover
Battery positive cable and fuse block connecting nut (Qty.: 1)
Caution: Refer to “0.2.1.30 Fastener Caution”.
2
Tighten
9±1.5 N·m
Battery positive cable and front harness connecting nut (Qty.: 1)
Caution: Refer to “0.2.1.30 Fastener Caution”.
3
Tighten
9±1.5 N·m
Battery positive cable retaining clip nut (Qty.: 1)
Caution: Refer to “0.2.1.30 Fastener Caution”.
4
Tighten
9±1.5 N·m
9-23 Engine/Propulsion

Battery Positive Cable Replacement (B15T - MT) (Cont’d)

Callout Component Name
5 Battery positive cable clip (Qty.: 4)
Starter battery end nut (Qty.: 1)
Caution: Refer to “0.2.1.30 Fastener Caution”.
6
Tighten
13±2 N·m
7 Battery positive cable generator end shield
Generator battery end nut (Qty.: 1)
Caution: Refer to “0.2.1.30 Fastener Caution”.
8
Tighten
13±2 N·m
9 Battery positive cable
 9-24 Engine/Propulsion

9.1.4.7 Battery Replacement (37462)

Replacement of Battery
Callout Component Name
Preliminary Procedure
1. Remove the cover plate assembly at left side of engine compartment. Refer to “2.1.2.17 Engine Compartment
Side Cover Replacement”.
2. Disconnect the battery negative pole. Refer to “9.1.4.2 Battery Negative Cable Disconnection and
Connection”.
3. Disconnect the battery positive cable. Refer to “Battery Positive Cable Replacement”.
Battery retaining nut (Qty.: 2)
Caution: Refer to “0.2.1.30 Fastener Caution”.
1
Tighten
3±1 N·m
2 Battery trim strip
3 Battery holder
4 Battery
9-25 Engine/Propulsion

9.1.4.8 Battery Tray Replacement

Battery Tray Replacement

Callout Component Name
Preliminary Procedure
1. Remove the cover plate assembly at left side of engine compartment. Refer to “2.1.2.17 Engine Compartment
Side Cover Replacement”.
2. Remove the battery. Refer to “9.1.4.7 Battery Replacement”.
3. Remove the engine control module. Refer to “9.3.4.1 Engine Control Module Replacement”.
4. Remove the air cleaner and battery tray connecting bolt (1.8L).
Battery tray fastening bolt (Qty.: 4)
Caution: Refer to “0.2.1.30 Fastener Caution”.
1
Tighten
20±3 N·m
Battery tray
2 Procedure
Disconnect the harness clip on the battery tray.
 9-26 Engine/Propulsion

9.1.4.10 Generator Replacement - 1.5T (37565)

Removal Steps
1. Disconnect the battery negative cable. Refer to “9.1.4.2 Battery
Negative Cable Disconnection and Connection”.
2. Remove the drive belt. Refer to “Water Pump Belt Replacement”.
3. Remove the drive belt idler.
4. Open the cable protective cover (1).
5. Turn to loosen the generator cable nut (2) and disconnect the
generator cable (3).
6. Disconnect the generator electrical connector (4) from the
generator.

7. Loosen generator bolt (1).

8. Remove generator assembly (2).

Installation Procedure
1. Install the generator to the bracket and tighten the generator bolt (1)
to 40±5 N·m.
2. Connect the battery positive wire (2) to the generator and tighten
the nut (3) to 13±2 N·m.
3. Close the dust cover (4).
4. Connect the generator electrical connector (5).
5. Install the drive belt. Refer to “Water Pump Belt Replacement”.
6. Connect the battery negative cable. Refer to “9.1.4.2 Battery
Negative Cable Disconnection and Connection”.
9-27 Engine/Propulsion

9.1.4.12 Starter Replacement - 1.5T (37552)

Starter Replacement (1.5L Turbocharged Engine)

Callout Component Name
Preliminary Procedure
1. Disconnect the battery negative wire. Refer to “9.1.4.2 Battery Negative Cable Disconnection and
Connection”.
Starter coil battery end nut
Caution: Refer to “0.2.1.30 Fastener Caution”.
1
Tighten
13±2 N·m
Starter coil starting end nut
Caution: Refer to “0.2.1.30 Fastener Caution”.
2
Tighten
6.5±1 N·m
Starter bolt
Caution: Refer to “0.2.1.30 Fastener Caution”.
3
Tighten
25±4 N·m
4 Starter assembly
 9-28 Engine/Propulsion

9.2 Engine Controls and Fuel - 1.5L

9.2.1 Specifications
9.2.1.1 Temperature Versus Resistance—Engine Coolant Temperature Sensor (1.5T) (210513)
Temperature Versus Resistance—Engine Coolant Temperature (ECT) Sensor
°C °F Minimum (Ω) Rated Value (Ω) Maximum (Ω)
100 212 161 187 214
90 194 211 243 277
80 176 281 323 366
70 158 382 436 492
60 140 525 596 670
50 122 739 834 934
40 104 1047 1175 1309
30 86 1530 1707 1893
20 68 2375 2500 2625
10 50 3397 3792 4208
0 32 5244 5896 6586
- 10 14 8291 9397 10570
- 20 -4 13524 15462 17521
- 30 - 22 22626 26114 29831
- 40 - 40 38855 45313 52211
9-29 Engine/Propulsion

9.2.1.2 Fastener Tightening Specifications (1.5T)

Fastener Specifications
Specification
Application
Metric
Oil pressure switch assembly 27±3 N·m
Engine control module bolt 8±2 N·m
Front oxygen sensor assembly 50±10 N·m
Rear oxygen sensor assembly 50±10 N·m
Intake air temperature/pressure sensor bolt (high
10±2 N·m
pressure)
Intake air temperature/pressure sensor bolt (low pressure) 2±0.5 N·m
Knock sensor bolt 20±5 N·m
Coolant temperature sensor assembly 18±2 N·m
Camshaft position sensor bolt 10±2 N·m
Camshaft position actuator solenoid valve bolt 10±2 N·m
Crankshaft position sensor bolt 10±2 N·m
Ignition coil fixing bolt 10±2 N·m
Fuel rail retaining bolt 18±2 N·m
Spark plug assembly 23±3 N·m
Throttle body bolt 10±2 N·m
Accelerator pedal retaining nut 10±1 N·m
Fuel filter retaining bolt 9±2 N·m
Air cleaner assembly mounting bolt 9±1 N·m
Bolt cluster–fuel tank 23±3 N·m
Bolt cluster–fuel pump 4±1 N·m
Clip retaining bolt 9±2 N·m
Muffler heat shield mounting bolt 7±1 N·m
Bolt cluster–canister assembly 5±1 N·m
Electronic recirculation valve bolt 10±2 N·m
Vehicle Speed Sensor 4±1 N·m
 9-30 Engine/Propulsion

9.2.1.3 Temperature Versus Resistance (1.5T) (210513)

Temperature Versus Resistance—Intake Air Temperature (IAT) Sensor
°C °F Minimum (Ω) Rated Value (Ω) Maximum (Ω)
100 212 186 183 190
90 194 243 238 248
80 176 322 315 330
70 158 436 425 446
60 140 595 580 611
50 122 834 810 722
40 104 1174 1139 1209
30 86 1706 1653 1760
20 68 2499 2416 2583
10 50 3791 3656 3927
0 32 5895 5671 6118
- 10 14 9395 9015 9775
- 20 -4 15458 14792 16124
- 30 - 22 26108 24907 27309
- 40 - 40 45303 43076 47529
9-31 Engine/Propulsion

9.2.2 Schematic and Routing Diagrams

9.2.2.1 B15T Engine Controls Schematics (209087)
9-32 Engine/Propulsion
9-33 Engine/Propulsion
9-34 Engine/Propulsion
9-35 Engine/Propulsion
9-36 Engine/Propulsion
9-37 Engine/Propulsion
9-38 Engine/Propulsion
9-39 Engine/Propulsion
9-40 Engine/Propulsion
9-41 Engine/Propulsion

9.2.3 Diagnostic Information and control circuit state parameters of each fuel injector:
Procedures 1. Fuel injector control circuit voltage too low test
9.2.3.1 Fuel Injector Circuit Diagnosis (1.5T) status
(226936) 2. Fuel injector control circuit open test status
Diagnostic Instructions 3. Each parameter of fuel injector control circuit
1. Perform “6.2.2.7 Diagnostic System Check - voltage too high test status should transfer
Vehicle” prior to using this diagnostic procedure. between “OK” and “Not Run” or between “Not
Run” and “OK”.
2. Refer to “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach. Circuit/System Testing
3. “6.2.2.6 Diagnostic Procedure Instructions” 1. Turn the ignition switch to OFF position and then
provides an overview of each diagnostic category. disconnect the fuel injector harness connector.
Diagnostic Fault Information 2. Turn the ignition switch to ON position and check
to confirm that the test lamp between the ignition
Short to circuit terminal and the ground illuminates.
Short to Open Signal
Circuit power
ground circuit Performance If the test lamp does not illuminate, test the circuit to
supply
see if it is open/with a high resistance. If the circuit is
Fuel
tested and confirmed to be normal and the ignition
injector P0264 - P0265 -
P02020 circuit fuse blows, test or replace the fuel injector.
1 11 12
control 3. Turn the ignition switch to OFF position, connect
Fuel a test lamp between each fuel injector control
injector P0270 - P0204 - P0271 - circuit terminal and the ignition circuit terminal
2 11 13 12 respectively.
control 4. The test lamp of each fuel injector should flash
Fuel as the engine is started.
injector P0261 - P0201 - P0262 - If the test lamp keeps illuminated, test the
3 11 13 12 corresponding control circuit to see if it is short to
control ground. If the circuit is tested and confirmed to be
Fuel normal, replace the engine control module (ECM).
injector P0267 - P0203 - P0268 - If the test lamp keeps off, test the corresponding
4 11 13 12
control circuit to see if it is short to voltage, or
control
open/with a high resistance. If the circuit is tested and
Circuit/System Description confirmed to be normal, replace the engine control
The control module enables the appropriate fuel module.
injector pulse for each cylinder. Ignition voltage is 5. If all circuits are tested and confirmed to be
supplied to the fuel injectors. The control module normal, test or replace the fuel injector.
controls each fuel injector by grounding the control
circuit via a solid state device called a driver.
Reference Information
Schematic Reference—Engine Controls Schematics
Connector End View Reference—Component
Connector End Views
Electrical Information Reference
1. Circuit Testing
2. Connector Repairs
3. Testing for Intermittent Conditions and Poor
Connections
4. Wiring Repairs
Scan Tool Reference
Caution: Refer to “6.1.1.1 Control Module
References” for scan tool information.
Circuit/System Verification
Keep the engine idling and observe the following
 9-42 Engine/Propulsion

Repair Instructions module inside the fuel tank. The fuel pump supplies
Perform the “6.2.2.8 Diagnostic Repair Verification” fuel through the fuel filter and the fuel feed pipe to the
after completing the diagnostic procedure. high pressure fuel pump. The fuel pump also provides
fuel for the Venturi pump at bottom of the fuel pump
1. Replace the fuel injector. module. The Venturi pump allows fuel filling to the fuel
2. Refer to “6.1.1.1 Control Module References” pump module. The fuel pump module contains a
for replacement, setup and programming. reverse flow check valve. The check valve maintains
9.2.3.2 Crankcase Ventilation System fuel pressure in the fuel pipeline and in this way, long
Inspection/Diagnosis cranking time is prevented.
Inspection Procedure Reference Information
1. Check the positive crankcase ventilation (PCV) Description and Operation
system, the positive crankcase ventilation hose Fuel System Description
and all pipe connections for leaks. Make repairs if Electrical Information Reference
necessary.
• Circuit Testing
2. Start the engine.
• Connector Repairs
3. Keep the engine idling, use fingers or a pair of
pliers to gently snap the positive crankcase • Testing for Intermittent Conditions and Poor
ventilation hose and hear the sound from the Connections
ventilation valve. Repeat this test for several • Wiring Repairs (CAN)
times. A sound will be produced from the Scan Tool Reference
ventilation valve each time the hose is snapped.
Refer to “6.1.1.1 Control Module References” for
4. If no sound is heard, check PCV valve for cracks scan tool information.
or damage.
Special Tools
5. Blow air to PCV. Resistance should appear as the
air passes PCV. • CH48027 Digital Pressure Gauge
6. If the clamp is protected properly, replace PCV. • J37287 Fuel Pipeline OFF Adapter
These are the tools needed here.
9.2.3.3 Fuel System Diagnosis (210564)
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• Refer to “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category.
Circuit/System Description
The engine control module (ECM) provides a high -
voltage signal for the fuel pump control module.
Except that the engine is idling or running, this high -
voltage signal from ECM to fuel pump control module
remains for 2s since ECM detects ignition. As this
signal is received, FPCM turns off the fuel pump
ground switch and provides different voltages for the
fuel pump module at the same time to maintain the
expected fuel pressure.
The fuel system is a returnless on - demand design.
The fuel pressure regulator is a part of the fuel pump
module and it eliminates the need for a return pipe
from the engine. A returnless fuel system reduces the
internal temperature of the fuel tank by not returning
hot fuel from the engine to the fuel tank. Reducing the
internal temperature of the fuel tank results in lower
evaporative emissions.
The fuel tank has its own fuel supply. An electric
turbine - style fuel pump is attached to the fuel pump
9-43 Engine/Propulsion
Circuit/System Verification
Notes:
• Clear all fuel system DTCs prior to performing this
diagnosis.
• Check the fuel system for damage or external
leakage prior to performing this diagnosis.
• Confirm whether the fuel in the fuel tank is
sufficient prior to continuing.
• To acquire the highest possible fuel pressure, the
fuel pump relay should be operated for several
times.
• Refer to Owner’s Manual CH48027–5 prior to
performing this test to acquire the safety
information and instructions.
• Do not perform fuel system diagnosis if the
engine coolant temperature exceeds 60°C
(150°F). Hot dip fuel boiling can result if the fuel
pressure reading is high. As the engine stops, the
fuel pressure can increase and reach the safety
valve upper limit 580 kPa (84PSI).
1. Turn the ignition system and all accessories off
and then install special tool ch - 48027.
2. Turn the ignition system and the engine off, and
connect a scan tool to control the fuel pump.
Confirm that the fuel pressure is between 345 -
414 kPa (50 - 60 PSI) and it does not drop by over
34 kPa (5 PSI) within one minute.
Circuit/System Testing
Notes:
• To acquire the highest possible fuel pressure, the
fuel pump relay should be operated for several
times.
• Do not start the engine.
1. Turn the ignition system and the engine off, and
connect a scan tool to control the fuel pump.
Observe the fuel pressure gauge while the fuel
pump is operating. Confirm that the fuel pressure
is between 345 - 414 kPa (50 - 60 psi).
⇒ If the fuel pressure is lower than the specified
range, remove the fuel tank and then test, inspect
and repair the items listed below. If all the
components are normal, replace the fuel pump
module.
• Fuel filter restriction or blockage
• Fuel feed pipe blockage
• Check the harness connector and fuel pump
ground circuit for poor connections.
2. Confirm that the fuel pressure does not drop by
over 34 kPa (5 PSI) within one minute.
⇒ If the fuel pressure is lower than the specified
value, carry out the following steps:
• Turn the ignition system off to reduce the fuel
pressure. Refer to “9.3.4.23 Fuel Pressure
Relief”.
• Remove the chassis fuel feed hose from the
engine fuel pipe.
• Install J37287 adapter between the chassis fuel
hose and the engine fuel pipe.
• Open the valve adapter on J37287.
• Turn the ignition system off, connect a scan tool
to control the fuel pump and draw air from CH -
48027.
• Connect a scan tool to control the fuel pump.
• Use J37287 to close the valve adapter.
• Observe the fuel pressure for one minute.
⇒ If the fuel pressure does not drop by over 34 kPa
(5 psi) within the specified time, replace the fuel
pump module.
3. Relief the fuel pressure to 69 kPa (10 psi).
Confirm that the fuel pressure does not drop by
over 14 kPa (2 PSI) within 5 minutes.
⇒ If the fuel pressure drop exceeds the specified
value, replace the fuel pump module.
4. Measure the fuel pressure with ch - 48027.
Operate the vehicle in the presence of the
customer. The fuel pressure should not drop at
acceleration, cruise or sharp turning.
⇒ If the fuel pressure drops, remove the fuel tank
and then inspect and repair the items listed below.
If all the items are normal, replace the fuel pump
module.
• Fuel filter restriction or blockage
• Fuel feed pipe blockage
• Check the harness connector and fuel pump
ground circuit for poor connections.
5. If the fuel system is tested and confirmed to be
normal, refer to “9.3.3.11 Symptoms - Engine
Controls”.
 9-44 Engine/Propulsion

Repair Instructions
Perform the diagnostic repair verification after
completing the diagnostic procedure.
• Fuel Feed Pipe Replacement (Engine–Fuel Tank)
Fuel Feed Pipe Replacement (Fuel Pump–Fuel
Filter)
• Fuel Filter Replacement
• Fuel Tank Fuel Pump Module Replacement
9.2.3.4 Symptoms - Engine Controls (1.5T)
(210561)
Diagnostic Instructions
1. Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
2. Refer to “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
3. “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category.
Symptoms Description
Symptoms cover conditions that are not covered
by
DTCs. Certain conditions can cause multiple
symptoms. These conditions are listed together
under “Symptoms Testing”. Conditions that may
only cause specific symptoms are listed
separately under “Additional Symptoms Testing”.
Perform “Symptoms Testing” before using
“Additional Symptoms Testing”.
Symptoms Definition
1. Backfire: Fuel ignites in the intake manifold or in
the exhaust system, making a loud popping
noise.
2. Cuts Out, Misses: A steady pulsation or jerking
that follows engine speed, which is usually more
for a long time. The vehicle does eventually run,
or may start but immediately stalls.
8. Hesitation, Sag, Stumble: Momentary lack of
response as the accelerator pedal is depressed.
This condition can occur at any vehicle speed.
This condition is usually more pronounced at first
attempt to make the vehicle move, as from a stop.
This fault may cause the engine to stall in severe
conditions.
9. Lack of Power, Sluggishness, or Sponginess: The
engine delivers less than expected power. Little or
no increase in speed happens when the
accelerator pedal is depressed part way.
10. Poor Fuel Economy: Fuel economy, as measured
by an actual road test, is noticeably lower than
expected. Also, the fuel economy is noticeably
lower than it was on this vehicle at one time, as
previously shown by an actual road test.
11. Rough, Unstable, or Incorrect Idle and Stalling:
The engine runs unevenly at idle. If severe, the
engine or the vehicle may shake. Engine idle may
vary in speed. Either condition may be severe
enough to stall the engine.
12. Surges/Chugging: Engine power varies under
steady throttle or cruise. It seems that the vehicle
speeds up and slows down with no change in the
accelerator pedal position.
Symptoms Verification
Perform the following inspections before using the
“Symptoms” table.
1. Ensure that the malfunction indicator lamp (MIL)
works normally. Connect the scan tool to control
the indicator lamp to illuminate and go out.
2. Ensure no DTCs are stored.

pronounced as the engine load increases. This

condition is not normally felt above 1,500 r/m or
48 km/h (30 mph). The exhaust has a steady
spitting sound at idle or at low speed.
3. Detonation/Spark Knock: A mild to severe ping
which usually gets worse while under acceleration.
The engine makes sharp metallic knocks that
change with throttle opening.
4. Afterflame: The engine continues running at an
unsteady speed after the ignition key is turned off.
5. Engine power reduction order from engine control
module (ECM): The engine control module
illuminates the engine power reduction indicator
and limits the engine power upon potential
engine/vehicle damages or exhaust system faults.
DTCs may be set.
6. Fuel Odor: An obvious odor produced by
uncombusted fuel.
7. Hard Start: Engine cranks OK, but does not start
9-45 Engine/Propulsion

3. Ensure that the scan tool data is within the normal – Collapsed
operating range. Refer to “6.1.1.1 Control – Damaged areas
Module References” for scan tool information.
– Looseness
4. Verify the customer concern.
– Incorrect installation
5. Perform “Visual/Physical Inspection” in this
– Leakage
section. “Visual/Physical Inspection” is extremely 6. Check for air leaks at the throttle body mounting
important, and can lead to correcting a condition area and the intake manifold sealing surfaces.
without additional testing. It may also help 7. Check the harness for the following conditions:
determine the cause of an intermittent condition.
– Poor connections
Identifying Intermittent Conditions
– Pinches
Many intermittent conditions occur as the
– Cuts
harness/connector moves due to engine torque, rough
pavement, vibration or physical movements of a 8. Check for loose, damaged, unseated, or missing
component. Refer to the following for a list of issues sensors/components.
that may cause an intermittent condition: 9. Check the terminals for corrosion and correct
1. Moisture and water intrusion in connectors, contact.
terminals, and components 10. Test the symptoms.
2. Incomplete connector mating 11. Backfire, Cuts Out/Misses, Detonation/Spark
3. Poor terminal contact Knock, Afterflame, Hard Start,
Hesitation/Sag/Stumble, Lack of
4. High circuit or component resistance—High
Power/Sluggishness/Sponginess, Poor Fuel
resistance can include any resistance, regardless
Economy, Rough, Unstable, or Incorrect Idle and
of the amount, which can interrupt the operation
Stalling, or Surges/Chugging.
of the component.
5. Harness that is too short or tight
6. Wire insulation that is chaffed or cut
7. High or low ambient temperature
8. High or low engine coolant temperature
9. High underhood temperature
10. Heat buildup in component or circuit due to circuit
resistance, poor terminal contact, or high
electrical load
11. High or low system voltage
12. High vehicle load conditions
13. Rough road surfaces
14. Electromagnetic interference (EMI)/circuit
interference from relays, solenoid valves or other
electrical surge
15. Incorrect installation of aftermarket, add - on
accessories
Visual/Physical Inspection
1. Ensure that the control module grounds are clean,
tight, and correctly located.
2. Ensure that the vacuum hoses are not split,
kinked, and improperly connected.
3. Ensure that the air cleaner is clean and free from
restrictions.
4. Ensure that there is no water intrusion in
connector terminals and components.
5. Check the air intake ducts for the following
conditions:

12. Test the fuel system for the following conditions:
– If the working volume and pressure of the
fuel system are correct—refer to “9.3.3.10
Fuel System Diagnosis”.
– Whether the fuel injector works normally.
– Refer to “9.3.3.9 Fuel Injector Circuit
Diagnosis”.
– Fuel quality problem.
13. Check the ignition system for the following
conditions:
– Spark plugs for incorrect heat range or an
abnormal condition—refer to “9.3.4.17 Spark
Plug
Inspection”.
– For diagnosis of coolant or oil fouled spark
plugs—refer to “9.5.3.6 Coolant in
Combustion Chamber” or “9.5.3.14 Oil
Consumption Diagnosis”.
– Wet down the secondary ignition system
with water from a spray bottle.
– Wetting down the secondary ignition system
may help locate damaged or deteriorated
components. Look/listen for arcing or
misfiring as the water is applied.
– Weak spark is detected using the J -
26792HEI spark tester.
14. Check for the following conditions:
– Whether the air conditioning compressor can
work normally.
– If the engine mixture is too lean or too rich.
Connect the scan tool and observe “Fuel
Trim” parameters.
– Check the heated oxygen sensors (HO2S).
The heated oxygen sensor should respond to
different throttle positions quickly.
Refer to “0.2.1.29 Heated Oxygen and Oxygen
Sensor Caution”.
Water intrusion in heated oxygen sensor connector
Check installation of the mass air flow sensor. If the
mass air flow sensor is not installed correctly, hard
start can result. Install the mass air flow sensor in the
correct direction.
– Fuel - fouled engine oil
– Vacuum hoses splits or kinks
– Knock sensor system for excessive spark retard
activity—observe whether the knock retard
parameter shown on the scan tool is greater than
0.
15. Check the exhaust system components for the
following conditions:
9-46 Engine/Propulsion
– The exhaust system components for the
following conditions:
– Three - way catalytic converter blockage
16. Electromagnetic interference (EMI) on a
reference voltage circuit can cause engine pause.
The scan tool can be used to detect
electromagnetic interference by monitoring the
engine speed parameter. If the engine speed
parameter increases suddenly but the actual
engine speed hardly changes, it indicates that
electromagnetic interference exists. In this case,
inspect to see if there is any high - voltage
component near the ignition control circuit.
17. Check the crankcase ventilation system for
blockage and air leakage.
18. The evaporative emission (EVAP) canister purge
solenoid valve is stuck open.
19. Check the engine coolant system for the following
conditions:
– Correct heat range of thermostat
– Correct engine coolant level—If the coolant
level is low, refer to “9.4.3.3 Loss of
Coolant”.
20. Check the engine for the following mechanical
failures:
Refer to “9.5.3.17 Symptoms - Engine
Mechanical”.
– Excessive oil in the combustion chamber or
leaking valve seals
– Engine oil consumption
– Incorrect cylinder compression
– Sticking or leaking valves
– Worn camshaft lobes
– Incorrect valve timing
– Worn rocker arm
– Broken valve springs
– Excessive carbon buildup in the combustion
chambers—Clean the chambers with top
engine cleaner. Follow the instructions on the
cleaner can.
– Incorrect engine parts
9-47 Engine/Propulsion
21. If the above conditions do not address the
symptom, refer to “Additional Symptoms Testing”.
Additional Symptoms Testing
Hard Start
• Check the throttle bore for long - time
accumulation of foreign materials. Check the
throttle and clean it if necessary.
• Test the engine coolant temperature (ECT) sensor.
Compare the engine coolant temperature sensor
value to the intake air temperature (IAT) sensor
value on a cold engine. The engine coolant
temperature and the intake air temperature
sensor values should be within approximately 3°C
(5°F). If the engine coolant temperature sensor is
out of range with the intake air temperature
sensor, test the resistance of the engine coolant
temperature sensor. Refer to “9.3.1.1
Temperature Versus Resistance—Engine
Coolant Temperature Sensor” table for
resistance specifications. Replace the engine
coolant temperature sensor if the resistance is not
within specification. Refer to “9.2.4.2 Engine
Coolant Temperature Sensor Replacement”. If
the sensor is within the specification, test the
engine coolant temperature sensor circuits for a
high resistance.
• Test the fuel pump relay operation. The fuel pump
should turn on for 2s when the ignition is turned
on. Refer to “9.2.3.3 Fuel Pump Electrical
Circuit Diagnosis”.
• Check the crankshaft to see if the end gap is so
large that the crankshaft position sensor variable
reluctance rotor misaligns with the crankshaft
position sensor. Refer to “9.5.5.25 Crankshaft
and Bearing Cleaning
and Inspection”.
Hesitation, Sag, Stumble
• Test the fuel pressure. Refer to “9.2.3.3 Fuel
Pump Electrical Circuit Diagnosis”.
• Test the generator. Refer to “9.1.3.6 Symptoms -
Engine Electrical”. If the generator output
voltage is lower than 9 V or higher than 16 V,
repair the charging system.
• Check the crankshaft to see if the end gap is so
large that the crankshaft position sensor variable
reluctance rotor misaligns with the crankshaft
position sensor. Refer to “9.5.5.25 Crankshaft
and Bearing Cleaning
and Inspection”. Test the intake manifold
absolute pressure (MAP) sensor. Refer to
“9.2.3.19 DTCP010528, P010600, P010711,
P010812, P011129, P011216 or P011317”.
Poor Fuel Economy
• Heavy loads being carried or towed
• Fast or frequent acceleration
• Check the brake system to see if braking drag
exist.
• Check the speedometer for abnormal operation.
• Check and confirm no engine coolant
temperature (ECT) value change. Start the
engine and warm it up to the operating
temperature. Connect the scan tool and observe
the parameter of “9.2.1.1 Temperature Versus
Resistance—Engine Coolant Temperature
Sensor” and compare the reading with those
listed in “6.2.1.2 K20 Engine Control Module:
Scan Tool Information”. If the reading is out of
the range specified in the list, test resistance of
the engine coolant temperature sensor. Refer to
“9.3.1.1 Temperature Versus
Resistance—Engine Coolant Temperature
Sensor” table for resistance specifications.
Replace the engine coolant temperature sensor if
the resistance is not within specification. Refer to
“9.2.4.2 Engine Coolant Temperature Sensor
Replacement”. If the sensor is within the
specification, test the engine coolant temperature
sensor circuits for a high resistance.
• Check the throttle bore for long - time
accumulation of foreign materials. Check the
throttle and clean it if necessary.
Detonation/Spark Knock
• Check the combustion chambers for excessive
carbon buildup. Clean the chambers with top
engine cleaner. Follow the instructions on the
cleaner can.
• Test the engine for an overheating condition.
Refer to “9.4.3.2 Engine Overheating”.
• Check and confirm no engine coolant
temperature (ECT) value change. Start the
engine and warm it up to the operating
temperature. Connect the scan tool and observe
the parameter of “9.2.1.1 Temperature Versus
Resistance—Engine Coolant Temperature
Sensor” and compare the reading with those
listed in “6.2.1.2 K20 Engine Control Module:
Scan Tool Information”. If the reading is out of
the range specified in the list, test resistance of
the engine coolant temperature sensor. Refer to
“9.3.1.1 Temperature Versus
Resistance—Engine Coolant Temperature
Sensor” table for resistance specifications.
Replace the engine coolant temperature sensor if
the resistance is not within specification. Refer to
“9.3.4.2 Engine Coolant Temperature Sensor
Replacement”. If the sensor is within the
specification, test the engine coolant temperature
sensor circuits for a high resistance.

• If no engine mechanical failure is present, fill high
- quality fuel satisfying the minimum vehicle
octane value requirement to the fuel tank. Lack of
Power, Hesitation or Cuts Out
• Check the engine electrical system for normal
operation. Refer to “9.1.3.6 Symptoms - Engine
Electrical”.
• Confirm that each fuel injector harness is
connected to the correct fuel injector. Rough,
Unstable, or Incorrect Idle and Stalling
• Check the throttle bore for long - time
accumulation of foreign materials. Check the
throttle and clean it if necessary.
• Inspect the engine mounts.
• Check the intake manifold and the exhaust
manifold for cast burrs. Surges/Chugging
• Test the heated oxygen sensors (HO2S). The
heated oxygen sensors should respond quickly to
a change in throttle position. If the heated oxygen
sensors do not respond to different throttle
positions, inspect for contamination from fuel,
silicon, or the incorrect use of room temperature
vulcanizing sealant. The sensors may have a
white powdery coating and result in a high, but
false signal voltage which gives a rich exhaust
indication. The powertrain control module
reduces the amount of fuel delivered to the
engine, causing a driveability fault.
• Confirm that each fuel injector harness is
connected to the correct fuel injector. Fuel Odor
• Saturated evaporative emission canister
• A condition with the internal components of the
fuel tank assembly. Refer to “9.3.3.10 Fuel Pump
Electrical Circuit Diagnosis”.
• Check the fuel pipeline for damage or aging.
9.2.3.5 DTCP042000
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
DTC Description
DTCP042000: Three - way catalytic converter oxygen
storage capacity aging
Circuit System Description
The three - way catalytic converter controls emissions
of hydrocarbons, carbon monoxide and
oxides of nitrogen. The catalyst within the converter
promotes a chemical reaction, which oxidizes the
9-48 Engine/Propulsion
hydrocarbons and the carbon monoxide that are
present in the exhaust gas. The catalytic converter
also stores oxygen. The engine control module
monitors this process by using the rear oxygen sensor.
The rear oxygen sensor produces an output signal that
the engine control module uses to calculate the
oxygen storage capacity of the catalyst. When the
catalyst is functioning properly, the rear oxygen sensor
response to the extra fuel is slow compared to the
response of the front oxygen sensor. When the rear
oxygen sensor response is near that of
the front oxygen sensor, the oxygen storage capability
and efficiency of the catalyst may be degraded below
an acceptable threshold.
Conditions for Running the DTC
• The engine speed, load, flow, exhaust
temperature are all shown on the diagnostic
window and no failure restraint factor is present.
Conditions for Setting the DTC
• The converter aging factor is < 0.2.
Action Taken When the DTC Sets
• DTC is recorded and the engine malfunction
indicator lamp illuminates.
Conditions for Clearing the DTC
• A history DTC will clear after 40 fault - free ignition
cycles.
• The body control module receives an order to
clear the DTC sent by the scan tool.
Reference Information
Electrical Information Reference
• Circuit Testing
• Connector Repairs
• Testing for Intermittent Conditions and Poor
Connections
• Wiring Repairs
9-49 Engine/Propulsion

Scan Tool Reference DTC Description

Refer to “6.1.1.1 Control Module References” for DTCP050000: Vehicle speed sensor signal abnormal
scan tool information. Circuit System Description
Circuit/System Inspection The vehicle speed sensor is installed on the
1. Clear the DTC. Does the DTC reoccur? transmission. While the vehicle is running, the vehicle
– Yes, an intermittent condition; refer to speed sensor sends to TCM rectangular pulse signals
11.3.4.7 Testing for Intermittent as the transmission output shaft spins. TCM calculates
Conditions and Poor Connections. the vehicle speed based on these rectangular pulse
signals. If no rectangular pulse signal is detected while
– If no, go to the next check. the vehicle is running, it is judged as vehicle speed
2. Check the system. Are other DTCs set up? sensor signal abnormal. In this case, TCM sets the
– If no, perform the corresponding fault DTC and illuminates AMT warning lamp.
diagnosis according to the DTC. Conditions for Running the DTC
– If no, go to the next check. • The ignition switch is turned to ON position;
3. Check the harness connectors or components. • The supply voltage is 8 V or higher;
Does breakage, poor contact, aging or looseness • The actual gear position is any of the drive gears
exist? or the reverse gear.
– If yes, inspect and remove the fault. Conditions for Setting the DTC
– If no, go to the next check. • The condition that the transmission input shaft
4. Check the three - way catalytic converter for the speed is higher 1,650 rpm and the propeller shaft
following conditions: speed is lower than 88 rpm lasts for 4s; or the
○ Dents condition that the average vehicle speed of the
left and right drive wheels is 15 km/h or higher
○ Severe discoloration caused by excessively
and the propeller shaft speed is lower than 88
high temperature
rpm lasts for 4s.
○ Internal looseness
Action Taken When the DTC Sets
○ Blockage
• Only Gear 1 or the reverse gear is available for
– If yes, replace the three - way catalytic driving.
converter.
Conditions for Clearing the DTC
– If no, go to the next check.
• 40 successive fault - free warmup cycles have
5. Check the exhaust system for the following passed.
conditions:
• One order to clear the DTC sent by the diagnostic
○ Leakage tool is received.
○ Component damage
○ Loose or missing metal member
○ Whether the oxygen sensor is installed
correctly
– If yes, repair to remove the exhaust system
fault.
– If no, replace the three - way catalytic
converter.
Repair Instructions
• Three - way Catalytic Converter Replacement
9.2.3.6 DTCP050000
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
 9-50 Engine/Propulsion

Reference Information – If yes, go to the next diagnostic step.

Schematic Reference 6. Turn the ignition switch to OFF position and
4.22.6iAMT Transmission Controls Schematics disconnect the battery negative cable.
(Vehicle Speed Sensor, Cruise Control) 7. Check ground circuit of the vehicle speed sensor.
Connector End View Reference Measure the resistance between terminal 3 of
B115 vehicle speed sensor harness connector
K71 Transmission Control Module X1, and B115 and the ground. Is it less than 1 Ω?
Vehicle Speed Sensor
– If no, test the circuit for open circuit/high
Electrical Information Reference resistance.
• Circuit Testing – If yes, go to the next diagnostic step.
• Connector Repairs 8. Connect the battery negative cable and turn the
• Testing for Intermittent Conditions and Poor ignition switch to ON position.
Connections 9. Measure the voltage between terminal 3 of B115
• Wiring Repairs vehicle speed sensor harness connector and the
Scan Tool Reference ground. Is it 0 V?
Refer to “6.1.1.1 Control Module References” for - If no, test the circuit for short to power supply.
scan tool information. – If yes, go to the next diagnostic step.
Circuit/System Inspection 10. Turn the ignition switch to OFF position and
1. Clear the DTC. Does the DTC reoccur? disconnect the battery negative cable.
– Yes, an intermittent condition; refer to 11. Disconnect K71 transmission control module X1
11.3.4.7 Testing for Intermittent harness connector X1.
Conditions and Poor Connections. 12. Check signal circuit of the vehicle speed sensor.
– If no, go to the next check. Measure the resistance between terminal 2 of
B115 vehicle speed sensor harness connector
2. Check the system. Are other DTCs set up?
and terminal 23 of K71 transmission control
– If yes, clear other DTCs first. module X1. Is it less than 1 Ω?
– If no, go to the next check. – If no, test the circuit for open circuit/high
3. Check relevant harness connectors or resistance.
components. Does breakage, poor contact, aging – If yes, go to the next diagnostic step.
or looseness exist?
– If yes, inspect and remove the fault.
– If no, go to the next check.
4. Operate the vehicle under the conditions for
running the DTC and confirm that the DTC is not
set again.
Circuit/System Testing
1. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
2. Disconnect B115 vehicle speed sensor harness
connector.
3. Perform vehicle speed sensor component testing.
Is it normal?
– If no, replace the vehicle speed sensor.
– If yes, go to the next diagnostic step.
4. Connect the battery negative cable and turn the
ignition switch to ON position.
5. Check power circuit of the vehicle speed sensor.
Measure the voltage between terminal 1 of B115
vehicle speed sensor harness connector and the
ground. Is it the battery voltage?
– If no, test the circuit for open circuit/high
resistance.
9-51 Engine/Propulsion

13. Measure the resistance between terminal 2 of Conditions for Setting the DTC
B115 vehicle speed sensor harness connector • The number of error counters sent by BCM is 255
and the ground. Is it infinite? or greater.
- If no, test the circuit for short to ground. Action Taken When the DTC Sets
– If yes, go to the next diagnostic step. • DTC is recorded.
14. Connect the battery negative cable and turn the • Communication interrupts within 5s and resumes
ignition switch to ON position. 5s later.
15. Measure the voltage between terminal 2 of B115 Conditions for Clearing the DTC
vehicle speed sensor harness connector and the
ground. Is it 0 V? • A history DTC will clear after 5 fault - free ignition
cycles.
- If no, test the circuit for short to power supply.
• The body control module receives an order to
– If yes, go to the next diagnostic step. clear the DTC sent by the scan tool.
16. Turn the ignition switch to OFF position and Reference Information
disconnect the battery negative cable.
Schematic Reference
17. Replace the transmission control module. Refer
to Transmission Control Module Programming Data Communication Schematics
and Setup. Operate the vehicle under conditions Connector End View Reference
for running the DTC. Is the DTC set? “Component Connector End Views”
– If no, diagnosis ends. Description and Operation
– If yes, install the original K71 transmission Data Link Communication Description and Operation
control module back and contact the
Electrical Information Reference
technician.
• Circuit Testing
Component Testing
• Connector Repairs
1. Turn the ignition switch to OFF position and
disconnect the battery negative cable. • Testing for Intermittent Conditions and Poor
Connections
2. Disconnect B115 vehicle speed sensor harness
connector. • Wiring Repairs
3. Connect an oscilloscope and read the
oscillograph of B115 vehicle speed sensor. Is it
rectangular wave? Is it normal?
– If no, replace the vehicle speed sensor.
– If yes, perform “Circuit/System Testing”.
Repair Instructions
• Vehicle Speed Sensor Replacement
• Transmission Control Module Replacement
• Transmission Control Module Programming and
Setup
9.2.3.7DTCU007300
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
DTC Description
DTCU007300: CAN communication network BUSOFF
error (BCAN)
Conditions for Running the DTC
The supply voltage is 6 V or higher
 9-52 Engine/Propulsion

Scan Tool Reference • DTC is recorded.

Refer to “6.1.1.1 Control Module References” for Conditions for Clearing the DTC
scan tool information. • A history DTC will clear after 5 fault - free ignition
Circuit/System Verification cycles.
Each bus unit has 2 counters, one sends error • The body control module receives an order to
counting and the other receives error counting. clear the DTC sent by the scan tool.
Counting is conducted according to the following rules: Reference Information
1. As the receiver detects an error, the receiver error Schematic Reference
counter adds 1, except that the error is a bit error
detected when active error flag or overload flag is Data Communication Schematics
sent. Connector End View Reference
2. The error counter adds 8 if the receiver detects “Component Connector End Views”
during first bit check a dominant bit after the error Description and Operation
flag is sent.
Data Link Communication Description and Operation
3. The sender error counter adds 8 every time the
Electrical Information Reference
senders send an error flag. Two circumstances
are not included: one is that after the sender • Circuit Testing
sends out an error acknowledgment, no dominant • Connector Repairs
bit acknowledgment is detected or an • Testing for Intermittent Conditions and Poor
acknowledgment error is detected and no Connections
dominant bit was detected when the sender sent
the acknowledgment error flag; the other is that • Wiring Repairs
upon occurrence of an arbiter stuffing error, the Scan Tool Reference
sender sends a recessive error flag but a Refer to “6.1.1.1 Control Module References” for
dominant bit is detected. Except the above two scan tool information.
circumstances, the sender error counter counting
does not change. Circuit/System Verification
4. When the number of error counters sent is 256 or Circuit/System Testing
greater the node enters BUS OFF status. 1. Check whether the ESP module communication
Repair Instructions on CAN bus is normal and if not, repair the
relevant network fault;
• Perform the “6.2.2.7 Diagnostic System Check -
Vehicle” after completing the diagnostic 2. If the above fault is removed or does not exist,
procedure. replace BCM.
• Refer to “6.1.1.1 Control Module References”
for control module replacement, setup, and
programming.
9.2.3.8 DTCU007700
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
DTC Description
DTCU007700: Network message $1F6 timeout
Conditions for Running the DTC
The ignition key is turned ON.
Conditions for Setting the DTC
No shift reminder message is received from ECM
within 5 cycles.
Action Taken When the DTC Sets
9-53 Engine/Propulsion
Repair Instructions
• Perform the “6.2.2.7 Diagnostic System Check -
Vehicle” after completing the diagnostic
procedure.
• Refer to “6.1.1.1 Control Module References”
for control module replacement, setup, and
programming.
9.2.3.9 DTCU012200
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
DTC Description
DTCU012200: ABS module signal invalid
Conditions for Running the DTC
• The whole vehicle is electrified.
Conditions for Setting the DTC
• An invalid standby vehicle speed bus signal is
received from ABS.
Action Taken When the DTC Sets
• If the engine main vehicle speed signal is normal
at this time, EPS performance will not be affected,
otherwise EPS at the default vehicle speed under
fault conditions will be applied.
Conditions for Clearing the DTC
• If the signal restores normal within the same
ignition cycle, the error will be reset.
Reference Information
Schematic Reference
Electronic Power Steering Control Module Pin
Schematics
Connector End View Reference
“Component Connector End Views”
Description and Operation
Data Link Communication Description and Operation
Electrical Information Reference
• Circuit Testing
• Connector Repairs
• Testing for Intermittent Conditions and Poor
Connections
• Wiring Repairs
Scan Tool Reference
Refer to “6.1.1.1 Control Module References” for
scan tool information.
Repair Instructions
1. Check ABS to see whether a wheel speed sensor
electrical fault exists and if so, repair to remove
the fault.
2. Replace EPS module assembly if necessary.
Repair Instructions
• Perform the “6.2.2.7 Diagnostic System Check -
Vehicle” after completing the diagnostic
procedure.
• Refer to “6.1.1.1 Control Module References”
for control module replacement, setup, and
programming.
9.2.3.10 DTCU011600
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
DTC Description
DTCU011600: Network message TCM node timeout
Conditions for Running the DTC
The ignition key is turned ON.
Conditions for Setting the DTC
Message $4C9,$603 is missing.
Action Taken When the DTC Sets
• DTC is recorded.
Conditions for Clearing the DTC
• A history DTC will clear after 5 fault - free ignition
cycles.
• The body control module receives an order to
clear the DTC sent by the scan tool.
 9-54 Engine/Propulsion

Reference Information 6. If all the circuits are tested and confirmed to be

Schematic Reference normal, replace the corresponding module.
Data Communication Schematics Repair Instructions
Connector End View Reference • Perform the “6.2.2.7 Diagnostic System Check -
Vehicle” after completing the diagnostic
“Component Connector End Views” procedure.
Description and Operation • Refer to “6.1.1.1 Control Module References”
Data Link Communication Description and Operation for control module replacement, setup, and
Electrical Information Reference programming.
• Circuit Testing 9.2.3.11 DTCP032716
• Connector Repairs Diagnostic Instructions
• Testing for Intermittent Conditions and Poor • Perform “6.2.2.7 Diagnostic System Check -
Connections Vehicle” prior to using this diagnostic procedure.
• Wiring Repairs • Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
Scan Tool Reference
• “6.2.2.6 Diagnostic Procedure Instructions”
Refer to “6.1.1.1 Control Module References” for
provides an overview of each diagnostic category
scan tool information.
DTC Description
Circuit/System Verification
DTCP032716: knock sensor circuit fault
Circuit/System Testing
Circuit System Description
1. Connect the scan tool to confirm that this network
trouble code is currently set. Knock sensor is used to detect collision or “detonation”
happened as the fuel - air mixture is ignited before the
2. Turn the ignition switch to OFF position and
optimum combustion point exceeds the pressure in the
measure the resistance between TCM ground
combustion chamber. This can happen when the
circuit and the ground to see if it is less than 5 Ω.
transmission is engaged at a high - speed gear and
– If the resistance is higher than the specified the engine load is high. The detection element within
range, test the circuit to see if it is open/ with the knock sensor is a piezoelectric ceramic crystal
a high resistance. through which no voltage passes under normal
3. Turn the ignition switch to OFF position and then conditions. When the sensor is subject to a
disconnect TCM module harness connector. mechanical pressure with a detonation frequency of
4. Turn the ignition switch to ON position and about 15 kHz, electric structure of the crystal will be
confirm that the test lamps between the following destructed and as a result, voltage output is generated.
circuits and the ground illuminate respectively: The voltage output is directly in proportion to the
detonation frequency.
○ Battery positive voltage input circuit
Conditions for Running the DTC
○ Battery positive voltage output circuit
• The engine speed is higher than 2600.
○ Ignition voltage input circuit
Conditions for Setting the DTC
○ Ignition voltage output circuit
• The open circuit remains for 25 combustion
○ Switch controlled battery positive voltage cycles.
power circuit
– If the test lamp does not illuminate, test the
circuit to see if it is open/ with a high
resistance. If the circuit fuse blows, test the
circuit to see if it is short to ground. If the
circuit is tested and confirmed to be normal,
replace TCM.
5. Turn the ignition switch to OFF position and
measure the resistance between CAN serial data
circuit of the module out of communication and
BCM to see if it is less than 5 Ω.
– If the resistance is higher than the specified
range, test the circuit to see if it is open/ with
a high resistance.
9-55 Engine/Propulsion

Action Taken When the DTC Sets – If yes, go to the next diagnostic step.
• The ignition angle delays - 9KW and the engine 3. Disconnect K20 engine control module harness
malfunction indicator lamp illuminates. connector X1.
Conditions for Clearing the DTC 4. Measure the resistance between terminal 2 of
• A history DTC will clear after 40 fault - free ignition B68 knock sensor harness connector and
cycles. terminal 25 of K20 engine control module harness
connector X1. Is it less than 1 Ω?
• The body control module receives an order to
clear the DTC sent by the scan tool. – If no, test the circuit for open circuit/high
resistance.
Reference Information
– If yes, go to the next diagnostic step.
Schematic Reference
5. Measure the resistance between terminal 2 of
4.10.12 Engine Controls Schematics (Crankshaft B68 knock sensor harness connector and the
Position Sensor, Coolant Temperature Sensor, and ground. Is it infinite?
Knock Sensor) - 1.5 T
- If no, test the circuit for short to ground.
Connector End View Reference
– If yes, go to the next diagnostic step.
K20 Engine Control Module X1, and B68 Knock
Sensor 6. Measure the resistance between terminal 1 of
B68 knock sensor harness connector and
Electrical Information Reference terminal 26 of K20 engine control module harness
• Circuit Testing connector X1. Is it less than 1 Ω?
• Connector Repairs – If no, test the circuit for open circuit/high
• Testing for Intermittent Conditions and Poor resistance.
Connections – If yes, go to the next diagnostic step.
• Wiring Repairs 7. Measure the resistance between terminal 1 of
Scan Tool Reference B68 knock sensor harness connector and the
ground. Is it infinite?
Refer to “6.1.1.1 Control Module References” for
scan tool information. - If no, test the circuit for short to ground.
Circuit/System Inspection – If yes, go to the next diagnostic step.
1. Clear the DTC. Does the DTC reoccur? 8. Connect the battery negative cable and turn the
ignition switch to ON position.
– Yes, an intermittent condition; refer to
11.3.4.7 Testing for Intermittent
Conditions and Poor Connections.
– If no, go to the next check.
2. Check the system. Are other DTCs set up?
– If no, perform the corresponding fault
diagnosis according to the DTC.
– If no, go to the next check.
3. Check the harness connectors or components.
Does breakage, poor contact, aging or looseness
exist?
– If yes, inspect and remove the fault.
– If no, perform “Circuit/System Testing”.
4. Operate the vehicle under the conditions for
running the DTC and confirm that the DTC is not
set again.
Circuit/System Testing
1. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
2. Perform knock sensor component testing. Is it
normal?
– If no, replace the knock sensor.
 9-56 Engine/Propulsion

9. Measure the voltage between terminal 2 of B68 • BUS OFF fault happens continuously for twice.
knock sensor harness connector and the ground. Action Taken When the DTC Sets
Is it 0 V?
• DTC is recorded and the engine malfunction
- If no, test the circuit for short to power supply. indicator lamp does not illuminate.
– If yes, go to the next diagnostic step. Conditions for Clearing the DTC
10. Measure the voltage between terminal 1 of B68 • A history DTC will clear after 40 fault - free ignition
knock sensor harness connector and the ground. cycles.
Is it 0 V?
• The body control module receives an order to
- If no, test the circuit for short to power supply. clear the DTC sent by the scan tool.
– If yes, go to the next diagnostic step. Reference Information
11. Turn the ignition switch to OFF position and Schematic Reference
disconnect the battery negative cable.
4.12.3 Data Communication Schematics (CAN Bus -
12. Replace the engine control module. Refer to LV3)
Engine Control Module Programming and Setup.
Operate the vehicle under conditions for running Connector End View Reference
the DTC. Is the DTC set? K20 Engine Control Module X2, and X84 Data Link
– If no, diagnosis ends. Connector
– If yes, install the original module back and Electrical Information Reference
contact the technician. • Circuit Testing
Component Testing • Connector Repairs
1. Turn the ignition switch to OFF position and • Testing for Intermittent Conditions and Poor
disconnect the battery negative cable. Connections
2. Disconnect B68 knock sensor harness connector. • Wiring Repairs
3. Measure the voltage between terminal 2 and Scan Tool Reference
terminal 1 of B68 knock sensor harness Refer to “6.1.1.1 Control Module References” for
connector. Is it 4.9 MΩ ( - 40°C–150°C)? scan tool information.
– If no, replace the knock sensor. Circuit/System Inspection
– If yes, perform “circuit system testing”. 1. Clear the DTC. Does the DTC reoccur?
Repair Instructions – Yes, an intermittent condition; refer to
• Knock Sensor Replacement 11.3.4.7 Testing for Intermittent
• Engine Control Module Replacement Conditions and Poor Connections.
• Engine Control Module Programming and Setup – If no, go to the next check.
9.2.3.12 DTCU000100
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
DTC Description
DTCU000100: CAN communication related diagnosis
Circuit System Description
The engine control module communicates via high -
speed CAN.
Conditions for Running the DTC
• Start upon 1000 ms after the communication core
is activated.
Conditions for Setting the DTC
9-57 Engine/Propulsion

2. Check the system. Are other DTCs set up? 8. Connect the battery negative cable and turn the
– If no, perform the corresponding fault ignition switch to ON position.
diagnosis according to the DTC. 9. Measure the voltage between terminal 49 of K20
– If no, go to the next check. engine control module harness connector X2 and
the ground. Is it 2.7 ± 0.1 V?
3. Check the harness connectors or components.
Does breakage, poor contact, aging or looseness - If no, test the circuit for short to power supply.
exist? – If yes, go to the next diagnostic step.
– If yes, inspect and remove the fault. 10. Turn the ignition switch to OFF position and
– If no, perform “Circuit/System Testing”. disconnect the battery negative cable.
Circuit/System Testing 11. Check the CAN network L circuit. Measure the
resistance between terminal 33 of K20 engine
Confirm the following conditions: control module harness connector X2 and
• Control module and local interconnect network terminal 11 of X84 data link connector harness
device equipped for vehicle connector. Is it less than 1 Ω?
• Control module position on CAN serial data circuit – If no, test the circuit for open circuit/high
• Power supply+, ignition, ground, communication resistance.
enabling and serial data circuit terminals of – If yes, go to the next diagnostic step.
control module 12. Measure the resistance between terminal 33 of
1. Before diagnosis, it should be confirmed that K20 engine control module harness connector X2
there is no DTC in communication among other and the ground. Is it infinite?
modules. If there is a DTC, diagnose it first. - If no, test the circuit for short to ground.
2. Turn the ignition switch to OFF position and – If yes, go to the next diagnostic step.
disconnect the battery negative cable.
3. Measure the resistance between terminal 3
(CANH) and terminal 11 (CANL) of X84 data link
connector under the following conditions:
Condition A: Measure the resistance under the
connection state of all connectors. Is it 60±5 Ω?
Condition B: Measure the resistance with 1 control
module separated from the engine control module or
body control module. Is it 120±5 Ω?
Condition C: Measure the resistance with connectors
of engine control module and body control module
being separated. Is it infinite?
4. If the above - mentioned resistance does not
meet the standard value, disconnect the harness
connector at the control module which cannot
communicate.
5. Disconnect K20 engine control module harness
connector X2.
6. Check the CAN network H circuit. Measure the
resistance between terminal 49 of K20 engine
control module harness connector X2 and
terminal 3 of X84 data link connector harness
connector. Is it less than 1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
7. Measure the resistance between terminal 49 of
K20 engine control module harness connector X2
and the ground. Is it infinite?
- If no, test the circuit for short to ground.
– If yes, go to the next diagnostic step.
 9-58 Engine/Propulsion

13. Connect the battery negative cable and turn the pulse width modulation signals for the solenoid valve
ignition switch to ON position. by monitoring data of the crankshaft position sensor
14. Measure the voltage between terminal 33 of K20 and the intake camshaft position sensor. In this way,
engine control module harness connector X2 and the intake camshaft timing control requirements are
the ground. Is it 2.3 ± 0.1 V? satisfied.
- If no, test the circuit for short to power supply. Conditions for Running the DTC
– If yes, go to the next diagnostic step. • DTCP000A71, P000A77: Engine speed
600~4,800 rpm, coolant temperature 20~120°C,
15. Turn the ignition switch to OFF position and engine oil temperature 10~130°C
disconnect the battery negative cable.
• DTCP001013, P208811, P208912, P001621,
16. Replace the engine control module. Refer to P001622: Engine is running and the battery
Engine Control Module Programming and Setup. voltage is higher than 9 V.
Operate the vehicle under conditions for running
the DTC. Is the DTC set? • DTCP001200: Crankshaft and camshaft self -
learning is finished and diagnosis is carried out at
– If no, diagnosis ends. starting.
– If yes, install the original module back and • DTCP001629: Offline inspection.
contact the technician.
• DTCP034100: Starting.
Repair Instructions
Conditions for Setting the DTC
• Engine Control Module Replacement
• DTCP000A71, P000A77: During each VVT
• Engine Control Module Programming and Setup (engine variable valve timing) test cycle, the
9.2.3.13 DTCP000A71, P000A77, P001013, maximum position angle reached by VVT (engine
P001200, P001621, P001622, P001629, variable valve timing) deviates from the position
P034100, P208811 or P208912 angle of VVT (engine variable valve timing) at the
Diagnostic Instructions beginning of testing.
• Perform “6.2.2.7 Diagnostic System Check - • DTCP001013: Circuit remains open for 0.5s.
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
DTC Description
DTCP000A71: intake VVT operation fault (slow)
DTCP000A77: intake VVT operation fault (stuck)
DTCP001013: intake VVT circuit open
DTCP001200: intake camshaft lock position operation
not plausible
DTCP001621: intake camshaft position advanced
DTCP001622: intake camshaft position delayed
DTCP001629: intake camshaft position jump
DTCP034100: intake camshaft phase sensor signal
not plausible
DTCP208811: intake VVT circuit short to ground
DTCP208912: intake VVT circuit short to power supply
Circuit System Description
While the engine is running, the engine control module
inputs information as per the crankshaft position and
outputs pulse width modulation signals to control the
intake camshaft solenoid valve. The power supply is
from power source flowing through the main relay. The
camshaft position actuator solenoid valve advance or
delay the camshaft oil flow by controlling the oil
pressure; the engine control module provides drive
9-59 Engine/Propulsion

• DTCP001200: The difference between actual – If no, go to the next check.

angle of intake VVT (engine variable valve timing) 3. Check the harness connectors or components.
and the default position angle is greater than 10 Does breakage, poor contact, aging or looseness
KW. exist?
• DTCP001621: Signal position advance detected. – If yes, inspect and remove the fault.
• DTCP001622: Signal position delay detected. – If no, go to the next check.
• DTCP001629: Average deviation is > 20deg•CrS. 4. Check the engine oil. Do problems such as
• DTCP034100: Signal not plausible. insufficient oil, too much sundries, incorrect
• DTCP208811: Circuit remains short to ground for viscosity and low oil pressure exist?
0.5s. – If yes, replace the engine oil or find out the
• DTCP208912: Circuit remains short to power cause of low oil pressure.
supply for 0.5s. – If no, go to the next check.
Action Taken When the DTC Sets 5. Check the camshaft position actuator solenoid
• DTCP000A71, P000A77, P001200: DTC is valve - intake. Does problems such as blockage
recorded and engine malfunction indicator lamp by sundries, seizure, not fully released oil
does not illuminate. pressure and lock pin failure exist?
• DTCP001013, P001621, P001622, P001629, – If yes, carry out inspections, repairs and
P034100, P208811, P208912: DTC is recorded maintenance as necessary.
and engine malfunction indicator lamp – If no, go to the next check.
illuminates. 6. Check fuse F9UA. Has it blown?
Conditions for Clearing the DTC – If yes, replace the fuse and check to position
• A history DTC will clear after 40 fault - free ignition and remove the power circuit short to ground
cycles. fault.
• The body control module receives an order to – If no, perform “Circuit/System Testing”.
clear the DTC sent by the scan tool.
Reference Information
Schematic Reference
4.10.16 Engine Controls Schematics (Intake Camshaft
Position Sensor, and Intake VVT Valve) - 1.5 T
Connector End View Reference
K20 Engine Control Module X1, and Q6F Camshaft
Position Actuator Solenoid Valve - Intake
Electrical Information Reference
• Circuit Testing
• Connector Repairs
• Testing for Intermittent Conditions and Poor
Connections
• Wiring Repairs
Scan Tool Reference
Refer to “6.1.1.1 Control Module References” for
scan tool information.
Circuit/System Inspection
1. Clear the DTC. Does the DTC reoccur?
– Yes, an intermittent condition; refer to
11.3.4.7 Testing for Intermittent
Conditions and Poor Connections.
– If no, go to the next check.
2. Check the system. Are other DTCs set up?
– If no, perform the corresponding fault
diagnosis according to the DTC.
 9-60 Engine/Propulsion

Circuit/System Testing – If yes, install the original module back and

1. Turn the ignition switch to OFF position and contact the technician.
disconnect the battery negative cable. Component Testing
2. Perform the camshaft position actuator solenoid 1. Turn the ignition switch to OFF position and
valve - intake component testing. Is it normal? disconnect the battery negative cable.
– If no, replace the camshaft position actuator 2. Disconnect Q6F camshaft position actuator
solenoid valve - intake. solenoid valve - intake harness connector.
– If yes, go to the next diagnostic step. 3. Remove the camshaft position actuator solenoid
3. Connect the battery negative cable and turn the valve - intake.
ignition switch to ON position. 4. Measure the resistance between terminal 1 and
4. Check power circuit of the camshaft position terminal 2 of the camshaft position actuator
actuator solenoid valve - intake. Measure the solenoid valve - intake. Is it about 9 Ω?
voltage between terminal 1 of Q6F camshaft – If no, replace the camshaft position actuator
position actuator solenoid valve - intake harness solenoid valve - intake.
connector and the ground. Is it the battery – If yes, perform “circuit system testing”.
voltage?
Repair Instructions
– If no, test the circuit for open circuit/high
resistance. • Camshaft Position Actuator Solenoid Valve -
Intake Replacement
– If yes, go to the next diagnostic step.
• Engine Control Module Replacement
5. Turn the ignition switch to OFF position and
disconnect the battery negative cable. • Engine Control Module Programming and Setup
6. Disconnect K20 engine control module harness 9.2.3.14 DTCP000B71, P000B77, P001313,
connector X1. P001500, P001821, P001822, P001829,
P034600, P209011 or P209112
7. Check control circuit of the camshaft position
actuator solenoid valve - intake. Measure the Diagnostic Instructions
resistance between terminal 2 of Q6F camshaft • Perform “6.2.2.7 Diagnostic System Check -
position actuator solenoid valve - intake harness Vehicle” prior to using this diagnostic procedure.
connector and terminal 7 of K20 engine control • Review “6.2.2.5 Strategy Based Diagnosis” for
module harness connector X1. Is it less than 1 Ω? an overview of the diagnostic approach.
– If no, test the circuit for open circuit/high • “6.2.2.6 Diagnostic Procedure Instructions”
resistance. provides an overview of each diagnostic category
– If yes, go to the next diagnostic step.
8. Measure the resistance between terminal 2 of
Q6F camshaft position actuator solenoid valve -
intake harness connector and the ground. Is it
infinite?
- If no, test the circuit for short to ground.
– If yes, go to the next diagnostic step.
9. Connect the battery negative cable and turn the
ignition switch to ON position.
10. Measure the voltage between terminal 2 of Q6F
camshaft position actuator solenoid valve - intake
harness connector and the ground. Is it 0 V?
- If no, test the circuit for short to power supply.
– If yes, go to the next diagnostic step.
11. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
12. Replace the engine control module. Refer to
Engine Control Module Programming and Setup.
Operate the vehicle under conditions for running
the DTC. Is the DTC set?
– If no, diagnosis ends.
9-61 Engine/Propulsion

DTC Description • DTCP001821: Signal position advance detected.

DTCP000B71: Exhaust VVT operation fault (slow) • DTCP001822: Signal position delay detected.
DTCP000B77: Exhaust VVT operation fault (stuck) • DTCP001829: Average deviation is > 20.
DTCP001313: Exhaust VVT circuit open • DTCP034600: Signal remains low.
DTCP001500: Exhaust camshaft lock position • DTCP209011: Circuit remains short to ground for
operation not plausible 0.5s.
DTCP001821: Exhaust camshaft position advance • DTCP209112: Circuit remains short to power
DTCP001822: Exhaust camshaft position delay supply for 0.5s.
DTCP001829: Exhaust camshaft position jump Action Taken When the DTC Sets
DTCP034600: Exhaust camshaft phase sensor signal • DTCP000B71, P000B77, P001500: DTC is
not plausible recorded and engine malfunction indicator lamp
does not illuminate.
DTCP209011: Exhaust VVT circuit short to ground
• DTCP001313, P001821, P001822, P001829,
DTCP209112: Exhaust VVT circuit short to power P209011, P209112, P034600: DTC is recorded
supply and engine malfunction indicator lamp
Circuit System Description illuminates.
While the engine is running, the engine control module Conditions for Clearing the DTC
inputs information as per the crankshaft position and • A history DTC will clear after 40 fault - free ignition
outputs pulse width modulation signals to control the cycles.
exhaust camshaft solenoid valve. The power supply is
from power source flowing through the main relay. The • The body control module receives an order to
camshaft position actuator solenoid valve advance or clear the DTC sent by the scan tool.
delay the camshaft oil flow by controlling the oil Reference Information
pressure; the engine control module provides drive Schematic Reference
pulse width modulation signals for the solenoid valve
by monitoring data of the crankshaft position sensor 4.10.16 Engine Controls Schematics (Intake Camshaft
and the exhaust camshaft position sensor. In this way, Position Sensor, and Intake VVT Valve) - 1.5 T
the exhaust camshaft timing control requirements are Connector End View Reference
satisfied. K20 Engine Control Module X1, and Q6F Camshaft
Conditions for Running the DTC Position Actuator Solenoid Valve - Exhaust
• DTCP000B71, P000B77: Engine speed
600~4,800 rpm, coolant temperature 50~120°C
• DTCP001313, P209011, P209112, P001821,
P001822: Engine is running and the battery
voltage is higher than 9 V.
• DTCP001500: Crankshaft and camshaft self -
learning is finished and diagnosis is carried out at
starting.
• DTCP001829: Offline inspection.
• DTCP034600: Starting.
Conditions for Setting the DTC
• DTCP000B71, P000B77: During each VVT
(engine variable valve timing) test cycle, the
deviation between the maximum position angle
reached by VVT (engine variable valve timing)
and the position angle of VVT (engine variable
valve timing) at the beginning of testing fails the
specification.
• DTCP001313: Circuit remains open for 0.5s.
• DTCP001500: The difference between actual
angle of intake VVT (engine variable valve timing)
and the default position angle is greater than 10
KW.
 9-62 Engine/Propulsion

Electrical Information Reference 3. Connect the battery negative cable and turn the
• Circuit Testing ignition switch to ON position.
• Connector Repairs 4. Check power circuit of the camshaft position
actuator solenoid valve - exhaust. Measure the
• Testing for Intermittent Conditions and Poor voltage between terminal 1 of Q6E camshaft
Connections position actuator solenoid valve - exhaust
• Wiring Repairs harness connector and the ground. Is it the
Scan Tool Reference battery voltage?
Refer to “6.1.1.1 Control Module References” for – If no, test the circuit for open circuit/high
scan tool information. resistance.
Circuit/System Inspection – If yes, go to the next diagnostic step.
1. Clear the DTC. Does the DTC reoccur? 5. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
– Yes, an intermittent condition; refer to
11.3.4.7 Testing for Intermittent 6. Disconnect K20 engine control module harness
Conditions and Poor Connections. connector X1.
– If no, go to the next check. 7. Check control circuit of the camshaft position
actuator solenoid valve - exhaust. Measure the
2. Check the system. Are other DTCs set up?
resistance between terminal 2 of Q6E camshaft
– If no, perform the corresponding fault position actuator solenoid valve - exhaust
diagnosis according to the DTC. harness connector and terminal 5 of K20 engine
– If no, go to the next check. control module harness connector X1. Is it less
3. Check the harness connectors or components. than 1 Ω?
Does breakage, poor contact, aging or looseness – If no, test the circuit for open circuit/high
exist? resistance.
– If yes, inspect and remove the fault. – If yes, go to the next diagnostic step.
– If no, go to the next check. 8. Measure the resistance between terminal 2 of
4. Check the engine oil. Do problems such as Q6E camshaft position actuator solenoid valve -
insufficient oil, too much sundries, incorrect exhaust harness connector and the ground. Is it
viscosity and low oil pressure exist? infinite?
– If yes, replace the engine oil or find out the - If no, test the circuit for short to ground.
cause of low oil pressure. – If yes, go to the next diagnostic step.
– If no, go to the next check.
5. Check the camshaft position actuator solenoid
valve - exhaust. Do problems such as blockage
by sundries, seizure, not fully released oil
pressure and lock pin failure exist?
– If yes, carry out inspections, repairs and
maintenance as necessary.
– If no, go to the next check.
6. Check fuse F9UA. Has it blown?
– If yes, replace the fuse and check to position
and remove the power circuit short to ground
fault.
– If no, perform “Circuit/System Testing”.
Circuit/System Testing
1. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
2. Perform camshaft position actuator solenoid
valve - exhaust component testing. Is it normal?
– If no, replace the camshaft position actuator
solenoid valve - exhaust.
– If yes, go to the next diagnostic step.
9-63 Engine/Propulsion

9. Connect the battery negative cable and turn the DTCP00531E: Upstream oxygen sensor heater
ignition switch to ON position. internal resistance not plausible
10. Measure the voltage between terminal 2 of Q6E Circuit System Description
camshaft position actuator solenoid valve - The oxygen sensor includes a sensing element that
exhaust harness connector and the ground. Is it 0 can get contact with exhaust from the exhaust
V? manifold. The oxygen sensor heating resistor adopts
- If no, test the circuit for short to power supply. 12 V power supply and it gets connected with another
– If yes, go to the next diagnostic step. resistor within the engine control module in a series
manner, forming a voltage sharing loop. The engine
11. Turn the ignition switch to OFF position and control module provides grounding for the heating
disconnect the battery negative cable. resistor. The sensing element of the oxygen sensor
12. Replace the engine control module. Refer to can be activated only when the temperature reaches
Engine Control Module Programming and Setup. about 300°C. Additional heating is provided by the
Operate the vehicle under conditions for running heating resistor element. This can reduce the warm -
the DTC. Is the DTC set? up time and minimize starting emission.
– If no, diagnosis ends. Conditions for Running the DTC
– If yes, install the original module back and • DTCP003013, P003111, P003212: Engine is
contact the technician. running and the battery voltage is higher than 9 V.
Component Testing • DTCP00531E: Exhaust temperature is within the
1. Turn the ignition switch to OFF position and diagnostic range 300~600°C.
disconnect the battery negative cable. Conditions for Setting the DTC
2. Disconnect Q6E camshaft position actuator • DTCP003013: Circuit remains open for 0.5s.
solenoid valve - exhaust harness connector. • DTCP003111: Circuit remains short to ground for
3. Remove the camshaft position actuator solenoid 0.5s.
valve - exhaust. • DTCP003212: Circuit remains short to power
4. Measure the resistance between terminal 1 and supply for 0.5s.
terminal 2 of the camshaft position actuator • DTCP00531E: Current resistance is higher than
solenoid valve - exhaust. Is it about 9 Ω? the threshold value.
– If no, replace the camshaft position actuator
solenoid valve - exhaust.
– If yes, perform “circuit system testing”.
Repair Instructions
• Camshaft Position Actuator Solenoid Valve -
Exhaust Replacement
• Engine Control Module Replacement
• Engine Control Module Programming and Setup
9.2.3.15 DTCP003013, P003111, P003212 or
P00531E
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
DTC Description
DTCP003013: Upstream oxygen sensor heater control
circuit open
DTCP003111: Upstream oxygen sensor heater control
circuit short to ground
DTCP003212: Upstream oxygen sensor heater control
circuit short to power supply
 9-64 Engine/Propulsion

Action Taken When the DTC Sets disconnect the battery negative cable.
• DTC is recorded and the engine malfunction 2. Perform front heated oxygen sensor component
indicator lamp illuminates. testing. Is it normal?
Conditions for Clearing the DTC – If no, replace the front heated oxygen sensor.
• A history DTC will clear after 40 fault - free ignition – If yes, go to the next diagnostic step.
cycles. 3. Connect the battery negative cable and turn the
• The body control module receives an order to ignition switch to ON position.
clear the DTC sent by the scan tool. 4. Check heating power circuit of the front heated
Reference Information oxygen sensor. Measure the voltage between
Schematic Reference terminal 2 of QWL10 front heated oxygen sensor
harness connector and the ground. Is it the
4.10.14 Engine Controls Schematics (Oxygen Sensor, battery voltage?
Coolant Temperature Sensor) - 1.5 T
– If no, test the circuit for open circuit/high
Connector End View Reference resistance.
K20 Engine Control Module X1, and QWL10 Front – If yes, go to the next diagnostic step.
Heated Oxygen Sensor
5. Turn the ignition switch to OFF position and
Electrical Information Reference disconnect the battery negative cable.
• Circuit Testing 6. Disconnect K20 engine control module harness
• Connector Repairs connector X1.
• Testing for Intermittent Conditions and Poor 7. Check heating control circuit of the front heated
Connections oxygen sensor. Measure the resistance between
• Wiring Repairs terminal 4 of QWL10 front heated oxygen sensor
harness connector and terminal 9 of K20 engine
Scan Tool Reference
control module harness connector X1. Is it less
Refer to “6.1.1.1 Control Module References” for than 1 Ω?
scan tool information.
– If no, test the circuit for open circuit/high
Circuit/System Inspection resistance.
1. Clear the DTC. Does the DTC reoccur? – If yes, go to the next diagnostic step.
– Yes, an intermittent condition; refer to
11.3.4.7 Testing for Intermittent
Conditions and Poor Connections.
– If no, go to the next check.
2. Check the system. Are other DTCs set up?
– If no, perform the corresponding fault
diagnosis according to the DTC.
– If no, go to the next check.
3. Check the harness connectors or components.
Does breakage, poor contact, aging or looseness
exist?
– If yes, inspect and remove the fault.
– If no, go to the next check.
4. Check fuse F9UA. Has it blown?
– If yes, replace the fuse and check to position
and remove the power circuit short to ground
fault.
– If no, perform “Circuit/System Testing”.
5. Operate the vehicle under the conditions for
running the DTC and confirm that the DTC is not
set again.
Circuit/System Testing
1. Turn the ignition switch to OFF position and
9-65 Engine/Propulsion

8. Measure the resistance between terminal 4 of DTCP003400: Supercharging system relief valve short
QWL10 front heated oxygen sensor harness to ground
connector and the ground. Is it infinite? DTCP003500: Supercharging system relief valve short
- If no, test the circuit for short to ground. to power supply
– If yes, go to the next diagnostic step. DTCP226100: Relief control valve mechanical fault
9. Connect the battery negative cable and turn the Circuit System Description
ignition switch to ON position. The twin scroll turbocharger includes one exhaust
10. Measure the voltage between terminal 4 of relief valve that is controlled by the engine control
QWL10 front heated oxygen sensor harness module (ECM) via pulse width modulation (PWM). The
connector and the ground. Is it 0 V? valve is used to regulation pressure ratio of the
- If no, test the circuit for short to power supply. compressor. The compressor by - pass valve
controlled by the engine control module is integrated
– If yes, go to the next diagnostic step. within this device and it is used to avoid compressor
11. Turn the ignition switch to OFF position and surge or damage caused by vibration in case that the
disconnect the battery negative cable. closed throttle opens suddenly. The by - pass valve
12. Replace the engine control module. Refer to opens during deceleration when the throttle is closed
Engine Control Module Programming and Setup. and in this way, air recirculates in the turbocharger and
Operate the vehicle under conditions for running the compressor rotation speed is remained. As the
the DTC. Is the DTC set? engine load and speed increase, the engine control
module (ECM) commands the turbocharger by - pass
– If no, diagnosis ends.
valve to close. Once the throttle closes, this valve
– If yes, install the original module back and opens as it is demanded. In this way, air in the
contact the technician. turbocharger recirculates and compressor surge is
Component Testing avoided.
1. Turn the ignition switch to OFF position and Conditions for Running the DTC
disconnect the battery negative cable. • The engine is started.
2. Disconnect QWL10 front oxygen sensor harness Conditions for Setting the DTC
connector.
• DTCP003300: Circuit open detected
3. Remove the front heated oxygen sensor.
• DTCP003400: Circuit short to ground detected
4. Place the oxygen sensor under room temperature
• DTCP003500: Circuit short to power supply
and wait it to cool down to room temperature.
detected
5. Measure the resistance between terminal 2 and
• DTCP226100: Relief control valve mechanical
terminal 4 of QWL10 front heated oxygen sensor.
fault detected
Is it about 10 Ω?
– If no, replace the front heated oxygen sensor.
– If yes, perform “circuit system testing”.
Repair Instructions
• Front Heated Oxygen Sensor Replacement
• Engine Control Module Replacement
• Engine Control Module Programming and Setup
9.2.3.16 DTCP003300, P003400, P003500 or
P226100
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
DTC Description
DTCP003300: Supercharging system relief valve
control circuit open
 9-66 Engine/Propulsion

Action Taken When the DTC Sets 1. Turn the ignition switch to OFF position and
• DTC is recorded and the engine malfunction disconnect the battery negative cable.
indicator lamp illuminates. 2. Perform intake flow valve component testing. Is it
Conditions for Clearing the DTC normal?
• A history DTC will clear after 40 fault - free ignition – If no, replace the intake flow valve.
cycles. – If yes, go to the next diagnostic step.
• The body control module receives an order to 3. Connect the battery negative cable and turn the
clear the DTC sent by the scan tool. ignition switch to ON position.
Reference Information 4. Check power circuit of the intake flow valve.
Schematic Reference Measure the voltage between terminal 1 of Q20
intake flow valve harness connector and the
4.10.17 Engine Controls Schematics (Exhaust Flow ground. Is it the battery voltage?
Control Valve, Intake Flow Valve, Canister Solenoid
Valve) - 1.5 T – If no, test the circuit for open circuit/high
resistance.
Connector End View Reference
– If yes, go to the next diagnostic step.
K20 Engine Control Module X1, and Q20 Intake Flow
Valve 5. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
Electrical Information Reference
6. Disconnect K20 engine control module harness
• Circuit Testing connector X1.
• Connector Repairs 7. Measure the resistance between terminal 6 of
• Testing for Intermittent Conditions and Poor K20 engine control module harness connector X1
Connections and terminal 2 of Q20 intake flow valve harness
• Wiring Repairs connector. Is it less than 1 Ω?
Scan Tool Reference – If no, test the circuit for open circuit/high
resistance.
Refer to “6.1.1.1 Control Module References” for
scan tool information. – If yes, go to the next diagnostic step.
Circuit/System Inspection 8. Measure the resistance between terminal 2 of
Q20 intake flow valve harness connector and the
1. Clear the DTC. Does the DTC reoccur?
ground. Is it infinite?
– Yes, an intermittent condition; refer to
- If no, test the circuit for short to ground.
11.3.4.7 Testing for Intermittent
Conditions and Poor Connections. – If yes, go to the next diagnostic step.
– If no, go to the next check.
2. Check the system. Are other DTCs set up?
– If no, perform the corresponding fault
diagnosis according to the DTC.
– If no, go to the next check.
3. Check the harness connectors or components.
Does breakage, poor contact, aging or looseness
exist?
– If yes, inspect and remove the fault.
– If no, go to the next check.
4. Check fuse F9UA. Has it blown?
– If yes, replace the fuse and check to position
and remove the power circuit short to ground
fault.
– If no, perform “Circuit/System Testing”.
5. Operate the vehicle under the conditions for
running the DTC and confirm that the DTC is not
set again.
Circuit/System Testing
9-67 Engine/Propulsion

9. Connect the battery negative cable and turn the The oxygen sensor includes a sensing element that
ignition switch to ON position. can get contact with exhaust from the exhaust
10. Check control circuit of the intake flow valve. manifold. The oxygen sensor heating resistor adopts
Measure the voltage between terminal 2 of Q20 12 V power supply and it gets connected with another
intake flow valve harness connector and the resistor within the engine control module in a series
ground. Is it 0 V? manner, forming a voltage sharing loop. The engine
control module provides grounding for the heating
- If no, test the circuit for short to power supply. resistor. The sensing element of the oxygen sensor
– If yes, go to the next diagnostic step. can be activated only when the temperature reaches
11. Turn the ignition switch to OFF position and about 300°C. Additional heating is provided by the
disconnect the battery negative cable. heating resistor element. This can reduce the warm -
up time and minimize starting emission.
12. Replace the engine control module. Refer to
Engine Control Module Programming and Setup. Conditions for Running the DTC
Operate the vehicle under conditions for running • DTCP003613, P003711, P003812: Engine is
the DTC. Is the DTC set? running and the battery voltage is higher than 9 V.
– If no, diagnosis ends. • DTCP00541E: Exhaust temperature is within the
– If yes, install the original module back and diagnostic range 300~600°C.
contact the technician. Conditions for Setting the DTC
Component Testing • DTCP003613: Circuit remains open for 0.5s.
1. Turn the ignition switch to OFF position and • DTCP003711: Circuit remains short to ground for
disconnect the battery negative cable. 0.5s.
2. Disconnect Q20 intake flow valve harness • DTCP003812: Circuit remains short to power
connector. supply for 0.5s.
3. Measure the resistance between terminal 1 and • DTCP00541E: Current resistance is higher than
terminal 2 of Q20 intake flow valve harness the threshold value.
connector. Is it about 14 Ω?
– If no, replace the intake flow valve.
– If yes, perform “circuit system testing”.
Repair Instructions
• Intake Flow Valve Replacement
• Engine Control Module Replacement
• Engine Control Module Programming and Setup
9.2.3.17 DTCP003613, P003711, P003812 or
P00541E
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
DTC Description
DTCP003613: Downstream oxygen sensor heater
control circuit open
DTCP003711: Downstream oxygen sensor heater
control circuit short to ground
DTCP003812: Downstream oxygen sensor heater
control circuit short to power supply
DTCP00541E: Downstream oxygen sensor heater
internal resistance not plausible
Circuit System Description
 9-68 Engine/Propulsion

Action Taken When the DTC Sets disconnect the battery negative cable.
• DTC is recorded and the engine malfunction 2. Perform rear heated oxygen sensor component
indicator lamp illuminates. testing. Is it normal?
Conditions for Clearing the DTC – If no, replace the rear heated oxygen sensor.
• A history DTC will clear after 40 fault - free ignition – If yes, go to the next diagnostic step.
cycles. 3. Connect the battery negative cable and turn the
• The body control module receives an order to ignition switch to ON position.
clear the DTC sent by the scan tool. 4. Check heating power circuit of the rear heated
Reference Information oxygen sensor. Measure the voltage between
Schematic Reference terminal 2 of QWL11 rear heated oxygen sensor
harness connector and the ground. Is it the
4.10.14 Engine Controls Schematics (Oxygen Sensor, battery voltage?
Coolant Temperature Sensor) - 1.5 T
– If no, test the circuit for open circuit/high
Connector End View Reference resistance.
K20 Engine Control Module X2, and QWL11 Rear – If yes, go to the next diagnostic step.
Heated Oxygen Sensor
5. Turn the ignition switch to OFF position and
Electrical Information Reference disconnect the battery negative cable.
• Circuit Testing 6. Disconnect K20 engine control module harness
• Connector Repairs connector X2.
• Testing for Intermittent Conditions and Poor 7. Check heating control circuit of the rear heated
Connections oxygen sensor. Measure the resistance between
• Wiring Repairs terminal 4 of QWL11 rear heated oxygen sensor
harness connector and terminal Q3 of K20 engine
Scan Tool Reference
control module harness connector X2. Is it less
Refer to “6.1.1.1 Control Module References” for than 1 Ω?
scan tool information.
– If no, test the circuit for open circuit/high
Circuit/System Inspection resistance.
1. Clear the DTC. Does the DTC reoccur? – If yes, go to the next diagnostic step.
– Yes, an intermittent condition; refer to
11.3.4.7 Testing for Intermittent
Conditions and Poor Connections.
– If no, go to the next check.
2. Check the system. Are other DTCs set up?
– If no, perform the corresponding fault
diagnosis according to the DTC.
– If no, go to the next check.
3. Check the harness connectors or components.
Does breakage, poor contact, aging or looseness
exist?
– If yes, inspect and remove the fault.
– If no, go to the next check.
4. Check fuse F9UA. Has it blown?
– If yes, replace the fuse and check to position
and remove the power circuit short to ground
fault.
– If no, perform “Circuit/System Testing”.
5. Operate the vehicle under the conditions for
running the DTC and confirm that the DTC is not
set again.
Circuit/System Testing
1. Turn the ignition switch to OFF position and
9-69 Engine/Propulsion
8. Measure the resistance between terminal 4 of
QWL11 rear heated oxygen sensor harness
connector and the ground. Is it infinite?
- If no, test the circuit for short to ground.
– If yes, go to the next diagnostic step.
9. Connect the battery negative cable and turn the
ignition switch to ON position.
10. Measure the voltage between terminal 4 of
QWL11 rear heated oxygen sensor harness
connector and the ground. Is it 0 V?
- If no, test the circuit for short to power supply.
– If yes, go to the next diagnostic step.
11. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
12. Replace the engine control module. Refer to
Engine Control Module Programming and Setup.
Operate the vehicle under conditions for running
the DTC. Is the DTC set?
– If no, diagnosis ends.
– If yes, install the original module back and
contact the technician.
Component Testing
1. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
2. Disconnect QWL11 rear oxygen sensor harness
connector.
3. Remove the rear heated oxygen sensor.
4. Place the oxygen sensor under room temperature
and wait it to cool down to room temperature.
5. Measure the resistance between terminal 2 and
terminal 4 of QWL11 rear heated oxygen sensor.
Is it about 10 Ω?
– If no, replace the rear heated oxygen sensor.
– If yes, perform “circuit system testing”.
Repair Instructions
• Rear Heated Oxygen Sensor Replacement
• Engine Control Module Replacement
• Engine Control Module Programming and Setup
9.2.3.18 DTCP009629, P009716, P009817, P023621,
P023622, P023629, P02362A, P023711 or
P023815
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
DTC Description
DTCP009629: Intake air temperature sensor 2 signal
not plausible
DTCP009716: Intake air temperature sensor 2 circuit
voltage too low
DTCP009817: Intake air temperature sensor 2 circuit
voltage too high
DTCP023621: Turbocharging pressure sensor signal
range exceeds lower limit
DTCP023622: Turbocharging pressure sensor signal
range exceeds upper limit
DTCP023629: Turbocharging pressure sensor signal
not plausible (high)
DTCP02362A: Turbocharging pressure sensor signal
not plausible (low)
DTCP023711: Turbocharging pressure sensor signal
voltage too low
DTCP023815: Turbocharging pressure sensor signal
voltage too high
Circuit System Description
The intake air temperature sensor measures the
absolute pressure and intake air temperature after the
intercooler. It provides information about engine load
and intake air temperature. The part used to measure
the intake air pressure is a piezoelectric sensor which
sends to the controller “load signals” based on the
difference between the barometric pressure and the
intake manifold pressure; the controller provides 5 V
voltage and the sensor gives a 0~5 V voltage
feedback to the controller as the intake air pressure
changes. The part used to measure the intake air
temperature is an NTC (Negative Temperature
Coefficient) sensor the resistance of which changes as
the intake air temperature changes. It sends to the
controller a voltage indicating the intake air
temperature change. The pressure ratio is directly
proportional to the output voltage and the temperature
is reversely proportional to the output resistance.
 9-70 Engine/Propulsion

Conditions for Running the DTC set again.

• The engine is started. Circuit/System Testing
Conditions for Setting the DTC 1. Turn the ignition switch to OFF position and
• A fault is detected. disconnect the battery negative cable.
Action Taken When the DTC Sets 2. Disconnect B65B intake manifold pressure and
air temperature sensor (after intercooler) harness
• DTCP009629, 009716, 009817: The engine connector.
malfunction indicator lamp illuminates
3. Connect the battery negative cable and turn the
• DTCP023621, P023622, P023629, P02362A, ignition switch to ON position.
P023711, P023815: The engine malfunction
indicator lamp does not illuminate. 4. Check power circuit of the intake manifold
pressure and air temperature sensor (after
Conditions for Clearing the DTC intercooler) Measure the voltage between
• A history DTC will clear after 40 fault - free ignition terminal 3 of B65B intake manifold pressure &
cycles. temperature sensor (after intercooler) harness
• The body control module receives an order to connector and the ground. Is it about 5 V?
clear the DTC sent by the scan tool. – If no, perform the following test:
Reference Information (1) Turn the ignition switch to the OFF position
Schematic Reference and disconnect the battery negative cable.
4.10.11 Engine Controls Schematics (Intake Air (2) Disconnect K20 engine control module
Pressure & Temperature Sensor) - 1.5 T harness connector X2.
Connector End View Reference (3) Measure the resistance between terminal 3
of B65B intake manifold pressure and air
K20 Engine Control Module X2, and B65B Intake
temperature sensor (after intercooler)
Manifold Pressure and Air Temperature Sensor (after
harness connector and terminal C2 of K20
Intercooler)
engine control module harness connector X2.
Electrical Information Reference Is it less than 1 Ω?
• Circuit Testing – If no, test the circuit for open circuit/high
• Connector Repairs resistance.
• Testing for Intermittent Conditions and Poor – If yes, go to the next diagnostic step.
Connections
• Wiring Repairs
Scan Tool Reference
Refer to “6.1.1.1 Control Module References” for
scan tool information.
Circuit/System Inspection
1. Clear the DTC. Does the DTC reoccur?
– Yes, an intermittent condition; refer to
11.3.4.7 Testing for Intermittent
Conditions and Poor Connections.
– If no, go to the next check.
2. Check the system. Are other DTCs set up?
– If no, perform the corresponding fault
diagnosis according to the DTC.
– If no, go to the next check.
3. Check the harness connectors or components.
Does breakage, poor contact, aging or looseness
exist?
– If yes, inspect and remove the fault.
– If no, perform “Circuit/System Testing”.
4. Operate the vehicle under the conditions for
running the DTC and confirm that the DTC is not
9-71 Engine/Propulsion

(4) Measure the resistance between terminal 3 temperature sensor (after intercooler)
of B65B intake manifold pressure and air harness connector and the ground. Is it
temperature sensor (after intercooler) infinite?
harness connector and the ground. Is it – If no, test the circuit for short to ground.
infinite?
– If yes, go to the next diagnostic step.
– If no, test the circuit for short to ground.
(6) Connect the battery negative cable and turn
– If yes, go to the next diagnostic step. the ignition switch to ON position.
(5) Connect the battery negative cable and turn (7) Measure the voltage between terminal 2 of
the ignition switch to ON position. B65B intake manifold pressure and air
(6) Measure the voltage between terminal 3 of temperature sensor (after intercooler)
B65B intake manifold pressure and air harness connector and the ground. Is it 0 V?
temperature sensor (after intercooler) – If no, test the circuit for short to power supply.
harness connector and the ground. Is it 0 V?
– If yes, go to the next diagnostic step.
– If no, test the circuit for short to power supply.
(8) Turn the ignition switch to the OFF position
– If yes, go to the next diagnostic step. and disconnect the battery negative cable.
(7) Turn the ignition switch to the OFF position (9) Check voltage signal circuit of the intake
and disconnect the battery negative cable. manifold pressure and air temperature
(8) Replace the engine control module. Refer to sensor (after intercooler). Measure the
Engine Control Module Programming and resistance between terminal 4 of B65B intake
Setup. Operate the vehicle under conditions manifold pressure and air temperature
for running the DTC. Is the DTC set? sensor (after intercooler) harness connector
– If no, diagnosis ends. and terminal O3 of K20 engine control
module harness connector X2. Is it less than
– If yes, install the original module back and 1 Ω?
contact the technician.
– If no, test the circuit for open circuit/high
– If yes, perform the following test: resistance.
(1) Turn the ignition switch to the OFF position – If yes, go to the next diagnostic step.
and disconnect the battery negative cable.
(2) Check ground circuit of the intake manifold
pressure and air temperature sensor (after
intercooler). Measure the resistance between
terminal 1 of B65B intake manifold pressure
and air temperature sensor (after intercooler)
harness connector and the ground. Is it less
than 1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
(3) Disconnect K20 engine control module
harness connector X2.
(4) Check temperature signal circuit of the intake
manifold pressure and air temperature
sensor (after intercooler) Measure the
resistance between terminal 2 of B65B intake
manifold pressure and air temperature
sensor (after intercooler) harness connector
and terminal H2 of K20 engine control
module harness connector X2. Is it less than
1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
(5) Measure the resistance between terminal 2
of B65B intake manifold pressure and air
 9-72 Engine/Propulsion

(10) Measure the resistance between terminal 4 circuit voltage too low
of B65B intake manifold pressure and air DTCP011317: Intake manifold temperature sensor
temperature sensor (after intercooler) circuit voltage too high
harness connector and the ground. Is it
infinite? Circuit System Description
– If no, test the circuit for short to ground. The intake air pressure & temperature sensor
measures the intake manifold absolute pressure and
– If yes, go to the next diagnostic step. the intake air temperature. It provides information
(11) Connect the battery negative cable and turn about engine load and intake air temperature. The part
the ignition switch to ON position. used to measure the intake air pressure is a
(12) Measure the voltage between terminal 4 of piezoelectric sensor which sends to the controller
B65B intake manifold pressure and air “load signals” based on the difference between the
temperature sensor (after intercooler) barometric pressure and the intake manifold pressure;
harness connector and the ground. Is it 0 V? the controller provides 5 V voltage and the sensor
gives a 0~5 V voltage feedback to the controller as the
– If no, test the circuit for short to power supply. intake air pressure changes. The part used to
– If yes, go to the next diagnostic step. measure the intake air temperature is an NTC
(13) Turn the ignition switch to the OFF position (Negative Temperature Coefficient) sensor the
and disconnect the battery negative cable. resistance of which changes as the intake air
temperature changes. It sends to the controller a
(14) Replace the intake manifold pressure and air
voltage indicating the intake air temperature change.
temperature sensor (after Intercooler) and
The pressure ratio is directly proportional to the output
the engine control module. Refer to Engine
voltage and the temperature is reversely proportional
Control Module Programming and Setup.
to the output resistance.
Operate the vehicle under conditions for
running the DTC. Is the DTC set? Conditions for Running the DTC
– If no, diagnosis ends. • DTCP010528, P010600: The engine speed
is >800 rpm.
– If yes, install the original module back and
contact the technician. • DTCP010711, P010812: Time after starting
is >1s.
Repair Instructions
• DTCP011129, P011216: Starting.
• Intake Manifold Pressure and Air Temperature
Sensor (after Intercooler) Replacement • DTCP011317: Coolant temperature ≥60°C; air
flow ≤24kg/h; vehicle speed ≤10km/h.
• Engine Control Module Replacement
• Engine Control Module Programming and Setup
9.2.3.19 DTCP010528, P010600, P010711, P010812,
P011129, P011216 or P011317
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
DTC Description
DTCP010528: Intake air pressure sensor signal no
change
DTCP010600: Intake air pressure sensor not plausible
DTCP010711: Intake air pressure sensor circuit
voltage too low
DTCP010812: Intake air pressure sensor circuit
voltage too high
DTCP011129: Intake manifold temperature sensor
signal not plausible
DTCP011216: Intake manifold temperature sensor
9-73 Engine/Propulsion

Conditions for Setting the DTC – If no, go to the next check.

• DTCP010528, P010600: Pressure displayed on 2. Check the system. Are other DTCs set up?
the pressure sensor depends on engine speed – If no, perform the corresponding fault
and throttle opening diagnosis according to the DTC.
• DTCP010711: Pressure sensor voltage is <0.20 – If no, go to the next check.
V.
3. Check the harness connectors or components.
• DTCP010812: Pressure sensor voltage is > 4.88 Does breakage, poor contact, aging or looseness
V. exist?
• DTCP011129: Sampling conditions are satisfied – If yes, inspect and remove the fault.
and the difference between the highest and the
lowest temperature of the intake manifold within – If no, perform “Circuit/System Testing”.
one driving cycle is <0.75. 4. Operate the vehicle under the conditions for
• DTCP011216: Intake manifold temperature running the DTC and confirm that the DTC is not
sensor voltage remains <0.1 V for 2S. set again.
• DTCP011317: Intake manifold temperature Circuit/System Testing
sensor voltage remains >4.8486 V for 2S. 1. Turn the ignition switch to OFF position and
Action Taken When the DTC Sets disconnect the battery negative cable.
• DTCP010528, P010600, P010711, P010812: 2. Disconnect B65A intake manifold pressure and air
Use the default pressure signal to conduct fuel temperature sensor (intake manifold) harness
mixing; the engine malfunction indicator lamp connector.
illuminates. 3. Connect the battery negative cable and turn the
• DTCP011129, P011216, P011317: Use the ignition switch to ON position.
default intake air temperature signal; the engine 4. Check power circuit of the intake manifold
malfunction indicator lamp illuminates. pressure and air temperature sensor (intake
Conditions for Clearing the DTC manifold). Measure the voltage between terminal
3 of B65A intake manifold pressure and air
• A history DTC will clear after 40 fault - free ignition temperature sensor (intake manifold) harness
cycles. connector and the ground. Is it about 5 V?
• The body control module receives an order to – If no, perform the following test:
clear the DTC sent by the scan tool.
(1) Turn the ignition switch to the OFF position
Reference Information and disconnect the battery negative cable.
Schematic Reference
4.10.11 Engine Controls Schematics (Intake Air
Pressure & Temperature Sensor) - 1.5 T
Connector End View Reference
K20 Engine Control Module X1, B65A Intake Manifold
Pressure and Air Temperature Sensor (Intake
Manifold)
Electrical Information Reference
• Circuit Testing
• Connector Repairs
• Testing for Intermittent Conditions and Poor
Connections
• Wiring Repairs
Scan Tool Reference
Refer to “6.1.1.1 Control Module References” for
scan tool information.
Circuit/System Inspection
1. Clear the DTC. Does the DTC reoccur?
– Yes, an intermittent condition; refer to
11.3.4.7 Testing for Intermittent
Conditions and Poor Connections.

(2) Disconnect K20 engine control module
harness connector X1.
(3) Measure the resistance between terminal 3
of B65A intake manifold pressure and air
temperature sensor (intake manifold)
harness connector and terminal 45 of K20
engine control module harness connector X1.
Is it less than 1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
(4) Measure the resistance between terminal 3
of B65A intake manifold pressure and air
temperature sensor (intake manifold)
harness connector and the ground. Is it
infinite?
– If no, test the circuit for short to ground.
– If yes, go to the next diagnostic step.
(5) Connect the battery negative cable and turn
the ignition switch to ON position.
(6) Measure the voltage between terminal 3 of
B65A intake manifold pressure and air
temperature sensor (intake manifold)
harness connector and the ground. Is it 0 V?
– If no, test the circuit for short to power
supply.
– If yes, go to the next diagnostic step.
(7) Turn the ignition switch to the OFF position
and disconnect the battery negative cable.
(8) Replace the engine control module. Refer to
Engine Control Module Programming and
Setup. Operate the vehicle under conditions
for running the DTC. Is the DTC set?
– If no, diagnosis ends.
– If yes, install the original module back
and contact the technician.
– If yes, perform the following test:
(1) Turn the ignition switch to the OFF position
and disconnect the battery negative cable.
(2) Disconnect K20 engine control module
harness connector X1.
(3) Check ground circuit of the intake manifold
pressure and air temperature sensor (intake
manifold). Measure the resistance between
terminal 1 of B65A intake manifold pressure
and air temperature sensor (intake manifold)
harness connector and the ground. Is it less
than 1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
(4) Check temperature signal circuit of the intake
manifold pressure and air temperature
9-74 Engine/Propulsion
sensor (intake manifold). Measure the
resistance between terminal 2 of B65A intake
manifold pressure and air temperature
sensor (intake manifold) harness connector
and terminal 38 of K20 engine control
module harness connector X1. Is it less than
1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
(5) Measure the resistance between terminal 2
of B65A intake manifold pressure and air
temperature sensor (intake manifold)
harness connector and the ground. Is it
infinite?
– If no, test the circuit for short to ground.
– If yes, go to the next diagnostic step.
(6) Check pressure signal circuit of the intake
manifold pressure and air temperature
sensor (intake manifold). Measure the
resistance between terminal 4 of B65A intake
manifold pressure and air temperature
sensor (intake manifold) harness connector
and terminal 27 of K20 engine control
module harness connector X1. Is it less than
1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
(7) Measure the resistance between terminal 4
of B65A intake manifold pressure and air
temperature sensor (intake manifold)
harness connector and the ground. Is it
infinite?
– If no, test the circuit for short to ground.
– If yes, go to the next diagnostic step.
9-75 Engine/Propulsion

(8) Connect the battery negative cable and turn controller to correct fuel injection and ignition. The
the ignition switch to ON position. sensor is an NTC (negative temperature coefficient)
(9) Measure the voltage between terminal 2 of thermistor the resistance of which decreases as the
B65A intake manifold pressure and air temperature increases, not linearly however. This
temperature sensor (intake manifold) thermistor is installed in a copper heat conductive
harness connector and the ground. Is it 0 V? sleeve.
– If no, test the circuit for short to power Conditions for Running the DTC
supply. • DTCP011629: Starting.
– If yes, go to the next diagnostic step. • DTCP011716, P011817: Electrified.
(10) Measure the voltage between terminal 4 of Conditions for Setting the DTC
B65A intake manifold pressure and air • DTCP011629: Engine coolant temperature
temperature sensor (intake manifold) remains low.
harness connector and the ground. Is it 0 V?
• DTCP011716: Circuit is inspected, out of lower
– If no, test the circuit for short to power limit.
supply.
• DTCP011817: Circuit is inspected, out of upper
– If yes, go to the next diagnostic step. limit or voltage signal fluctuation exceeding 1 V.
(11) Turn the ignition switch to the OFF position Action Taken When the DTC Sets
and disconnect the battery negative cable.
• Use the default engine coolant temperature; the
(12) Replace the intake manifold pressure and engine malfunction indicator lamp illuminates.
intake air temperature sensor (intake
manifold) and the engine control module. Conditions for Clearing the DTC
Refer to Engine Control Module • A history DTC will clear after 40 fault - free ignition
Programming and Setup. Operate the vehicle cycles.
under conditions for running the DTC. Is the • The body control module receives an order to
DTC set? clear the DTC sent by the scan tool.
– If no, diagnosis ends. Reference Information
– If yes, install the original module back Schematic Reference
and contact the technician.
4.10.12 Engine Controls Schematics (Crankshaft
Repair Instructions Position Sensor, Coolant Temperature Sensor, and
• Intake Manifold Pressure and Air Temperature Knock Sensor) - 1.5 T
Sensor (Intake Manifold) Replacement
• Engine Control Module Replacement
• Engine Control Module Programming and Setup
9.2.3.20 DTCP011629, P011716 or P011817
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
DTC Description
DTCP011629: Engine coolant temperature sensor
signal not plausible
DTCP011716: Engine coolant temperature sensor
circuit voltage too low
DTCP011817: Engine coolant temperature sensor
circuit voltage too high
Circuit System Description
The coolant temperature sensor is used to provide
engine coolant temperature information. This helps the
 9-76 Engine/Propulsion

Connector End View Reference - If no, test the circuit for short to ground.
B34 Engine Coolant Temperature Sensor, and K20 – If yes, go to the next diagnostic step.
Engine Control Module X1 6. Connect the battery negative cable and turn the
Electrical Information Reference ignition switch to ON position.
• Circuit Testing 7. Measure the voltage between terminal 1 of B34
• Connector Repairs engine coolant temperature sensor harness
connector and the ground. Is it 0 V?
• Testing for Intermittent Conditions and Poor
Connections - If no, test the circuit for short to power supply.
• Wiring Repairs – If yes, go to the next diagnostic step.
Scan Tool Reference 8. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
Refer to “6.1.1.1 Control Module References” for
scan tool information. 9. Replace the engine control module. Refer to
Engine Control Module Programming and Setup.
Circuit/System Inspection Operate the vehicle under conditions for running
1. Clear the DTC. Does the DTC reoccur? the DTC. Is the DTC set?
– Yes, an intermittent condition; refer to – If no, diagnosis ends.
11.3.4.7 Testing for Intermittent – If yes, install the original module back and
Conditions and Poor Connections. contact the technician.
– If no, go to the next check.
2. Check the system. Are other DTCs set up?
– If no, perform the corresponding fault
diagnosis according to the DTC.
– If no, go to the next check.
3. Check the harness connectors or components.
Does breakage, poor contact, aging or looseness
exist?
– If yes, inspect and remove the fault.
– If no, perform “Circuit/System Testing”.
4. Operate the vehicle under the conditions for
running the DTC and confirm that the DTC is not
set again.
Circuit/System Testing
1. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
2. Perform engine coolant temperature sensor
component testing. Is it normal?
– If no, replace the engine coolant temperature
sensor.
– If yes, go to the next diagnostic step.
3. Disconnect K20 engine control module harness
connector X1.
4. Measure the resistance between terminal 1 of
B34 engine coolant temperature sensor harness
connector and terminal 37 of K20 engine control
module harness connector X1. Is it less than 1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
5. Measure the resistance between terminal 1 of
B34 engine coolant temperature sensor harness
connector and the ground. Is it infinite?
9-77 Engine/Propulsion

Component Testing Conditions for Setting the DTC

1. Turn the ignition switch to OFF position and • DTCP012129: Signal not plausible.
disconnect the battery negative cable. • DTCP012216: Signal voltage keeps < 0.176 V for
2. Disconnect B34 engine coolant temperature 0.14s.
sensor harness connector. • DTCP012317: Signal voltage keeps > 4.629 V for
3. Remove the engine coolant temperature sensor. 0.14s.
4. Measure the resistance between terminal 1 and Action Taken When the DTC Sets
terminal 2 of B34 engine coolant temperature • The engine malfunction indicator lamp illuminates
sensor harness connector. Is it within the during several driving cycles.
standard range of 2.45~2.55 kΩ (20°C)?
Conditions for Clearing the DTC
– If no, replace the engine coolant temperature
sensor. • A history DTC will clear after 40 fault - free ignition
cycles.
– If yes, perform “circuit system testing”.
• The body control module receives an order to
Repair Instructions clear the DTC sent by the scan tool.
• Engine Coolant Temperature Sensor Reference Information
Replacement
Schematic Reference
• Engine Control Module Replacement
4.10.13 Engine Controls Schematics (Accelerator
• Engine Control Module Programming and Setup Pedal Position Sensor, Electronic Throttle Control) -
9.2.3.21 DTCP012129, P012216 or P012317 1.5 T
Diagnostic Instructions Connector End View Reference
• Perform “6.2.2.7 Diagnostic System Check - Q38 Throttle, and K20 Engine Control Module X1
Vehicle” prior to using this diagnostic procedure. Electrical Information Reference
• Review “6.2.2.5 Strategy Based Diagnosis” for • Circuit Testing
an overview of the diagnostic approach.
• Connector Repairs
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category • Testing for Intermittent Conditions and Poor
Connections
DTC Description
• Wiring Repairs
DTCP012129: Electronic throttle position sensor 1
signal not plausible Scan Tool Reference
DTCP012216: Electronic throttle position sensor 1 Refer to “6.1.1.1 Control Module References” for
signal circuit voltage too low scan tool information.
DTCP012317: Electronic throttle position sensor 1
signal circuit voltage too high
Circuit System Description
Both the throttle position sensor and the throttle
actuator are integrated on the throttle. The throttle
position sensor is actually a rotating potentiometer
characteristic of linear output. Rocker arm of the
potentiometer is installed coaxially with the throttle. As
the throttle rotates, the rocker arm is taken to slide to a
certain position. The potentiometer outputs a voltage
signal that is proportional to the throttle position. One
throttle is equipped with two potentiometers installed in
reverse phase. The engine control module judge the
throttle rotation angle based on these two signals. 5 V
supply power voltage and reference ground for the two
potentiometers are provided by the engine control
module.
Conditions for Running the DTC
• DTCP012129: Engine speed is >1,200 rpm.
• DTCP012216, P012317: Time after starting is >
12s.
 9-78 Engine/Propulsion

Circuit/System Inspection (4) Measure the resistance between terminal 4

1. Clear the DTC. Does the DTC reoccur? of Q38 throttle harness connector and the
ground. Is it infinite?
– Yes, an intermittent condition; refer to
11.3.4.7 Testing for Intermittent – If no, test the circuit for short to ground.
Conditions and Poor Connections. – If yes, go to the next diagnostic step.
– If no, go to the next check. (5) Connect the battery negative cable and turn
2. Check the system. Are other DTCs set up? the ignition switch to ON position.
– If no, perform the corresponding fault (6) Measure the voltage between terminal 4 of
diagnosis according to the DTC. Q38 throttle harness connector and the
ground. Is it 0 V?
– If no, go to the next check.
– If no, test the circuit for short to power
3. Check the harness connectors or components. supply.
Does breakage, poor contact, aging or looseness
exist? – If yes, go to the next diagnostic step.
– If yes, inspect and remove the fault. (7) Turn the ignition switch to the OFF position
and disconnect the battery negative cable.
– If no, go to the next check.
(8) Replace the engine control module. Refer to
4. Turn the ignition switch to ON position, and Engine Control Module Programming and
confirm the “Throttle Angle 1” and “Throttle Setup. Operate the vehicle under conditions
Position Sensor 1 Voltage Original Value” for running the DTC. Is the DTC set?
displayed real - time on the scan tool. Does the
parameter change as the accelerator pedal input – If no, diagnosis ends.
changes and is the change within the reasonable – If yes, install the original module back and
range of 0.57 V - 4.6 V? contact the technician.
– If yes, clean the throttle, carry out throttle – If yes, perform the following test:
matching/self - learning and then take a road (1) Turn the ignition switch to the OFF position
test, if the DTC appears again, perform and disconnect the battery negative cable.
“Circuit/System Testing”.
– If no, perform “Circuit/System Testing”.
5. Operate the vehicle under the conditions for
running the DTC and confirm that the DTC is not
set again.
Circuit/System Testing
1. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
2. Disconnect Q38 throttle harness connector.
3. Connect the battery negative cable and turn the
ignition switch to ON position.
4. Check the throttle power circuit. Measure the
voltage between terminal 4 of Q38 throttle
harness connector and the ground. Is it about
5V?
– If no, perform the following test:
(1) Turn the ignition switch to the OFF position
and disconnect the battery negative cable.
(2) Disconnect K20 engine control module
harness connector X1.
(3) Measure the resistance between terminal 4
of Q38 throttle harness connector and
terminal 43 of K20 engine control module
harness connector X1. Is it less than 1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
9-79 Engine/Propulsion

(2) Disconnect K20 engine control module and contact the technician.
harness connector X1. Repair Instructions
(3) Check the throttle ground circuit. Measure • Throttle Replacement
the resistance between terminal 5 of Q38
throttle harness connector and the ground. Is • Throttle Matching/Self - learning
it less than 1 Ω? • Engine Control Module Replacement
– If no, test the circuit for open circuit/high • Engine Control Module Programming and Setup
resistance. 9.2.3.22 DTCP013000, P013116, P013217, P013300,
– If yes, go to the next diagnostic step. P013400, P219500 or P219600
(4) Check the throttle control circuit. Measure the Diagnostic Instructions
resistance between terminal 1 of Q38 throttle • Perform “6.2.2.7 Diagnostic System Check -
harness connector and terminal 13 of K20 Vehicle” prior to using this diagnostic procedure.
engine control module harness connector X1.
• Review “6.2.2.5 Strategy Based Diagnosis” for
Is it less than 1 Ω?
an overview of the diagnostic approach.
– If no, test the circuit for open circuit/high
• “6.2.2.6 Diagnostic Procedure Instructions”
resistance.
provides an overview of each diagnostic category
– If yes, go to the next diagnostic step.
DTC Description
(5) Measure the resistance between terminal 1
DTCP013000: Upstream oxygen sensor signal not
of Q38 throttle harness connector and the
plausible
ground. Is it infinite?
DTCP013116: Upstream oxygen sensor signal circuit
– If no, test the circuit for short to ground.
voltage too low
– If yes, go to the next diagnostic step.
DTCP013217: Upstream oxygen sensor signal circuit
(6) Connect the battery negative cable and turn voltage too high
the ignition switch to ON position.
DTCP013300: Upstream oxygen sensor aging
(7) Measure the voltage between terminal 5 of
DTCP013400: Upstream oxygen sensor circuit signal
Q38 throttle harness connector and the
fault
ground. Is it 0 V?
DTCP219500: Upstream oxygen sensor aging—signal
– If no, test the circuit for short to power
remains rich
supply.
DTCP219600: Upstream oxygen sensor aging—signal
– If yes, go to the next diagnostic step.
remains lean
(8) Measure the voltage between terminal 1 of
Circuit System Description
Q38 throttle harness connector and the
ground. Is it 0 V? The upstream oxygen sensor is used to detect the
oxygen content in the discharged exhaust based on
– If no, test the circuit for short to power
which it can be judged whether the mixture is lean or
supply.
rich. The sensor sends electric signal (which varies
– If yes, go to the next diagnostic step. between 0.1 V~0.9 V) to the engine control module
(9) Turn the ignition switch to the OFF position and the module continuously adjusts the mixture
and disconnect the battery negative cable. concentration so that the air - fuel ration remains at
(10) Measure the resistance between the 14.7:1.
following terminals of Q38 throttle harness
connector and the ground. Is it infinite?
• Terminal 1, 2, 4 and 5 of Q38
- If no, test the circuit to see if it is short -
circuited.
– If yes, go to the next diagnostic step.
(11) Replace the throttle and the engine control
module. Refer to Engine Control Module
Programming and Setup. Operate the vehicle
under conditions for running the DTC. Is the
DTC set?
– If no, diagnosis ends.
– If yes, install the original module back
 9-80 Engine/Propulsion

Conditions for Running the DTC Connector End View Reference

• DTCP013000: Battery voltage > 11 V; no fuel K20 Engine Control Module X1, and QWL10 Front
injector drive stage fault; engine speed > 25 rpm; Heated Oxygen Sensor
oxygen sensor is hot enough. Electrical Information Reference
• DTCP013116: Battery voltage > 11 V; engine • Circuit Testing
speed > 25 rpm; exhaust temperature model
value > 800°C; oxygen sensor is hot enough for > • Connector Repairs
89s. • Testing for Intermittent Conditions and Poor
• DTCP013217: Battery voltage > 11 V; engine Connections
speed > 25 rpm; exhaust temperature model • Wiring Repairs
value > 800°C; oxygen sensor is hot enough for > Scan Tool Reference
90s.
Refer to “6.1.1.1 Control Module References” for
• DTCP013300: Front oxygen closed - loop control scan tool information.
activated; fuel supply self - learning function
Circuit/System Inspection
turned on; no diagnostic resistance condition;
engine speed, load and exhaust temperature are 1. Clear the DTC. Does the DTC reoccur?
shown on the diagnostic window; front oxygen – Yes, an intermittent condition; refer to
heating passes diagnosis. 11.3.4.7 Testing for Intermittent
• DTCP013400: Upstream oxygen sensor remains Conditions and Poor Connections.
hot enough for 90s. – If no, go to the next check.
• DTCP219500, P219600: Rear oxygen closed - 2. Check the system. Are other DTCs set up?
loop control activated; catalytic converter shows – If no, perform the corresponding fault
no fault; engine speed, load and exhaust diagnosis according to the DTC.
temperature are shown on the diagnostic window.
– If no, go to the next check.
Conditions for Setting the DTC
3. Check the harness connectors or components.
• DTCP013000: Upstream oxygen sensor output Does breakage, poor contact, aging or looseness
voltage remains higher than 2 V for 90s. exist?
• DTCP013116: Upstream oxygen sensor output – If yes, inspect and remove the fault.
voltage is < 0.06 V.
– If no, go to the next check.
• DTCP013217: Upstream oxygen sensor output
voltage is > 1.2V.
• DTCP013300: Delay time of filtered upstream
signal cycle exceeds the threshold value.
• DTCP013400: Upstream oxygen sensor voltage
range 0.4 - 0.6 V, or front/rear oxygen voltage
is >1.2 V, or upstream oxygen sensor internal
resistance is higher than 20,000 Ω.
• DTCP219500: Rear oxygen control integral value
is > 0.95.
• DTCP219600: Rear oxygen control integral value
is < - 0.95.
Action Taken When the DTC Sets
• DTC is recorded and the engine malfunction
indicator lamp illuminates.
Conditions for Clearing the DTC
• A history DTC will clear after 40 fault - free ignition
cycles.
• The body control module receives an order to
clear the DTC sent by the scan tool.
Reference Information Schematic Reference
4.10.14 Engine Controls Schematics (Oxygen Sensor,
Coolant Temperature Sensor) - 1.5 T
9-81 Engine/Propulsion

4. Check the fuel quality to see if it meets the 10. Turn the ignition switch to OFF position and
requirements, if the air filter element is dirty or disconnect the battery negative cable.
blocked; if the engine air intake system is poorly 11. Replace the engine control module. Refer to
sealed or leaks? Engine Control Module Programming and Setup.
– If yes, inspect and remove the fault. Operate the vehicle under conditions for running
– If no, perform “Circuit/System Testing”. the DTC. Is the DTC set?
5. Operate the vehicle under the conditions for – If no, diagnosis ends.
running the DTC and confirm that the DTC is not – If yes, install the original module back and
set again. contact the technician.
Circuit/System Testing Component Testing
1. Turn the ignition switch to OFF position and 1. Start the vehicle, allow the engine to warm up to
disconnect the battery negative cable. the normal coolant temperature and then keep
2. Perform front heated oxygen sensor component the engine idling. Connect an oscilloscope with
testing. Is it normal? the upstream oxygen sensor harness connector
not disconnected and measure the waveform
– If no, replace the front heated oxygen sensor. average voltage between terminal 4 of K20
– If yes, go to the next diagnostic step. engine control module harness connector X1 and
3. Disconnect QWL10 front heated oxygen sensor the ground to see if it varies between 0.1~0.9 V?
harness connector and K20 engine control – If no, replace the front heated oxygen sensor.
module harness connector X1. – If yes, perform “circuit system testing”.
4. Measure the resistance between terminal 3 of Repair Instructions
QWL10 front heated oxygen sensor harness
connector and terminal 16 of K20 engine control • Front Heated Oxygen Sensor Replacement
module harness connector X1. Is it less than 1 Ω? • Engine Control Module Replacement
– If no, test the circuit for open circuit/high • Engine Control Module Programming and Setup
resistance.
– If yes, go to the next diagnostic step.
5. Check signal circuit of the front heated oxygen
sensor. Measure the resistance between terminal
1 of QWL10 front heated oxygen sensor harness
connector and terminal 40 of K20 engine control
module harness connector X1. Is it less than 1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
6. Measure the resistance between terminal 1 of
QWL10 front heated oxygen sensor harness
connector and the ground. Is it infinite?
- If no, test the circuit for short to ground.
– If yes, go to the next diagnostic step.
7. Connect the battery negative cable and turn the
ignition switch to ON position.
8. Measure the voltage between terminal 3 of
QWL10 front heated oxygen sensor harness
connector and the ground. Is it 0 V?
- If no, test the circuit for short to power supply.
– If yes, go to the next diagnostic step.
9. Measure the voltage between terminal 1 of
QWL10 front heated oxygen sensor harness
connector and the ground. Is it 0 V?
- If no, test the circuit for short to power supply.
– If yes, go to the next diagnostic step.
 9-82 Engine/Propulsion

9.2.3.23 DTCP013600, P013716, P013817, P014000, voltage is < 0.06 V.

P227000 or P227100 • DTCP013817: Downstream oxygen sensor output
Diagnostic Instructions voltage is > 1.2V.
• Perform “6.2.2.7 Diagnostic System Check - • DTCP014000: Downstream oxygen sensor
Vehicle” prior to using this diagnostic procedure. voltage range 0.4 - 0.6 V, or front/rear oxygen
• Review “6.2.2.5 Strategy Based Diagnosis” for voltage is >1.2 V, or downstream oxygen sensor
an overview of the diagnostic approach. internal resistance is > 20,000 Ω.
• “6.2.2.6 Diagnostic Procedure Instructions” • DTCP227000: Rear oxygen voltage remains
provides an overview of each diagnostic category lower than the target value for 0.2s.
DTC Description • DTCP227100: Rear oxygen voltage remains
higher than the target value for 0.2s.
DTCP013600: Downstream oxygen sensor signal not
plausible Action Taken When the DTC Sets
DTCP013716: Downstream oxygen sensor signal • DTC is recorded and the engine malfunction
circuit voltage too low indicator lamp illuminates.
DTCP013817: Downstream oxygen sensor signal Conditions for Clearing the DTC
circuit voltage too high • A history DTC will clear after 40 fault - free ignition
DTCP014000: Downstream oxygen sensor circuit cycles.
signal fault • The body control module receives an order to
DTCP227000: Downstream oxygen sensor clear the DTC sent by the scan tool.
aging—signal remains lean Reference Information
DTCP227100: Downstream oxygen sensor Schematic Reference
aging—signal remains rich 4.10.14 Engine Controls Schematics (Oxygen Sensor,
Circuit System Description Coolant Temperature Sensor) - 1.5 T
The primary task of the downstream oxygen sensor is Connector End View Reference
to cooperate with the upstream oxygen sensor to K20 Engine Control Module X2, and QWL11 Rear
detect three - way catalytic converter faults, followed Heated Oxygen Sensor
by closed - loop control, as a supplement to the
upstream oxygen sensor. The downstream oxygen Electrical Information Reference
sensor can reflect the operating performance of the • Circuit Testing
three - way catalytic converter. As a basically stable • Connector Repairs
signal, its electric signal fluctuates within 0.4~0.5 V.
• Testing for Intermittent Conditions and Poor
Conditions for Running the DTC Connections
• DTCP013600: Battery voltage > 11 V; no fuel • Wiring Repairs
injector drive stage fault; engine speed > 25 rpm;
oxygen sensor is hot enough.
• DTCP013716: Battery voltage > 11 V; engine
speed > 25 rpm; exhaust temperature model
value > 800°C; oxygen sensor is hot enough for >
89s.
• DTCP013817: Battery voltage > 11 V; engine
speed > 25 rpm; exhaust temperature model
value > 800°C; oxygen sensor is hot enough for >
90s.
• DTCP014000: Upstream oxygen sensor remains
hot enough for 90s.
• DTCP219500, P219600: Exhaust flow is shown
on the diagnostic window and enriching or
thinning is conducted actively for 12s.
Conditions for Setting the DTC
• DTCP013600: Downstream oxygen sensor output
voltage remains > 2 V for 90s.
• DTCP013716: Downstream oxygen sensor output
9-83 Engine/Propulsion

Scan Tool Reference 7. Connect the battery negative cable and turn the
Refer to “6.1.1.1 Control Module References” for ignition switch to ON position.
scan tool information. 8. Measure the voltage between terminal 3 of
Circuit/System Inspection QWL11 rear heated oxygen sensor harness
connector and the ground. Is it 0 V?
1. Clear the DTC. Does the DTC reoccur?
- If no, test the circuit for short to power supply.
– Yes, an intermittent condition; refer to
11.3.4.7 Testing for Intermittent – If yes, go to the next diagnostic step.
Conditions and Poor Connections. 9. Measure the voltage between terminal 1 of
– If no, go to the next check. QWL11 rear heated oxygen sensor harness
connector and the ground. Is it 0 V?
2. Check the system. Are other DTCs set up?
- If no, test the circuit for short to power supply.
– If no, perform the corresponding fault
diagnosis according to the DTC. – If yes, go to the next diagnostic step.
– If no, go to the next check. 10. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
3. Check the harness connectors or components.
Does breakage, poor contact, aging or looseness 11. Replace the engine control module. Refer to
exist? Engine Control Module Programming and Setup.
Operate the vehicle under conditions for running
– If yes, inspect and remove the fault. the DTC. Is the DTC set?
– If no, perform “Circuit/System Testing”. – If no, diagnosis ends.
4. Operate the vehicle under the conditions for – If yes, install the original module back and
running the DTC and confirm that the DTC is not contact the technician.
set again.
Circuit/System Testing
1. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
2. Perform rear heated oxygen sensor component
testing. Is it normal?
– If no, replace the rear heated oxygen sensor.
– If yes, go to the next diagnostic step.
3. Disconnect QWL11 rear heated oxygen sensor
harness connector and K20 engine control
module harness connector X2.
4. Measure the resistance between terminal 3 of
QWL11 rear heated oxygen sensor harness
connector and terminal L3 of K20 engine control
module harness connector X2. Is it less than 1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
5. Check signal circuit of the rear heated oxygen
sensor. Measure the resistance between terminal
1 of QWL11 rear heated oxygen sensor harness
connector and terminal E2 of K20 engine control
module harness connector X2. Is it less than 1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
6. Measure the resistance between terminal 1 of
QWL11 rear heated oxygen sensor harness
connector and the ground. Is it infinite?
- If no, test the circuit for short to ground.
– If yes, go to the next diagnostic step.
 9-84 Engine/Propulsion

Component Testing • DTC is recorded and the engine malfunction

1. Start the vehicle, allow the engine to warm up to indicator lamp illuminates.
the normal coolant temperature and then keep Conditions for Clearing the DTC
the engine idling. Connect an oscilloscope with • A history DTC will clear after 40 fault - free ignition
the downstream oxygen sensor harness cycles.
connector not disconnected and to measure the
waveform average voltage between terminal 37 of • The body control module receives an order to
K20 engine control module harness connector X2 clear the DTC sent by the scan tool.
and the ground to see if it varies between 0.4~0.5 Reference Information
V? Schematic Reference
– If no, replace the rear heated oxygen sensor. 4.10.18 Engine Controls Schematics (Fuel
– If yes, perform “circuit system testing”. Control—Fuel Injection Nozzle and Fuel Pump) - 1.5 T
Repair Instructions Connector End View Reference
• Rear Heated Oxygen Sensor Replacement Q17A Fuel Injection Nozzle 1, and K20 Engine Control
• Engine Control Module Replacement Module X1
• Engine Control Module Programming and Setup Electrical Information Reference
9.2.3.24 DTCP020113, P026111 or P026212 • Circuit Testing
Diagnostic Instructions • Connector Repairs
• Perform “6.2.2.7 Diagnostic System Check - • Testing for Intermittent Conditions and Poor
Vehicle” prior to using this diagnostic procedure. Connections
• Review “6.2.2.5 Strategy Based Diagnosis” for • Wiring Repairs
an overview of the diagnostic approach. Scan Tool Reference
• “6.2.2.6 Diagnostic Procedure Instructions” Refer to “6.1.1.1 Control Module References” for
provides an overview of each diagnostic category scan tool information.
DTC Description Circuit/System Inspection
DTCP020113: Cylinder 1 fuel injector control circuit 1. Clear the DTC. Does the DTC reoccur?
open – Yes, an intermittent condition; refer to
DTCP026111: Cylinder 1 fuel injector control circuit 11.3.4.7 Testing for Intermittent
voltage too low Conditions and Poor Connections.
DTCP026212: Cylinder 1 fuel injector control circuit – If no, go to the next check.
voltage too high 2. Check the system. Are other DTCs set up?
Circuit System Description – If no, perform the corresponding fault
As the engine control module electrifies the fuel diagnosis according to the DTC.
injector coil, magnetic field force is generated. When – If no, go to the next check.
the magnetic field force increases to the extent that it
can overcome the resultant force of the return spring
pressure, the needle valve gravity and the friction, the
needle valve starts to lift up and fuel injection
commences henceforth. As the fuel injection pulse
closes, the needle valve closes again under the action
of the return spring pressure.
Conditions for Running the DTC
• Engine is running and the battery voltage is higher
than 9 V.
Conditions for Setting the DTC
• DTCP020113: Circuit remains open for 0.5s.
• DTCP026111: Circuit remains short to ground for
0.5s.
• DTCP026212: Circuit remains short to power
supply for 0.5s.
Action Taken When the DTC Sets
9-85 Engine/Propulsion

3. Check the harness connectors or components. - If no, test the circuit for short to power supply.
Does breakage, poor contact, aging or looseness – If yes, go to the next diagnostic step.
exist?
11. Turn the ignition switch to OFF position and
– If yes, inspect and remove the fault. disconnect the battery negative cable.
– If no, go to the next check. 12. Replace the engine control module. Refer to
4. Check fuse F9UA. Has it blown? Engine Control Module Programming and Setup.
– If yes, replace the fuse and check to position Operate the vehicle under conditions for running
and remove the power circuit short to ground the DTC. Is the DTC set?
fault. – If no, diagnosis ends.
– If no, perform “Circuit/System Testing”. – If yes, install the original module back and
5. Operate the vehicle under the conditions for contact the technician.
running the DTC and confirm that the DTC is not Component Testing
set again. 1. Turn the ignition switch to OFF position and
Circuit/System Testing disconnect the battery negative cable.
1. Turn the ignition switch to OFF position and 2. Disconnect Q17A fuel injection nozzle 1 harness
disconnect the battery negative cable. connector.
2. Perform fuel injection nozzle 1 component testing. 3. Measure the resistance between terminal 1 and
Is it normal? terminal 2 of Q17A fuel injection nozzle 1 harness
– If no, replace the fuel injection nozzle 1. connector. Is it about 13 Ω (20°C)?
– If yes, go to the next diagnostic step. – If no, replace the fuel injection nozzle 1.
3. Connect the battery negative cable and turn the – If yes, perform “circuit system testing”.
ignition switch to ON position. Repair Instructions
4. Check power circuit of fuel injection nozzle 1. • Fuel Injector Replacement
Measure the voltage between terminal 1 of Q17A • Engine Control Module Replacement
fuel injection nozzle 1 harness connector and the
ground. Is it the battery voltage? • Engine Control Module Programming and Setup
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
5. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
6. Disconnect K20 engine control module harness
connector X1.
7. Check control circuit of fuel injection nozzle 1.
Measure the resistance between terminal 2 of
Q17A fuel injection nozzle 1 harness connector
and terminal 4 of the engine control module
harness connector X1. Is it less than 1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
8. Measure the resistance between terminal 2 of
Q17A fuel injection nozzle 1 harness connector
and the ground. Is it infinite?
- If no, test the circuit for short to ground.
– If yes, go to the next diagnostic step.
9. Connect the battery negative cable and turn the
ignition switch to ON position.
10. Measure the voltage between terminal 2 of Q17A
fuel injection nozzle 1 harness connector and the
ground. Is it 0 V?
 9-86 Engine/Propulsion

9.2.3.25 DTCP020213, P026411 or P026512 • Connector Repairs

Diagnostic Instructions • Testing for Intermittent Conditions and Poor
• Perform “6.2.2.7 Diagnostic System Check - Connections
Vehicle” prior to using this diagnostic procedure. • Wiring Repairs
• Review “6.2.2.5 Strategy Based Diagnosis” for Scan Tool Reference
an overview of the diagnostic approach. Refer to “6.1.1.1 Control Module References” for
• “6.2.2.6 Diagnostic Procedure Instructions” scan tool information.
provides an overview of each diagnostic category Circuit/System Inspection
DTC Description 1. Clear the DTC. Does the DTC reoccur?
DTCP020213: Cylinder 2 fuel injector control circuit – Yes, an intermittent condition; refer to
open 11.3.4.7 Testing for Intermittent
DTCP026411: Cylinder 2 fuel injector control circuit Conditions and Poor Connections.
voltage too low – If no, go to the next check.
DTCP026512: Cylinder 2 fuel injector control circuit 2. Check the system. Are other DTCs set up?
voltage too high
– If no, perform the corresponding fault
Circuit System Description diagnosis according to the DTC.
As the engine control module electrifies the fuel – If no, go to the next check.
injector coil, magnetic field force is generated. When
the magnetic field force increases to the extent that it 3. Check the harness connectors or components.
can overcome the resultant force of the return spring Does breakage, poor contact, aging or looseness
pressure, the needle valve gravity and the friction, the exist?
needle valve starts to lift up and fuel injection – If yes, inspect and remove the fault.
commences henceforth. As the fuel injection pulse – If no, go to the next check.
closes, the needle valve closes again under the action
4. Check fuse F9UA. Has it blown?
of the return spring pressure.
– If yes, replace the fuse and check to position
Conditions for Running the DTC
and remove the power circuit short to ground
• Engine is running and the battery voltage is higher fault.
than 9 V.
– If no, perform “Circuit/System Testing”.
Conditions for Setting the DTC
5. Operate the vehicle under the conditions for
• DTCP020213: Circuit remains open for 0.5s. running the DTC and confirm that the DTC is not
• DTCP026411: Circuit remains short to ground for set again.
0.5s.
• DTCP026512: Circuit remains short to power
supply for 0.5s.
Action Taken When the DTC Sets
• DTC is recorded and the engine malfunction
indicator lamp illuminates.
Conditions for Clearing the DTC
• A history DTC will clear after 40 fault - free ignition
cycles.
• The body control module receives an order to
clear the DTC sent by the scan tool.
Reference Information
Schematic Reference
4.10.18 Engine Controls Schematics (Fuel
Control—Fuel Injection Nozzle and Fuel Pump) - 1.5 T
Connector End View Reference
Q17B Fuel Injection Nozzle 2, and K20 Engine Control
Module X1
Electrical Information Reference
• Circuit Testing
9-87 Engine/Propulsion

Circuit/System Testing disconnect the battery negative cable.

1. Turn the ignition switch to OFF position and 2. Disconnect Q17B fuel injection nozzle 2 harness
disconnect the battery negative cable. connector.
2. Perform fuel injection nozzle 2 component testing. 3. Measure the resistance between terminal 1 and
Is it normal? terminal 2 of Q17B fuel injection nozzle 2 harness
– If no, replace the fuel injection nozzle 2. connector. Is it about 13 Ω (20°C)?
– If yes, go to the next diagnostic step. – If no, replace the fuel injection nozzle 2.
3. Connect the battery negative cable and turn the – If yes, perform “circuit system testing”.
ignition switch to ON position. Repair Instructions
4. Check power circuit of fuel injection nozzle 2. • Fuel Injector Replacement
Measure the voltage between terminal 1 of Q17B • Engine Control Module Replacement
fuel injection nozzle 2 harness connector and the
ground. Is it the battery voltage? • Engine Control Module Programming and Setup
– If no, test the circuit for open circuit/high 9.2.3.26 DTCP020313, P026711 or P026812
resistance. Diagnostic Instructions
– If yes, go to the next diagnostic step. • Perform “6.2.2.7 Diagnostic System Check -
5. Turn the ignition switch to OFF position and Vehicle” prior to using this diagnostic procedure.
disconnect the battery negative cable. • Review “6.2.2.5 Strategy Based Diagnosis” for
6. Disconnect K20 engine control module harness an overview of the diagnostic approach.
connector X1. • “6.2.2.6 Diagnostic Procedure Instructions”
7. Check control circuit of fuel injection nozzle 2. provides an overview of each diagnostic category
Measure the resistance between terminal 2 of DTC Description
Q17B fuel injection nozzle 2 harness connector DTCP020313: Cylinder 3 fuel injector control circuit
and terminal 3 of the engine control module open
harness connector X1. Is it less than 1 Ω?
DTCP026711: Cylinder 3 fuel injector control circuit
– If no, test the circuit for open circuit/high voltage too low
resistance.
DTCP026812: Cylinder 3 fuel injector control circuit
– If yes, go to the next diagnostic step. voltage too high
8. Measure the resistance between terminal 2 of
Q17B fuel injection nozzle 2 harness connector
and the ground. Is it infinite?
- If no, test the circuit for short to ground.
– If yes, go to the next diagnostic step.
9. Connect the battery negative cable and turn the
ignition switch to ON position.
10. Measure the voltage between terminal 2 of Q17B
fuel injection nozzle 2 harness connector and the
ground. Is it 0 V?
- If no, test the circuit for short to power supply.
– If yes, go to the next diagnostic step.
11. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
12. Replace the engine control module. Refer to
Engine Control Module Programming and Setup.
Operate the vehicle under conditions for running
the DTC. Is the DTC set?
– If no, diagnosis ends.
– If yes, install the original module back and
contact the technician.
Component Testing
1. Turn the ignition switch to OFF position and
 9-88 Engine/Propulsion

Circuit System Description – If no, perform the corresponding fault

As the engine control module electrifies the fuel diagnosis according to the DTC.
injector coil, magnetic field force is generated. When – If no, go to the next check.
the magnetic field force increases to the extent that it 3. Check the harness connectors or components.
can overcome the resultant force of the return spring Does breakage, poor contact, aging or looseness
pressure, the needle valve gravity and the friction, the exist?
needle valve starts to lift up and fuel injection
commences henceforth. As the fuel injection pulse – If yes, inspect and remove the fault.
closes, the needle valve closes again under the action – If no, go to the next check.
of the return spring pressure. 4. Check fuse F9UA. Has it blown?
Conditions for Running the DTC – If yes, replace the fuse and check to position
• Engine is running and the battery voltage is and remove the power circuit short to ground
higher than 9 V. fault.
Conditions for Setting the DTC – If no, perform “Circuit/System Testing”.
• DTCP020313: Circuit remains open for 0.5s. 5. Operate the vehicle under the conditions for
• DTCP026711: Circuit remains short to ground for running the DTC and confirm that the DTC is not
0.5s. set again.
• DTCP026812: Circuit remains short to power Circuit/System Testing
supply for 0.5s. 1. Turn the ignition switch to OFF position and
Action Taken When the DTC Sets disconnect the battery negative cable.
• DTC is recorded and the engine malfunction 2. Perform fuel injection nozzle 3 component testing.
indicator lamp illuminates. Is it normal?
Conditions for Clearing the DTC – If no, replace the fuel injection nozzle 3.
• A history DTC will clear after 40 fault - free ignition – If yes, go to the next diagnostic step.
cycles. 3. Connect the battery negative cable and turn the
• The body control module receives an order to ignition switch to ON position.
clear the DTC sent by the scan tool. 4. Check power circuit of fuel injection nozzle 3.
Reference Information Measure the voltage between terminal 1 of Q17C
fuel injection nozzle 3 harness connector and the
Schematic Reference ground. Is it the battery voltage?
4.10.18 Engine Controls Schematics (Fuel – If no, test the circuit for open circuit/high
Control—Fuel Injection Nozzle and Fuel Pump) - 1.5 T resistance.
Connector End View Reference – If yes, go to the next diagnostic step.
Q17C Fuel Injection Nozzle 3, and K20 Engine Control
Module X1
Electrical Information Reference
• Circuit Testing
• Connector Repairs
• Testing for Intermittent Conditions and Poor
Connections
• Wiring Repairs
Scan Tool Reference
Refer to “6.1.1.1 Control Module References” for
scan tool information.
Circuit/System Inspection
1. Clear the DTC. Does the DTC reoccur?
– Yes, an intermittent condition; refer to
11.3.4.7 Testing for Intermittent
Conditions and Poor Connections.
– If no, go to the next check.
2. Check the system. Are other DTCs set up?
9-89 Engine/Propulsion

5. Turn the ignition switch to OFF position and • Review “6.2.2.5 Strategy Based Diagnosis” for
disconnect the battery negative cable. an overview of the diagnostic approach.
6. Disconnect K20 engine control module harness • “6.2.2.6 Diagnostic Procedure Instructions”
connector X1. provides an overview of each diagnostic category
7. Check control circuit of fuel injection nozzle 3. DTC Description
Measure the resistance between terminal 2 of DTCP020413: Cylinder 4 fuel injector control circuit
Q17C fuel injection nozzle 3 harness connector open
and terminal 8 of the engine control module
harness connector X1. Is it less than 1 Ω? DTCP027011: Cylinder 4 fuel injector control circuit
voltage too low
– If no, test the circuit for open circuit/high
resistance. DTCP027112: Cylinder 4 fuel injector control circuit
voltage too high
– If yes, go to the next diagnostic step.
Circuit System Description
8. Measure the resistance between terminal 2 of
Q17C fuel injection nozzle 3 harness connector As the engine control module electrifies the fuel
and the ground. Is it infinite? injector coil, magnetic field force is generated. When
the magnetic field force increases to the extent that it
- If no, test the circuit for short to ground. can overcome the resultant force of the return spring
– If yes, go to the next diagnostic step. pressure, the needle valve gravity and the friction, the
9. Connect the battery negative cable and turn the needle valve starts to lift up and fuel injection
ignition switch to ON position. commences henceforth. As the fuel injection pulse
closes, the needle valve closes again under the action
10. Measure the voltage between terminal 2 of Q17C of the return spring pressure.
fuel injection nozzle 3 harness connector and the
ground. Is it 0 V? Conditions for Running the DTC
- If no, test the circuit for short to power supply. • Engine is running and the battery voltage is
higher than 9 V.
– If yes, go to the next diagnostic step.
Conditions for Setting the DTC
11. Turn the ignition switch to OFF position and
disconnect the battery negative cable. • DTCP020413: Circuit remains open for 0.5s.
12. Replace the engine control module. Refer to • DTCP027011: Circuit remains short to ground for
Engine Control Module Programming and Setup. 0.5s.
Operate the vehicle under conditions for running • DTCP027112: Circuit remains short to power
the DTC. Is the DTC set? supply for 0.5s.
– If no, diagnosis ends.
– If yes, install the original module back and
contact the technician.
Component Testing
1. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
2. Disconnect Q17C fuel injection nozzle 3 harness
connector.
3. Measure the resistance between terminal 1 and
terminal 2 of Q17C fuel injection nozzle 3 harness
connector. Is it about 13 Ω (20°C)?
– If no, replace the fuel injection nozzle 3.
– If yes, perform “circuit system testing”.
Repair Instructions
• Fuel Injector Replacement
• Engine Control Module Replacement
• Engine Control Module Programming and Setup
9.2.3.27 DTCP020413, P027011 or P027112
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
 9-90 Engine/Propulsion

Action Taken When the DTC Sets disconnect the battery negative cable.
• DTC is recorded and the engine malfunction 2. Perform fuel injection nozzle 4 component testing.
indicator lamp illuminates. Is it normal?
Conditions for Clearing the DTC – If no, replace the fuel injection nozzle 4.
• A history DTC will clear after 40 fault - free ignition – If yes, go to the next diagnostic step.
cycles. 3. Connect the battery negative cable and turn the
• The body control module receives an order to ignition switch to ON position.
clear the DTC sent by the scan tool. 4. Check power circuit of fuel injection nozzle 4.
Reference Information Measure the voltage between terminal 1 of Q17D
Schematic Reference fuel injection nozzle 4 harness connector and the
ground. Is it the battery voltage?
4.10.18 Engine Controls Schematics (Fuel
Control—Fuel Injection Nozzle and Fuel Pump) - 1.5 T – If no, test the circuit for open circuit/high
resistance.
Connector End View Reference
– If yes, go to the next diagnostic step.
Q17D Fuel Injector Nozzle 4, and K20 Engine Control
Module X2 5. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
Electrical Information Reference
6. Disconnect K20 engine control module harness
• Circuit Testing connector X1.
• Connector Repairs 7. Check control circuit of fuel injection nozzle 4.
• Testing for Intermittent Conditions and Poor Measure the resistance between terminal 2 of
Connections Q17D fuel injection nozzle 4 harness connector
• Wiring Repairs and terminal 10 of the engine control module
harness connector X1. Is it less than 1 Ω?
Scan Tool Reference
– If no, test the circuit for open circuit/high
Refer to “6.1.1.1 Control Module References” for
resistance.
scan tool information.
– If yes, go to the next diagnostic step.
Circuit/System Inspection
8. Measure the resistance between terminal 2 of
1. Clear the DTC. Does the DTC reoccur?
Q17D fuel injection nozzle 4 harness connector
– Yes, an intermittent condition; refer to and the ground. Is it infinite?
11.3.4.7 Testing for Intermittent
- If no, test the circuit for short to ground.
Conditions and Poor Connections.
– If yes, go to the next diagnostic step.
– If no, go to the next check.
2. Check the system. Are other DTCs set up?
– If no, perform the corresponding fault
diagnosis according to the DTC.
– If no, go to the next check.
3. Check the harness connectors or components.
Does breakage, poor contact, aging or looseness
exist?
– If yes, inspect and remove the fault.
– If no, go to the next check.
4. Check fuse F9UA. Has it blown?
– If yes, replace the fuse and check to position
and remove the power circuit short to ground
fault.
– If no, perform “Circuit/System Testing”.
5. Operate the vehicle under the conditions for
running the DTC and confirm that the DTC is not
set again.
Circuit/System Testing
1. Turn the ignition switch to OFF position and
9-91 Engine/Propulsion

9. Connect the battery negative cable and turn the the throttle rotates, the rocker arm is taken to slide to a
ignition switch to ON position. certain position. The potentiometer outputs a voltage
10. Measure the voltage between terminal 2 of Q17D signal that is proportional to the throttle position. One
fuel injection nozzle 4 harness connector and the throttle is equipped with two potentiometers installed in
ground. Is it 0 V? reverse phase. The engine control module judge the
throttle rotation angle based on these two signals. 5 V
- If no, test the circuit for short to power supply. supply power voltage and reference ground for the two
– If yes, go to the next diagnostic step. potentiometers are provided by the engine control
11. Turn the ignition switch to OFF position and module.
disconnect the battery negative cable. Conditions for Running the DTC
12. Replace the engine control module. Refer to • DTCP022129: Engine speed is >1,200 rpm.
Engine Control Module Programming and Setup. • DTCP022216, P022317: Time after starting is >
Operate the vehicle under conditions for running 12S.
the DTC. Is the DTC set?
Conditions for Setting the DTC
– If no, diagnosis ends.
• DTCP022129: Signal remains not plausible for
– If yes, install the original module back and 0.2800s.
contact the technician.
• DTCP022216: Signal voltage remains < 0.156 V
Component Testing for 0.1400s.
1. Turn the ignition switch to OFF position and • DTCP022317: Signal voltage remains > 4.883V
disconnect the battery negative cable. for 0.1400s.
2. Disconnect Q17D fuel injection nozzle 4 harness
connector.
3. Measure the resistance between terminal 1 and
terminal 2 of Q17D fuel injection nozzle 4 harness
connector. Is it about 13 Ω (20°C)?
– If no, replace the fuel injection nozzle 4.
– If yes, perform “circuit system testing”.
Repair Instructions
• Fuel Injector Replacement
• Engine Control Module Replacement
• Engine Control Module Programming and Setup
9.2.3.28 DTCP022129, P022216 or P022317
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
DTC Description
DTCP022129: Electronic throttle position sensor 2
signal not plausible
DTCP022216: Electronic throttle position sensor 2
signal circuit voltage too low
DTCP022317: Electronic throttle position sensor 2
signal circuit voltage too high
Circuit System Description
Both the throttle position sensor and the throttle
actuator are integrated on the throttle. The throttle
position sensor is actually a rotating potentiometer
characteristic of linear output. Rocker arm of the
potentiometer is installed coaxially with the throttle. As
 9-92 Engine/Propulsion

Action Taken When the DTC Sets – If no, perform “Circuit/System Testing”.
• DTC is recorded and the engine malfunction 5. Operate the vehicle under the conditions for
indicator lamp does not illuminate. running the DTC and confirm that the DTC is not
Conditions for Clearing the DTC set again.
• A history DTC will clear after 40 fault - free ignition Circuit/System Testing
cycles. 1. Turn the ignition switch to OFF position and
• The body control module receives an order to disconnect the battery negative cable.
clear the DTC sent by the scan tool. 2. Disconnect Q38 throttle harness connector.
Reference Information 3. Connect the battery negative cable and turn the
Schematic Reference ignition switch to ON position.
4.10.13 Engine Controls Schematics (Accelerator 4. Check the throttle power circuit. Measure the
Pedal Position Sensor, Electronic Throttle Control) - voltage between terminal 4 of Q38 throttle
1.5 T harness connector and the ground. Is it about
5V?
Connector End View Reference
– If no, perform the following test:
Q38 Throttle, and K20 Engine Control Module X1
(1) Turn the ignition switch to the OFF position
Electrical Information Reference and disconnect the battery negative cable.
• Circuit Testing (2) Disconnect K20 engine control module
• Connector Repairs harness connector X1.
• Testing for Intermittent Conditions and Poor (3) Measure the resistance between terminal 4
Connections of Q38 throttle harness connector and
• Wiring Repairs terminal 43 of K20 engine control module
harness connector X1. Is it less than 1 Ω?
Scan Tool Reference
– If no, test the circuit for open circuit/high
Refer to “6.1.1.1 Control Module References” for
resistance.
scan tool information.
– If yes, go to the next diagnostic step.
Circuit/System Inspection
(4) Measure the resistance between terminal 4
1. Clear the DTC. Does the DTC reoccur?
of Q38 throttle harness connector and the
– Yes, an intermittent condition; refer to ground. Is it infinite?
11.3.4.7 Testing for Intermittent
– If no, test the circuit for short to ground.
Conditions and Poor Connections.
– If yes, go to the next diagnostic step.
– If no, go to the next check.
2. Check the system. Are other DTCs set up?
– If no, perform the corresponding fault
diagnosis according to the DTC.
– If no, go to the next check.
3. Check the harness connectors or components.
Does breakage, poor contact, aging or looseness
exist?
– If yes, inspect and remove the fault.
– If no, go to the next check.
4. Turn the ignition switch to ON position, and
confirm the “Throttle Angle 2” and “Throttle
Position Sensor 2 Voltage Original Value”
displayed real - time on the scan tool. Does the
parameter change as the accelerator pedal input
changes and is the change within the reasonable
range of 4.42 V - 0.38 V?
– If yes, clean the throttle, carry out throttle
matching/self - learning and then take a road
test, if the DTC appears again, perform
“Circuit/System Testing”.
9-93 Engine/Propulsion

(5) Connect the battery negative cable and turn Q38 throttle harness connector and the
the ignition switch to ON position. ground. Is it 0 V?
(6) Measure the voltage between terminal 4 of – If no, test the circuit for short to power
Q38 throttle harness connector and the supply.
ground. Is it 0 V? – If yes, go to the next diagnostic step.
– If no, test the circuit for short to power (9) Turn the ignition switch to the OFF position
supply. and disconnect the battery negative cable.
– If yes, go to the next diagnostic step. (10) Measure the resistance between the
(7) Turn the ignition switch to the OFF position following terminals of Q38 throttle harness
and disconnect the battery negative cable. connector and the ground. Is it infinite?
(8) Replace the engine control module. Refer to Terminal 1, 2, 4 and 5 of Q38
Engine Control Module Programming and - If no, test the circuit to see if it is short -
Setup. Operate the vehicle under conditions circuited.
for running the DTC. Is the DTC set? – If yes, go to the next diagnostic step.
– If no, diagnosis ends. (11) Replace the throttle and the engine control
– If yes, install the original module back module. Refer to Engine Control Module
and contact the technician. Programming and Setup. Operate the vehicle
– If yes, perform the following test: under conditions for running the DTC. Is the
DTC set?
(1) Turn the ignition switch to the OFF position
and disconnect the battery negative cable. – If no, diagnosis ends.
(2) Disconnect K20 engine control module – If yes, install the original module back
harness connector X1. and contact the technician.
(3) Check the throttle signal ground circuit. Repair Instructions
Measure the resistance between terminal 5 • Throttle Matching/Self - learning
of Q38 throttle harness connector and • Throttle Replacement
terminal 22 of K20 engine control module
harness connector X1. Is it less than 1 Ω? • Engine Control Module Replacement
– If no, test the circuit for open circuit/high • Engine Control Module Programming and Setup
resistance.
– If yes, go to the next diagnostic step.
(4) Check the throttle control circuit. Measure the
resistance between terminal 2 of Q38 throttle
harness connector and terminal 14 of K20
engine control module harness connector X1.
Is it less than 1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
(5) Measure the resistance between terminal 2
of Q38 throttle harness connector and the
ground. Is it infinite?
– If no, test the circuit for short to ground.
– If yes, go to the next diagnostic step.
(6) Connect the battery negative cable and turn
the ignition switch to ON position.
(7) Measure the voltage between terminal 5 of
Q38 throttle harness connector and the
ground. Is it 0 V?
– If no, test the circuit for short to power
supply.
– If yes, go to the next diagnostic step.
(8) Measure the voltage between terminal 2 of
 9-94 Engine/Propulsion

9.2.3.29 DTCP023400, P029900, P024300, P024500 Connections

or P024600 • Wiring Repairs
Diagnostic Instructions Scan Tool Reference
• Perform “6.2.2.7 Diagnostic System Check - Refer to “6.1.1.1 Control Module References” for
Vehicle” prior to using this diagnostic procedure. scan tool information.
• Review “6.2.2.5 Strategy Based Diagnosis” for Circuit/System Inspection
an overview of the diagnostic approach.
1. Clear the DTC. Does the DTC reoccur?
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category – Yes, an intermittent condition; refer to
11.3.4.7 Testing for Intermittent
DTC Description Conditions and Poor Connections.
DTCP023400: Excessive turbine - controlled pressure – If no, go to the next check.
increase
2. Check the system. Are other DTCs set up?
DTCP029900: Turbocharging pressure too low
– If no, perform the corresponding fault
DTCP024300: Exhaust control valve drive circuit fault diagnosis according to the DTC.
DTCP024500: Exhaust control valve drive circuit – If no, go to the next check.
voltage too low
3. Check the harness connectors or components.
DTCP024600: Exhaust control valve drive circuit Does breakage, poor contact, aging or looseness
voltage too high exist?
Circuit System Description – If yes, inspect and remove the fault.
The flow control valve controls the valve port to fully – If no, go to the next check.
open/close or to a certain extent as the valve element
moves relatively in the valve body. In this way, exhaust 4. Check fuse F9UA. Has it blown?
flow control is realized. – If yes, replace the fuse and check to position
Conditions for Running the DTC and remove the power circuit short to ground
fault.
• The ignition switch is turned to ON position.
– If no, perform “Circuit/System Testing”.
Conditions for Setting the DTC
5. Operate the vehicle under the conditions for
• DTCP024300: Circuit open. running the DTC and confirm that the DTC is not
• DTCP024500: Circuit short to ground. set again.
• DTCP024600: Circuit short to power supply.
Action Taken When the DTC Sets
• DTC is recorded and the engine malfunction
indicator lamp illuminates.
Conditions for Clearing the DTC
• A history DTC will clear after 40 fault - free ignition
cycles.
• The body control module receives an order to
clear the DTC sent by the scan tool.
Reference Information
Schematic Reference
4.10.17 Engine Controls Schematics (Exhaust Flow
Control Valve, Intake Flow Valve, Canister Solenoid
Valve) - 1.5 T
Connector End View Reference
Q15 Exhaust Flow Control Valve, and K20 Engine
Control Module X1
Electrical Information Reference
• Circuit Testing
• Connector Repairs
• Testing for Intermittent Conditions and Poor
9-95 Engine/Propulsion

Circuit/System Testing disconnect the battery negative cable.

1. Turn the ignition switch to OFF position and 2. Disconnect Q15 exhaust flow control valve
disconnect the battery negative cable. harness connector.
2. Perform exhaust flow control valve component 3. Measure the resistance between terminal 1 and
testing. Is it normal? terminal 2 of Q15 exhaust flow control valve
– If no, replace the exhaust flow control valve. harness connector. Is it about 25 Ω?
– If yes, go to the next diagnostic step. – If no, replace the exhaust flow control valve.
3. Connect the battery negative cable and turn the – If yes, perform “circuit system testing”.
ignition switch to ON position. Repair Instructions
4. Check power circuit of the exhaust flow control • Exhaust Flow Control Valve Replacement
valve. Measure the voltage between terminal 1 of • Engine Control Module Replacement
Q15 exhaust flow control valve harness connector
and the ground. Is it the battery voltage? • Engine Control Module Programming and Setup
– If no, test the circuit for open circuit/high 9.2.3.30 DTCP030021, P030022, P030029, P030121,
resistance. P030122, P030129, P030221, P030222,
P030229, P030321, P030322, P030329,
– If yes, go to the next diagnostic step. P030421, P030422 or P030429
5. Turn the ignition switch to OFF position and Diagnostic Instructions
disconnect the battery negative cable.
• Perform “6.2.2.7 Diagnostic System Check -
6. Disconnect K20 engine control module harness Vehicle” prior to using this diagnostic procedure.
connector X1.
• Review “6.2.2.5 Strategy Based Diagnosis” for
7. Check control circuit of the exhaust flow control an overview of the diagnostic approach.
valve. Measure the resistance between terminal 2
of Q15 exhaust flow control valve harness • “6.2.2.6 Diagnostic Procedure Instructions”
connector and terminal 1 of the engine control provides an overview of each diagnostic category
module harness connector X1. Is it less than 1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
8. Measure the resistance between terminal 2 of
Q15 exhaust flow control valve harness connector
and the ground. Is it infinite?
- If no, test the circuit for short to ground.
– If yes, go to the next diagnostic step.
9. Connect the battery negative cable and turn the
ignition switch to ON position.
10. Measure the voltage between terminal 2 of Q15
exhaust flow control valve harness connector and
the ground. Is it 0 V?
- If no, test the circuit for short to power supply.
– If yes, go to the next diagnostic step.
11. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
12. Replace the engine control module. Refer to
Engine Control Module Programming and Setup.
Operate the vehicle under conditions for running
the DTC. Is the DTC set?
– If no, diagnosis ends.
– If yes, install the original module back and
contact the technician.
Component Testing
1. Turn the ignition switch to OFF position and
 9-96 Engine/Propulsion

DTC Description Schematic Reference

DTCP030021: Multiple cylinder misfire 4.10.15 Engine Controls Schematics (Ignition Coil) -
DTCP030022: Multiple cylinder misfire 1.5 T
DTCP030029: Multiple cylinder misfire Connector End View Reference
DTCP030121: Cylinder 1 misfire T8A Ignition Coil 1, T8B Ignition Coil 2, T8C Ignition
Coil 3, T8D Ignition Coil 4, and K20 Engine Control
DTCP030122: Cylinder 1 misfire Module X1
DTCP030129: Cylinder 1 misfire Electrical Information Reference
DTCP030221: Cylinder 2 misfire • Circuit Testing
DTCP030222: Cylinder 2 misfire • Connector Repairs
DTCP030229: Cylinder 2 misfire • Testing for Intermittent Conditions and Poor
DTCP030321: Cylinder 3 misfire Connections
DTCP030322: Cylinder 3 misfire • Wiring Repairs
DTCP030329: Cylinder 3 misfire Scan Tool Reference
DTCP030421: Cylinder 4 misfire Refer to “6.1.1.1 Control Module References” for
DTCP030422: Cylinder 4 misfire scan tool information.
DTCP030429: Cylinder 4 misfire Circuit/System Inspection
Circuit System Description 1. Clear the DTC. Does the DTC reoccur?
The time when engine misfire happens is determined – Yes, an intermittent condition; refer to
based on information from the crankshaft position 11.3.4.7 Testing for Intermittent
sensor and the misfiring cylinder is determined based Conditions and Poor Connections.
on information from the camshaft position sensor. The – If no, go to the next check.
engine control module can detect each misfiring 2. Check the system. Are other DTCs set up?
cylinder by monitoring the crankshaft rotation speed
change of each cylinder. – If no, perform the corresponding fault
diagnosis according to the DTC.
Conditions for Running the DTC
– If no, go to the next check.
• The engine speed is between 530 - 5600 r/m and
keeps stable;
• The intake air temperature is not lower than -
30°C;
• The engine load is not lower than zero torque (the
lowest) load line;
• Engine fuel supply is not interrupted;
• No failing circuit is detected;
• Torque interference is not activated.
Conditions for Setting the DTC
• ECU detects angular acceleration change of the
camshaft caused by misfire, which indicates that
the misfire is serious enough to result in emission
level beyond OBD limit value or damage to the
catalytic converter.
Action Taken When the DTC Sets
• DTC is recorded and the engine malfunction
indicator lamp illuminates.
Conditions for Clearing the DTC
• A history DTC will clear after 40 fault - free ignition
cycles.
• The body control module receives an order to
clear the DTC sent by the scan tool.
Reference Information
9-97 Engine/Propulsion

3. Check the harness connectors or components. 4. Connect the battery negative cable and turn the
Does breakage, poor contact, aging or looseness ignition switch to ON position.
exist? 5. Check power circuit of ignition primary coil.
– If yes, inspect and remove the fault. Measure the voltage between the power circuit
– If no, go to the next check. terminal of the following ignition coil harness
connector and the ground respectively. Is it the
4. Check fuse F9UA. Has it blown? battery voltage?
– If yes, replace the fuse and check to position ○ Terminal 1 of T8A
and remove the power circuit short to ground
fault. ○ Terminal 1 of T8B
– If no, go to the next check. ○ Terminal 1 of T8C
5. Is any abnormal noise is heard while the engine is ○ Terminal 1 of T8D
idling under room temperature? – If no, test the circuit for open circuit/high
– If yes, check the engine for a mechanical resistance.
fault. – If yes, go to the next diagnostic step.
– If no, go to the next check. 6. Turn the ignition switch to OFF position and
6. Confirm whether the following circumstances disconnect the battery negative cable.
exist and if any, repair the failing/faulty 7. Disconnect K20 engine control module harness
component as necessary. connector X1.
○ Vacuum hose cracks, torts or is not 8. Check control circuit of ignition primary coil.
connected properly. Measure the resistance between terminal of the
○ Engine vacuum leakage exists. following ignition coil harness connectors and the
following terminals of K20 engine control module
○ The crankshaft ventilation system leaks. harness connector respectively. Is it less than 1
○ The fuel pressure is too low or too high. Ω?
○ The fuel quality fails the standard. ○ Terminal 2 of T8A and terminal 36 of K20 X1
7. Check the spark plug of the cylinder with a misfire ○ Terminal 2 of T8B and terminal 24 of K20 X1
DTC for damage and replace it if necessary. At ○ Terminal 2 of T8C and terminal 35 of K20 X1
the same time, measure the corresponding
cylinder pressure to see if it satisfies the standard. ○ Terminal 2 of T8D and terminal 12 of K20 X1
– If yes, inspect and make repairs. – If no, test the circuit for open circuit/high
resistance.
– If no, perform “Circuit/System Testing”.
– If yes, go to the next diagnostic step.
8. Operate the vehicle under the conditions for
running the DTC and confirm that the DTC is not
set again.
Circuit/System Testing
1. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
2. Perform component testing on T8A ignition coil 1,
T8B ignition coil 2, T8C ignition coil 3 and T8D
ignition coil 4 respectively. Is all normal?
– If no, replace T8A ignition coil 1, T8B ignition
coil 2, T8C ignition coil 3 and T8D ignition coil
4.
– If yes, go to the next diagnostic step.
3. Install a new spark plug on high - tension cable of
the misfiring cylinder and conduct arcing test on
this cylinder. Observe the spark strength and if it
is very strong, check the corresponding fuel
injector. Refer to fuel injector relevant fault codes.
If the spark is very weak, replace the
corresponding ignition coil. If no spark is
generated, go to the next diagnostic step.
 9-98 Engine/Propulsion

9. Measure the resistance between terminal of the • Review “6.2.2.5 Strategy Based Diagnosis” for
following ignition coil harness connectors and the an overview of the diagnostic approach.
ground respectively. Is it infinite? • “6.2.2.6 Diagnostic Procedure Instructions”
○ Terminal 2 of T8A provides an overview of each diagnostic category
○ Terminal 2 of T8B DTC Description
○ Terminal 2 of T8C DTCP044413: Canister control valve control circuit
○ Terminal 2 of T8D open
- If no, test the circuit for short to ground. DTCP045816: Canister control valve control circuit
voltage too low
– If yes, go to the next diagnostic step.
DTCP045917: Canister control valve control circuit
10. Connect the battery negative cable and turn the voltage too high
ignition switch to ON position.
Circuit System Description
11. Measure the voltage between terminal of the
following ignition coil harness connectors and the The canister control valve is used to control the
ground respectively. Is it 0 V? regenerated gas flow of the fuel evaporative emission
control system. It is installed on the vacuum pipeline
○ Terminal 2 of T8A from the canister to the intake manifold. The canister
○ Terminal 2 of T8B in the fuel evaporative emission control system absorb
○ Terminal 2 of T8C fuel vapor from the fuel tank until it gets saturated. The
engine control module controls the canister control
○ Terminal 2 of T8D
valve to open so that fresh air mixes with the saturated
- If no, test the circuit for short to power supply. fuel vapor in the canister, and regenerated gas flow is
– If yes, go to the next diagnostic step. thus formed and it is led back to the engine intake air
12. Turn the ignition switch to OFF position and pipe. The engine control module changes duty ratio of
disconnect the battery negative cable. the pulse signal sent to the canister control valve
based on different engine operating conditions and
13. Replace the engine control module. Refer to thus controls flow of the regenerated gas. Besides, the
Engine Control Module Programming and Setup. flow is also affected by the pressure difference at both
Operate the vehicle under conditions for running ends.
the DTC. Is the DTC set?
– If no, diagnosis ends.
– If yes, install the original module back and contact
the technician.
Component Testing
1. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
2. Disconnect harness connector of T8A ignition coil
1, T8B ignition coil 2, T8C ignition coil 3 and T8D
ignition coil 4 respectively.
3. Remove T8A ignition coil 1, T8B ignition coil 2,
T8C ignition coil 3 and T8D ignition coil 4.
4. Measure each ignition primary coil resistance
(under 20°C)? Is it about 0.8 Ω?
– If no, replace the ignition coil.
– If yes, perform “circuit system testing”.
Repair Instructions
• Ignition Coil Replacement
• Engine Control Module Replacement
• Engine Control Module Programming and Setup
9.2.3.31 DTCP044413, P045816 or P045917
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
9-99 Engine/Propulsion

Conditions for Running the DTC 4. Check fuse F9UA. Has it blown?
• Engine is running and the battery voltage is – If yes, replace the fuse and check to position
higher than 9 V. and remove the power circuit short to ground
Conditions for Setting the DTC fault.
• DTCP044413: Circuit remains open for 0.5s. – If no, perform “Circuit/System Testing”.
• DTCP045816: Circuit remains short to ground for 5. Operate the vehicle under the conditions for
0.5s. running the DTC and confirm that the DTC is not
set again.
• DTCP045917: Circuit remains short to power
supply for 0.5s. Circuit/System Testing
Action Taken When the DTC Sets 1. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
• DTC is recorded and the engine malfunction
indicator lamp illuminates. 2. Perform canister solenoid valve component
testing. Is it normal?
Conditions for Clearing the DTC
– If no, replace the canister solenoid valve.
• A history DTC will clear after 40 fault - free ignition
cycles. – If yes, go to the next diagnostic step.
• The body control module receives an order to 3. Connect the battery negative cable and turn the
clear the DTC sent by the scan tool. ignition switch to ON position.
Reference Information 4. Check power circuit of the canister solenoid valve.
Measure the voltage between terminal 2 of
Schematic Reference Q12WL1 canister solenoid valve harness
4.10.17 Engine Controls Schematics (Intake Air Flow connector and the ground. Is it the battery
Control Valve, Intake Air Flow Valve, Canister Solenoid voltage?
Valve) - 1.5 T – If no, test the circuit for open circuit/high
Connector End View Reference resistance.
Q12WL1 Canister Control Valve, and K20 Engine – If yes, go to the next diagnostic step.
Control Module X1 5. Turn the ignition switch to OFF position and
Electrical Information Reference disconnect the battery negative cable.
• Circuit Testing
• Connector Repairs
• Testing for Intermittent Conditions and Poor
Connections
• Wiring Repairs
Scan Tool Reference
Refer to “6.1.1.1 Control Module References” for
scan tool information.
Circuit/System Inspection
1. Clear the DTC. Does the DTC reoccur?
– Yes, an intermittent condition; refer to
11.3.4.7 Testing for Intermittent
Conditions and Poor Connections.
– If no, go to the next check.
2. Check the system. Are other DTCs set up?
– If no, perform the corresponding fault
diagnosis according to the DTC.
– If no, go to the next check.
3. Check the harness connectors or components.
Does breakage, poor contact, aging or looseness
exist?
– If yes, inspect and remove the fault.
– If no, go to the next check.

6. Disconnect K20 engine control module harness
connector X1.
7. Check control circuit of the canister solenoid
valve. Measure the resistance between terminal
30 of K20 engine control module harness
connector X1 and terminal 1 of Q12WL1 canister
solenoid valve harness connector. Is it less than 1
Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
8. Measure the resistance between terminal 1 of
Q12WL1 canister solenoid valve harness
connector and the ground. Is it infinite?
- If no, test the circuit for short to ground.
– If yes, go to the next diagnostic step.
9. Connect the battery negative cable and turn the
ignition switch to ON position.
10. Measure the voltage between terminal 1 of
Q12WL1 canister solenoid valve harness
connector and the ground. Is it 0 V?
- If no, test the circuit for short to power supply.
– If yes, go to the next diagnostic step.
11. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
12. Replace the engine control module. Refer to
Engine Control Module Programming and Setup.
Operate the vehicle under conditions for running
the DTC. Is the DTC set?
– If no, diagnosis ends.
– If yes, install the original module back and
contact the technician.
Component Testing
1. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
2. Disconnect Q12WL1 canister solenoid valve
harness connector.
3. Measure the resistance between terminal 1 and
terminal 2 of Q12WL1 canister solenoid valve
harness connector. Is it about 17 Ω?
– If no, replace the canister solenoid valve.
– If yes, perform “circuit system testing”.
Repair Instructions
• Evaporative Emission Purging Solenoid
Valve Replacement
• Engine Control Module Replacement
• Engine Control Module Programming and
Setup
9.2.3.32 DTCP046217 or P046316
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
9-100 Engine/Propulsion
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
DTC Description
DTCP046217: Fuel level sensor circuit voltage too low
DTCP046316: Fuel level sensor circuit voltage too
high
Circuit System Description
Two pins are connected with the fuel level sensor and
they are at the sensor signal end and the sensor
ground end respectively. The voltage generated by the
sensor changes as the fuel level changes. The higher
the level, the lower the voltage. DTCP046217 will be
set if the voltage is too low. Two pins are connected
with the fuel tank fuel level sensor and they are at the
sensor signal end and the sensor ground end
respectively. The voltage generated by the sensor
changes as the fuel level changes. The lower the level,
the higher the voltage. DTCP046316 will be set if the
voltage is too high.
Conditions for Running the DTC
• The engine is started.
Conditions for Setting the DTC
• The fuel level signal voltage does not conform to
the standard value.
Action Taken When the DTC Sets
• The engine malfunction indicator lamp
illuminates.
Conditions for Clearing the DTC
• A history DTC will clear after 40 fault - free ignition
cycles.
• The body control module receives an order to
clear the DTC sent by the scan tool.
9-101 Engine/Propulsion

Reference Information sensor assembly harness connector and terminal

Schematic Reference N4 of K20 engine control module harness
connector X2. Is it less than 1 Ω?
4.10.18 Engine Controls Schematics (Fuel
Control—Fuel Injection Nozzle and Fuel Pump) - 1.5 T – If no, test the circuit for open circuit/high
resistance.
Connector End View Reference
– If yes, go to the next diagnostic step.
A7 Fuel Pump and Fuel Level Sensor Assembly, and
K20 Engine Control Module X2 6. Measure the resistance between terminal 1 of A7
fuel pump and fuel level sensor assembly
Electrical Information Reference harness connector and the ground. Is it infinite?
• Circuit Testing - If no, test the circuit for short to ground.
• Connector Repairs – If yes, go to the next diagnostic step.
• Testing for Intermittent Conditions and Poor 7. Check ground circuit of the fuel pump and fuel
Connections level sensor assembly. Measure the resistance
• Wiring Repairs between terminal 2 of A7 fuel pump and fuel level
Scan Tool Reference sensor assembly harness connector and terminal
L3 of K20 engine control module harness
Refer to “6.1.1.1 Control Module References” for
connector X2. Is it less than 1 Ω?
scan tool information.
– If no, test the circuit for open circuit/high
Circuit/System Inspection
resistance.
1. Clear the DTC. Does the DTC reoccur?
– If yes, go to the next diagnostic step.
– Yes, an intermittent condition; refer to
8. Measure the resistance between terminal 2 of A7
11.3.4.7 Testing for Intermittent
fuel pump and fuel level sensor assembly
Conditions and Poor Connections.
harness connector and the ground. Is it infinite?
– If no, go to the next check.
- If no, test the circuit for short to ground.
2. Check the system. Are other DTCs set up?
– If yes, go to the next diagnostic step.
– If no, perform the corresponding fault
diagnosis according to the DTC.
– If no, go to the next check.
3. Check the harness connectors or components.
Does breakage, poor contact, aging or looseness
exist?
– If yes, inspect and remove the fault.
– If no, perform “Circuit/System Testing”.
4. Operate the vehicle under the conditions for
running the DTC and confirm that the DTC is not
set again.
Circuit/System Testing
1. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
2. Perform fuel pump and fuel level sensor
assembly component testing. Is it normal?
– If no, replace the fuel pump and fuel level
sensor assembly.
– If yes, go to the next diagnostic step.
3. Disconnect A7 fuel pump and fuel level sensor
assembly harness connector and K20 engine
control module harness connector X2.
4. Connect the battery negative cable and turn the
ignition switch to ON position.
5. Check signal circuit of the fuel pump and fuel
level sensor assembly. Measure the resistance
between terminal 1 of A7 fuel pump and fuel level
 9-102 Engine/Propulsion

9. Connect the battery negative cable and turn the DTCP069212: Coolant fan relay control circuit short to
ignition switch to ON position. power supply (low - speed)
10. Measure the voltage between terminal 2 of A7 Circuit System Description
fuel pump and fuel level sensor assembly The engine control module can real - time adjust and
harness connector and the ground. Is it 0 V? control the coolant fan low - speed relay to turn on,
- If no, test the circuit for short to power supply. depending on the detected engine coolant
– If yes, go to the next diagnostic step. temperature. The 12 V power source reaches the
coolant fan low - speed relay after the main relay is
11. Measure the voltage between terminal 1 of A7 turned on. The engine control module provides ground
fuel pump and fuel level sensor assembly signal for the coolant fan low - speed relay. After the
harness connector and the ground. Is it 0 V? engine starts to run, the low - speed fan turns off when
- If no, test the circuit for short to power supply. the engine coolant temperature sensor detects that the
– If yes, go to the next diagnostic step. temperature is lower than 94°C and at this time, the
voltage at both ends of the coolant fan low - speed
12. Turn the ignition switch to OFF position and
relay coil is 12 V; when the temperature is higher than
disconnect the battery negative cable.
100°C but lower than 112°C, the coolant fan low -
13. Replace the engine control module. Refer to speed relay turns on and the coolant fan runs at low
Engine Control Module Programming and Setup. speed.
Operate the vehicle under conditions for running
Conditions for Running the DTC
the DTC. Is the DTC set?
• DTCP048013: The engine is running and the
– If no, diagnosis ends.
battery voltage is higher than 9 V.
– If yes, install the original module back and
• DTCP069111: The engine is running and the
contact the technician.
bottom layer satisfies the diagnostic conditions.
Component Testing
• DTCP069212: The engine is running and the
1. Turn the ignition switch to OFF position and battery voltage is higher than 9 V.
disconnect the battery negative cable.
2. Disconnect A7 fuel pump and fuel level sensor
assembly harness connector.
3. Measure the resistance between terminal 1 and
terminal 2 of A7 fuel pump and fuel level sensor
assembly harness connector. Is it between 12 Ω -
125 Ω?
– If no, replace the fuel pump and fuel level
sensor assembly.
– If yes, perform “circuit system testing”.
Repair Instructions
• Fuel Pump and Fuel Level Sensor Assembly
Replacement
• Engine Control Module Replacement
• Engine Control Module Programming and Setup
9.2.3.33 DTCP048013, P069111 or P069212
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
DTC Description
DTCP048013: Coolant fan relay control circuit open
(low - speed)
DTCP069111: Coolant fan relay control circuit short to
ground (low - speed)
9-103 Engine/Propulsion

Conditions for Setting the DTC – If no, go to the next check.

• DTCP048013: Circuit remains open for 0.5s. 4. Check fuse F10UA to see if it has blown?
• DTCP069111: The number of fault occurrences – If yes, replace the fuse and check to position
exceeds the threshold within 400 combustion and remove the power circuit short to ground
cycles. fault.
• DTCP069212: Circuit remains short to power – If no, perform “Circuit/System Testing”.
supply for 0.5s. 5. Operate the vehicle under the conditions for
Action Taken When the DTC Sets running the DTC and confirm that the DTC is not
• DTCP048013: DTC is recorded and the engine set again.
malfunction indicator lamp does not illuminate. Circuit/System Testing
• DTCP069111: The ignition angle delays - 9KW 1. Turn the ignition switch to OFF position and
and the engine malfunction indicator lamp does disconnect the battery negative cable.
not illuminate. 2. Perform coolant fan low - speed relay component
• DTCP069212: DTC is recorded and the engine testing. Is it normal?
malfunction indicator lamp does not illuminate. – If no, replace the coolant fan low - speed
Conditions for Clearing the DTC relay.
• A history DTC will clear after 40 fault - free ignition – If yes, go to the next diagnostic step.
cycles. 3. Connect the battery negative cable and turn the
• The body control module receives an order to ignition switch to ON position.
clear the DTC sent by the scan tool. 4. Measure the voltage between terminal 85 of
Reference Information coolant fan low - speed relay base and the ground.
Schematic Reference Is it the battery voltage?
4.10.20 Engine Controls Schematics (Engine Cooling – If no, test the circuit for open circuit/high
System) - 1.5 T resistance.
Connector End View Reference – If yes, go to the next diagnostic step.
K20 engine control moduleX2 5. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
Electrical Information Reference
• Circuit Testing
• Connector Repairs
• Testing for Intermittent Conditions and Poor
Connections
• Wiring Repairs
Scan Tool Reference
Refer to “6.1.1.1 Control Module References” for
scan tool information.
Circuit/System Inspection
1. Clear the DTC. Does the DTC reoccur?
– Yes, an intermittent condition; refer to
11.3.4.7 Testing for Intermittent
Conditions and Poor Connections.
– If no, go to the next check.
2. Check the system. Are other DTCs set up?
– If no, perform the corresponding fault
diagnosis according to the DTC.
– If no, go to the next check.
3. Check the harness connectors or components.
Does breakage, poor contact, aging or looseness
exist?
– If yes, inspect and remove the fault.
 9-104 Engine/Propulsion

6. Disconnect K20 engine control module harness 85 of the coolant fan low - speed relay and the 12
connector X2. V power supply. Install a jumper wire between
7. Measure the resistance between terminal 86 of terminal 86 of the coolant fan low - speed relay
coolant fan low - speed relay base and terminal and the ground. Measure the resistance between
H4 of K20 engine control module harness terminal 30 and terminal 87. Is it less than 1 Ω?
connector X2. Is it less than 1 Ω? – If no, replace the coolant fan low - speed
– If no, test the circuit for open circuit/high relay.
resistance. – If yes, perform “circuit system testing”.
– If yes, go to the next diagnostic step. Repair Instructions
8. Measure the resistance between terminal 86 of • Engine Control Module Replacement
coolant fan low - speed relay base and the ground. • Engine Control Module Programming and Setup
Is it infinite?
9.2.3.34 DTCP048113, P069311 or P069412
- If no, test the circuit for short to ground.
Diagnostic Instructions
– If yes, go to the next diagnostic step.
• Perform “6.2.2.7 Diagnostic System Check -
9. Connect the battery negative cable and turn the Vehicle” prior to using this diagnostic procedure.
ignition switch to ON position.
• Review “6.2.2.5 Strategy Based Diagnosis” for
10. Measure the voltage between terminal 86 of an overview of the diagnostic approach.
coolant fan low - speed relay base and the ground.
Is it 0 V? • “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
- If no, test the circuit for short to power supply.
DTC Description
– If yes, go to the next diagnostic step.
DTCP048113: Coolant fan relay control circuit open
11. Turn the ignition switch to OFF position and (high - speed)
disconnect the battery negative cable.
DTCP069311: Coolant fan relay control circuit short to
12. Replace the engine control module. Refer to ground (high - speed)
Engine Control Module Programming and Setup.
Operate the vehicle under conditions for running DTCP069412: Coolant fan relay control circuit short to
the DTC. Is the DTC set? power supply (high - speed)
– If no, diagnosis ends.
– If yes, install the original module back and
contact the technician.
Component Testing
1. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
2. Remove the coolant fan low - speed relay.
3. Measure the resistance between terminal 85 and
terminal 86 of the coolant fan low - speed relay. Is
it about 104 Ω?
– If no, replace the coolant fan low - speed
relay.
– If yes, go to the next test.
4. Measure the resistance between the following
terminals of the coolant fan low - speed relay
respectively. Is it infinite?
○ 86 and 30
○ 86 and 87
○ 85 and 87
○ 85 and 30
– If no, replace the coolant fan low - speed
relay.
– If yes, go to the next test.
5. Install a 2A fused jumper wire between terminal
9-105 Engine/Propulsion

Circuit System Description Conditions and Poor Connections.

The engine control module can real - time adjust and – If no, go to the next check.
control the coolant fan high - speed relay to turn on, 2. Check the system. Are other DTCs set up?
depending on the detected engine coolant
temperature. The 12 V power source reaches the – If no, perform the corresponding fault
coolant fan high - speed relay after the main relay is diagnosis according to the DTC.
turned on. The engine control module provides ground – If no, go to the next check.
signal for the coolant fan high - speed relay. If the main 3. Check the harness connectors or components.
relay is not turned on, no voltage exists at either end of Does breakage, poor contact, aging or looseness
the coolant fan high - speed relay coil. After the engine exist?
starts to run, the high - speed fan turns off when the
– If yes, inspect and remove the fault.
engine coolant temperature sensor detects that the
temperature is lower than 112°C; when the – If no, go to the next check.
temperature is higher than 112°C, the coolant fan high 4. Check fuse F10UA to see if it has blown?
- speed relay turns on and the coolant fan runs at high – If yes, replace the fuse and check to position
speed. and remove the power circuit short to ground
Conditions for Running the DTC fault.
• Engine is running and the battery voltage is – If no, perform “Circuit/System Testing”.
higher than 9 V. 5. Operate the vehicle under the conditions for
Conditions for Setting the DTC running the DTC and confirm that the DTC is not
• DTCP048113: Circuit remains open for 0.5s. set again.
• DTCP069311: Circuit remains short to ground for Circuit/System Testing
0.5s. 1. Turn the ignition switch to OFF position and
• DTCP069412: Circuit remains short to power disconnect the battery negative cable.
supply for 0.5s. 2. Perform coolant fan high - speed relay
Action Taken When the DTC Sets component testing. Is it normal?
• DTC is recorded and the engine malfunction – If no, replace coolant fan high - speed relay.
indicator lamp does not illuminate. – If yes, go to the next diagnostic step.
Conditions for Clearing the DTC 3. Connect the battery negative cable and turn the
• A history DTC will clear after 40 fault - free ignition ignition switch to ON position.
cycles.
• The body control module receives an order to
clear the DTC sent by the scan tool.
Reference Information Schematic Reference
4.10.20 Engine Controls Schematics (Engine Cooling
System) - 1.5 T
Connector End View Reference
K20engine control moduleX2
Electrical Information Reference
• Circuit Testing
• Connector Repairs
• Testing for Intermittent Conditions and Poor
Connections
• Wiring Repairs
Scan Tool Reference
Refer to “6.1.1.1 Control Module References” for
scan tool information.
Circuit/System Inspection
1. Clear the DTC. Does the DTC reoccur?
– Yes, an intermittent condition; refer to
11.3.4.7 Testing for Intermittent
 9-106 Engine/Propulsion

4. Measure the voltage between terminal 85 of ○ 30 and 86

coolant fan high - speed relay base and the ○ 86 and 87
ground. Is it the battery voltage?
○ 85 and 87
– If no, test the circuit for open circuit/high
resistance. – If no, replace coolant fan high - speed relay.
– If yes, go to the next diagnostic step. – If yes, go to the next test.
5. Turn the ignition switch to OFF position and 5. Install a 2A fused jumper wire between terminal
disconnect the battery negative cable. 85 of the coolant fan high - speed relay and the
12 V power supply. Install a jumper wire between
6. Disconnect K20 engine control module harness terminal 86 of the coolant fan high - speed relay
connector X2. and the ground. Measure the resistance between
7. Measure the resistance between terminal 86 of terminal 30 and terminal 87. Is it less than 1 Ω?
coolant fan high - speed relay base and terminal – If no, replace coolant fan high - speed relay.
P2 of K20 engine control module harness
connector X2. Is it less than 1 Ω? – If yes, perform “circuit system testing”.
– If no, test the circuit for open circuit/high Repair Instructions
resistance. • Engine Control Module Replacement
– If yes, go to the next diagnostic step. • Engine Control Module Programming and Setup
8. Measure the resistance between terminal 86 of 9.2.3.35 DTCP050600, P050700, P154500, P154521,
coolant fan high - speed relay base and the P154522 or P155900
ground. Is it infinite? Diagnostic Instructions
- If no, test the circuit for short to ground. • Perform “6.2.2.7 Diagnostic System Check -
– If yes, go to the next diagnostic step. Vehicle” prior to using this diagnostic procedure.
9. Connect the battery negative cable and turn the • Review “6.2.2.5 Strategy Based Diagnosis” for
ignition switch to ON position. an overview of the diagnostic approach.
10. Measure the voltage between terminal 86 of • “6.2.2.6 Diagnostic Procedure Instructions”
coolant fan high - speed relay base and the provides an overview of each diagnostic category
ground. Is it 0 V?
- If no, test the circuit for short to power supply.
– If yes, go to the next diagnostic step.
11. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
12. Replace the engine control module. Refer to
Engine Control Module Programming and Setup.
Operate the vehicle under conditions for running
the DTC. Is the DTC set?
– If no, diagnosis ends.
– If yes, install the original module back and
contact the technician.
Component Testing
1. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
2. Remove the coolant fan high - speed relay.
3. Measure the resistance between terminal 85 and
terminal 86 of the coolant fan high - speed relay.
Is it about 80 Ω?
– If no, replace coolant fan high - speed relay.
– If yes, go to the next test.
4. Measure the resistance between the following
terminals of the coolant fan high - speed relay
respectively. Is it infinite?
○ 30 and 87
9-107 Engine/Propulsion

DTC Description • DTCP155900: None; the engine malfunction

DTCP050600: Idle control speed lower than the target indicator lamp does not illuminate.
idle speed Conditions for Clearing the DTC
DTCP050700: Idle control speed higher than the • A history DTC will clear after 40 fault - free ignition
target idle speed cycles.
DTCP154500: Electronic throttle position deviation • The body control module receives an order to
fault clear the DTC sent by the scan tool.
DTCP154521: Electronic throttle PID position control Reference Information
fault Electrical Information Reference
DTCP154522: Electronic throttle PID position control • Circuit Testing
fault
• Connector Repairs
DTCP155900: Electronic throttle limp position self -
learning fault • Testing for Intermittent Conditions and Poor
Connections
Circuit System Description
• Wiring Repairs
The throttle actuator control (TAC) motor is a DC
motor and it is a part of the throttle assembly. The Scan Tool Reference
throttle actuator control motor drives the throttle. The Refer to “6.1.1.1 Control Module References” for
engine control module (ECM) controls the throttle scan tool information.
actuator control motor based on input of the throttle Circuit/System Inspection
position sensor. The engine control module controls
1. Clear the DTC. Does the DTC reoccur?
idle speed based on multiple inputs. The engine
control module remains the expected idle speed by – Yes, an intermittent condition; refer to
demanding the throttle actuator control motor to open 11.3.4.7 Testing for Intermittent
or close the throttle. Conditions and Poor Connections.
Conditions for Running the DTC – If no, go to the next check.
• The idle speed, coolant temperature and the 2. Check the system. Are other DTCs set up?
intake air temperature meet the requirements. – If no, perform the corresponding fault
Conditions for Setting the DTC diagnosis according to the DTC.
• DTCP050600: The idle control integral part – If no, go to the next check.
reaches the maximum and the difference 3. Check the harness connectors or components.
between target and actual values is >100. Does breakage, poor contact, aging or looseness
• DTCP050700: The idle control integral part exist?
reaches the minimum and the difference between – If yes, inspect and remove the fault.
target and actual values is < - 200. – If no, go to the next check.
• DTCP154500: Deviation of the actual throttle
position from the target position exceeds the
specified threshold [4~50] and this lasts for over
0.5s.
• DTCP154521: Throttle PID duty ratio parameter
exceeds 80% and this lasts for over 0.6s.
• DTCP154522: Throttle PID duty ratio parameter
exceeds 80% and this lasts for over 5s.
• DTCP155900: Limp home position is <1.8006%
or >13.0785%.
Action Taken When the DTC Sets
• DTCP050600, P050700: DTC is recorded and the
engine malfunction indicator lamp does not
illuminate.
• DTCP154500, P154521, P154522: Limp home
mode is activated; throttle is turned off; the
maximum engine speed is only 2,000~4,000 rpm
with an idle speed of about 1,000 rpm; the engine
malfunction indicator lamp illuminates.
 9-108 Engine/Propulsion

4. Check to see if the following circumstances exist? increases. The sensor provides evaporator surface
○ Dirty throttle temperature input for the engine control module.
○ Dirty air filter element Conditions for Running the DTC
○ Air intake system leakage • Electrified.
○ Insufficient air in the air intake system Conditions for Setting the DTC
– If yes, inspect and repair/replace relevant • DTCP053716: Evaporator temperature is >134.
components. • DTCP053817: Evaporator temperature is < - 38.
– If no, go to the next check. Action Taken When the DTC Sets
5. Start the engine, connect a scan tool and enter • Air conditioning operation is restrained and the
the engine control system. Does any abnormal engine malfunction indicator lamp does not
data exist? illuminate.
– If yes, carry out fault diagnosis according to Conditions for Clearing the DTC
the abnormal data. • A history DTC will clear after 40 fault - free ignition
– If no, go to the next check. cycles.
6. Turn the ignition switch to ON position, and • The body control module receives an order to
confirm the “Fuel Trim Coefficient” displayed real - clear the DTC sent by the scan tool.
time on the scan tool. Does the parameter go out Reference Information
of the specified range under the vehicle running
condition? Schematic Reference
– If yes, check and remove the fault causing 4.10.14 Engine Controls Schematics (Oxygen Sensor,
the abnormal fuel trim coefficient. Coolant Temperature Sensor) - 1.5 T
– If no, go to the next check. Connector End View Reference
7. Perform throttle matching/self - learning and B39 Air Conditioning Evaporator Temperature Sensor,
reprogram the engine control module. Connect a and K20 Engine Control Module X2
scan tool to read DTCs. Is it set? Electrical Information Reference
– If yes, replace the throttle and the engine • Circuit Testing
control module. • Connector Repairs
– If no, diagnosis ends. • Testing for Intermittent Conditions and Poor
Repair Instructions Connections
• Throttle Replacement • Wiring Repairs
• Throttle Matching/Self - learning
• Engine Control Module Replacement
• Engine Control Module Programming and Setup
9.2.3.36DTCP053716 or P053817
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
DTC Description
DTCP053716: Air conditioning temperature sensor
voltage too high
DTCP053817: Air conditioning temperature sensor
voltage too low
Circuit System Description
The air conditioning evaporator temperature sensor is
a NTC (negative temperature coefficient) sensor the
resistance of which drops quickly as the temperature
9-109 Engine/Propulsion

Scan Tool Reference temperature sensor harness connector and

Refer to “6.1.1.1 Control Module References” for the ground. Is it infinite?
scan tool information. – If no, test the circuit for short to ground.
Circuit/System Inspection – If yes, go to the next diagnostic step.
1. Clear the DTC. Does the DTC reoccur? (5) Connect the battery negative cable and turn
– Yes, an intermittent condition; refer to the ignition switch to ON position.
11.3.4.7 Testing for Intermittent (6) Measure the voltage between terminal 1 of
Conditions and Poor Connections. B39 air conditioning evaporator temperature
– If no, go to the next check. sensor harness connector and the ground. Is
it 0 V?
2. Check the system. Are other DTCs set up?
– If no, test the circuit for short to power supply.
– If no, perform the corresponding fault
diagnosis according to the DTC. – If yes, go to the next diagnostic step.
– If no, go to the next check. (7) Turn the ignition switch to the OFF position
and disconnect the battery negative cable.
3. Check the harness connectors or components.
Does breakage, poor contact, aging or looseness (8) Replace the engine control module. Refer to
exist? Engine Control Module Programming and
Setup. Operate the vehicle under conditions
– If yes, inspect and remove the fault. for running the DTC. Is the DTC set?
– If no, go to the next check. – If no, diagnosis ends.
4. Operate the vehicle under the conditions for – If yes, install the original module back and
running the DTC and confirm that the DTC is not contact the technician.
set again.
– If yes, perform the following test:
Circuit/System Testing
(1) Turn the ignition switch to the OFF position and
1. Turn the ignition switch to OFF position and disconnect the battery negative cable.
disconnect the battery negative cable.
2. Preform air conditioning evaporator temperature
sensor component testing. Is it normal?
– If no, replace the evaporator temperature
sensor.
– If yes, go to the next diagnostic step.
3. Connect the battery negative cable and turn the
ignition switch to ON position.
4. Check signal circuit of the air conditioning
evaporator temperature sensor. Measure the
voltage between terminal 1 of B39 air conditioning
evaporator temperature sensor harness
connector and the ground. Is it about 5V?
– If no, perform the following test:
(1) Turn the ignition switch to the OFF position
and disconnect the battery negative cable.
(2) Disconnect K20 engine control module
harness connector X2.
(3) Measure the resistance between terminal 1
of B39 air conditioning evaporator
temperature sensor harness connector and
terminal O4 of K20 engine control module
harness connector X2. Is it less than 1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
(4) Measure the resistance between terminal 1
of B39 air conditioning evaporator
 9-110 Engine/Propulsion

(2) Disconnect K20 engine control module harness DTC Description

connector X2. DTCP056000: System battery voltage signal not
(3) Measure the resistance between terminal 2 of plausible
B39 air conditioning evaporator temperature DTCP056216: System battery voltage too low
sensor harness connector and terminal L3 of K20
engine control module harness connector X2. Is it DTCP056317: System battery voltage too high
less than 1 Ω? Circuit System Description
– If no, test the circuit for open circuit/high The engine control module monitors the system
resistance. voltage and ensures the voltage is within the correct
– If yes, go to the next diagnostic step. range. When the voltage goes beyond the range,
component damage and incorrect data can happen.
(4) Connect the battery negative cable and turn the
ignition switch to ON position. Conditions for Running the DTC
(5) Measure the voltage between terminal 2 of B39 • DTCP056000: Electrified.
air conditioning evaporator temperature sensor • DTCP056216: Starting for 180s.
harness connector and the ground. Is it 0 V? • DTCP056317: Vehicle speed is > 25 km/h.
– If no, test the circuit for short to power supply. Conditions for Setting the DTC
– If yes, go to the next diagnostic step. • DTCP056000: Sampling channel voltage is < 2.5
(6) Turn the ignition switch to the OFF position and V.
disconnect the battery negative cable. • DTCP056216: Voltage is < 9 V.
(7) Replace the engine control module. Refer to • DTCP056317: Voltage is > 17V.
Engine Control Module Programming and Setup.
Action Taken When the DTC Sets
Operate the vehicle under conditions for running
the DTC. Is the DTC set? • DTCP056000: Limp home mode is activated and
the engine malfunction indicator lamp does not
– If no, diagnosis ends.
illuminate.
– If yes, install the original module back and
• DTCP056216, P056317: DTC is recorded and the
contact the technician.
engine malfunction indicator lamp does not
Component Testing illuminate.
1. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
2. Disconnect B39 air conditioning evaporator
temperature sensor harness connector.
3. Measure the resistance between terminal 1 and
terminal 2 of B39 air conditioning evaporator
temperature sensor harness connector. Is it within
1.8 ± 0.1 KΩ?
– If no, replace the air conditioning evaporator
temperature sensor.
– If yes, perform “Circuit/System Testing”.
Repair Instructions
• Air Conditioning Evaporator Temperature Sensor
Replacement
• Engine Control Module Replacement
• Engine Control Module Programming and Setup
9.2.3.37 DTCP056000, P056216 or P056317
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
9-111 Engine/Propulsion

Conditions for Clearing the DTC 2. Disconnect K20 engine control module harness
• A history DTC will clear after 40 fault - free ignition connector X1 and X2.
cycles. 3. Connect the battery negative cable and turn the
• The body control module receives an order to ignition switch to ON position.
clear the DTC sent by the scan tool. 4. Check ignition circuit of the engine control module.
Reference Information Measure the voltage between terminal C3, D2, P1
and Q1 of K20 engine control module harness
Schematic Reference connector X2 and the ground respectively. Is it the
4.10.10 Engine Controls Schematics (Module Power, battery voltage?
Ground, Serial Data, and MIL) - 1.5 T – If no, test the circuit for open circuit/high
Connector End View Reference resistance.
K20 Engine Control Module X1, X2 – If yes, go to the next diagnostic step.
Electrical Information Reference 5. Turn the ignition switch to OFF position and
• Circuit Testing disconnect the battery negative cable.
• Connector Repairs 6. Check ground circuit of the engine control module.
Measure the resistance between the following
• Testing for Intermittent Conditions and Poor
ground circuit terminals of K20 engine control
Connections
module harness connectors and the ground
• Wiring Repairs respectively. Is it less than 1 Ω?
Scan Tool Reference ○ Terminal 47 of K20 X1
Refer to “6.1.1.1 Control Module References” for ○ Terminal 48 of K20 X1
scan tool information.
○ Terminal P4 of K20 X2
Circuit/System Inspection
○ Terminal Q4 of K20 X2
1. Clear the DTC. Does the DTC reoccur?
– If no, test the circuit for open circuit/high
– Yes, an intermittent condition; refer to resistance.
11.3.4.7 Testing for Intermittent
– If yes, go to the next diagnostic step.
Conditions and Poor Connections.
– If no, go to the next check.
2. Check the system. Are other DTCs set up?
– If no, perform the corresponding fault
diagnosis according to the DTC.
– If no, go to the next check.
3. Check the harness connectors or components.
Does breakage, poor contact, aging or looseness
exist?
– If yes, inspect and remove the fault.
– If no, go to the next check.
4. Check to see if fuse F9UA, F11UA and F14UA
have blown?
– If yes, replace the fuse and check and
remove the power circuit short to ground
fault.
– If no, go to the next check.
5. Check whether the battery voltage ad the charing
system are normal?
– If yes, replace the battery/check and repair
the charging system.
– If no, perform “Circuit/System Testing”.
Circuit/System Testing
1. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
 9-112 Engine/Propulsion

7. Replace the engine control module. Refer to Electrical Information Reference

Engine Control Module Programming and Setup. • Circuit Testing
Operate the vehicle under conditions for running
the DTC. Is the DTC set? • Connector Repairs
– If no, diagnosis ends. • Testing for Intermittent Conditions and Poor
Connections
– If yes, install the original module back and
contact the technician. • Wiring Repairs
Repair Instructions Scan Tool Reference
• Engine Control Module Replacement Refer to “6.1.1.1 Control Module References” for
scan tool information.
• Engine Control Module Programming and Setup
Circuit/System Inspection
9.2.3.38 DTCP05711C or P057129
1. Clear the DTC. Does the DTC reoccur?
Diagnostic Instructions
– Yes, an intermittent condition; refer to
• Perform “6.2.2.7 Diagnostic System Check - 11.3.4.7 Testing for Intermittent
Vehicle” prior to using this diagnostic procedure. Conditions and Poor Connections.
• Review “6.2.2.5 Strategy Based Diagnosis” for – If no, go to the next check.
an overview of the diagnostic approach.
2. Check the system. Are other DTCs set up?
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category – If yes, clear other DTCs first.
DTC Description – If no, go to the next check.
DTCP05711C: Stop lamp switch signal circuit fault 3. Check the harness connectors or components.
Does breakage, poor contact, aging or looseness
DTCP057129: Two stop switch signal circuits out of exist?
sync
– If yes, inspect and remove the fault.
Circuit System Description
– If no, go to the next check.
The brake pedal assembly includes 2 switch circuits
and 1 stop position sensor circuit. The stop switch 4. Depress the brake pedal. Can it return normally?
signal changes as the brake pedal position changes. It – If yes, inspect and remove the fault.
can provide redundancy protection as expected. – If no, go to the next check.
Conditions for Running the DTC
• The ignition switch is turned to ON position.
Conditions for Setting the DTC
• DTCP05711C: Stop lamp voltage signal is in an
unreasonable voltage range.
• DTCP057129: Stop lamp switch signal and stop
lamp signal are not synchronous for 20
successive times and each time lasts for over 1s.
Action Taken When the DTC Sets
• Cruise control is unavailable and the engine
malfunction indicator lamp does not illuminate.
Conditions for Clearing the DTC
• A history DTC will clear after 40 fault - free ignition
cycles.
• The body control module receives an order to
clear the DTC sent by the scan tool.
Reference Information
Schematic Reference
4.3.6A Exterior Lights Schematics (Stop Lamp) - Not
EPB
Connector End View Reference
K20 Engine Control Module X2, and B103 Stop Lamp
Switch
9-113 Engine/Propulsion

5. Check fuse F6UA. Has it blown? 11. Disconnect K20 engine control module harness
– If yes, replace the fuse and check and connector X2.
remove the power circuit short to ground 12. Measure the resistance between terminal 4 of
fault. B103 stop lamp switch harness connector and
– If no, perform “Circuit/System Testing”. terminal J2 of K20 engine control module harness
connector X2. Is it less than 1 Ω?
6. Operate the vehicle under the conditions for
running the DTC and confirm that the DTC is not – If no, test the circuit for open circuit/high
set again. resistance.
Circuit/System Testing – If yes, go to the next diagnostic step.
1. Turn the ignition switch to OFF position and 13. Measure the resistance between terminal 3 of
disconnect the battery negative cable. B103 stop lamp switch harness connector and
terminal G2 of K20 engine control module
2. Perform stop lamp switch component testing. Is it harness connector X2. Is it less than 1 Ω?
normal?
– If no, test the circuit for open circuit/high
– If no, replace the stop lamp switch. resistance.
– If yes, go to the next diagnostic step. – If yes, go to the next diagnostic step.
3. Measure the resistance between terminal 1 of 14. Replace the engine control module. Refer to
B103 stop lamp switch harness connector and Engine Control Module Programming and Setup.
F9UA fuse base. Is it less than 1 Ω? Operate the vehicle under conditions for running
– If no, test the circuit for open circuit/high the DTC. Is the DTC set?
resistance. – If no, diagnosis ends.
– If yes, go to the next diagnostic step. – If yes, install the original module back and
4. Measure the resistance between terminal 2 of contact the technician.
B103 stop lamp switch harness connector and Component Testing
F6UA fuse base. Is it less than 1 Ω?
1. Turn the ignition switch to OFF position and
– If no, test the circuit for open circuit/high disconnect the battery negative cable.
resistance.
2. Disconnect B103 stop lamp switch harness
– If yes, go to the next diagnostic step. connector.
5. Measure the resistance between terminal 4 of
B103 stop lamp switch harness connector and the
ground. Is it infinite?
- If no, test the circuit for short to ground.
– If yes, go to the next diagnostic step.
6. Measure the resistance between terminal 3 of
B103 stop lamp switch harness connector and the
ground. Is it infinite?
- If no, test the circuit for short to ground.
– If yes, go to the next diagnostic step.
7. Connect the battery negative cable and turn the
ignition switch to ON position.
8. Measure the voltage between terminal 4 of B103
stop lamp switch harness connector and the
ground. Is it 0 V?
- If no, test the circuit for short to power supply.
– If yes, go to the next diagnostic step.
9. Measure the voltage between terminal 3 of B103
stop lamp switch harness connector and the
ground. Is it 0 V?
- If no, test the circuit for short to power supply.
– If yes, go to the next diagnostic step.
10. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
 9-114 Engine/Propulsion

3. Release the brake pedal and measure the The electronic control module remains the coil side
resistance between terminal 1 and terminal 3 of grounded for 2s or until it receives the reference pulse
B103 stop lamp switch harness connector. Is it from the crankshaft position sensor. In this way, the
less than 1 Ω? fuel pump relay will be activated and battery voltage
– If no, replace the stop lamp switch. will be imposed on the fuel pump. if no follow - up
ignition signal is detected, the fuel pump relay will turn
– If yes, go to the next test. off.
4. Depress the brake pedal and measure the Conditions for Running the DTC
resistance between terminal 1 and terminal 3 of
B103 stop lamp switch harness connector. Is it • Engine is running and the battery voltage is
infinite? higher than 9 V.
– If no, replace the stop lamp switch. Conditions for Setting the DTC
– If yes, go to the next test. • DTCP062700: Circuit remains open for 0.5s.
5. Release the brake pedal and measure the • DTCP062811: Circuit remains short to ground for
resistance between terminal 2 and terminal 4 of 0.5s.
B103 stop lamp switch harness connector. Is it • DTCP062915: Circuit remains open for 0.5s.
infinite? Action Taken When the DTC Sets
– If no, replace the stop lamp switch. • DTC is recorded and the engine malfunction
– If yes, go to the next test. indicator lamp does not illuminate.
6. Depress the brake pedal and measure the Conditions for Clearing the DTC
resistance between terminal 2 and terminal 4 of • A history DTC will clear after 40 fault - free ignition
B103 stop lamp switch harness connector. Is it cycles.
less than 1 Ω?
• The body control module receives an order to
– If no, replace the stop lamp switch. clear the DTC sent by the scan tool.
– If yes, go to the next test. Reference Information
7. Measure the resistance between each stop lamp Schematic Reference
switch terminal and the stop lamp switch shell. Is
it infinite? 4.10.18 Engine Controls Schematics (Fuel
Control—Fuel Injection Nozzle and Fuel Pump) - 1.5 T
– If no, replace the stop lamp switch.
Connector End View Reference
– If yes, perform “Circuit/System Testing”.
K20engine control moduleX2
Repair Instructions
• Stop Lamp Switch Replacement
• Engine Control Module Replacement
• Engine Control Module Programming and Setup
9.2.3.39 DTCP062700, P062811 or P062915
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
DTC Description
DTCP062700: Fuel pump relay control circuit open
DTCP062811: Fuel pump relay control circuit short to
ground or open
DTCP062915: Fuel pump relay control circuit short to
power supply
Circuit System Description
When the ignition switch is turned on, the engine
control module grounds the fuel pump relay coil side.
9-115 Engine/Propulsion

Electrical Information Reference 6. Check control circuit of the fuel pump relay.
• Circuit Testing Measure the resistance between terminal 1 of fuel
pump relay base and terminal J3 of K20 engine
• Connector Repairs control module harness connector X2. Is it less
• Testing for Intermittent Conditions and Poor than 1 Ω?
Connections – If no, test the circuit for open circuit/high
• Wiring Repairs resistance.
Scan Tool Reference – If yes, go to the next diagnostic step.
Refer to “6.1.1.1 Control Module References” for 7. Measure the resistance between terminal 1 of fuel
scan tool information. pump relay base and the ground. Is it infinite?
Circuit/System Inspection - If no, test the circuit for short to ground.
1. Clear the DTC. Does the DTC reoccur? – If yes, go to the next diagnostic step.
– Yes, an intermittent condition; refer to 8. Connect the battery negative cable and turn the
11.3.4.7 Testing for Intermittent ignition switch to ON position.
Conditions and Poor Connections. 9. Measure the voltage between terminal 1 of fuel
– If no, go to the next check. pump relay base and the ground. Is it 0 V?
2. Check the system. Are other DTCs set up? - If no, test the circuit for short to power supply.
– If no, perform the corresponding fault – If yes, go to the next diagnostic step.
diagnosis according to the DTC. 10. Turn the ignition switch to OFF position and
– If no, go to the next check. disconnect the battery negative cable.
3. Check the harness connectors or components. 11. Replace the engine control module. Refer to
Does breakage, poor contact, aging or looseness Engine Control Module Programming and Setup.
exist? Operate the vehicle under conditions for running
– If yes, inspect and remove the fault. the DTC. Is the DTC set?
– If no, go to the next check. – If no, diagnosis ends.
4. Check fuse F10UA to see if it has blown? – If yes, install the original module back and
contact the technician.
– If yes, replace the fuse and check to position
and remove the power circuit short to ground
fault.
– If no, perform “Circuit/System Testing”.
5. Operate the vehicle under the conditions for
running the DTC and confirm that the DTC is not
set again.
Circuit/System Testing
1. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
2. Perform fuel pump relay component testing. Is it
normal?
– If no, replace the fuel pump relay.
– If yes, go to the next diagnostic step.
3. Connect the battery negative cable and turn the
ignition switch to ON position.
4. Check power circuit of the fuel pump relay.
Measure the voltage between terminal 2 of fuel
pump relay base and the ground. Is it the battery
voltage?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
5. Disconnect K20 engine control module harness
connector X2.
 9-116 Engine/Propulsion

Component Testing • Engine is running and the battery voltage is

1. Turn the ignition switch to OFF position and higher than 9 V.
disconnect the battery negative cable. Conditions for Setting the DTC
2. Remove the fuel pump relay. • DTCP064513: Circuit remains open for 0.5s.
3. Measure the resistance between terminal 1 and • DTCP064611: Circuit remains short to ground for
terminal 2 of the fuel pump relay. Is it between 0.5s.
60~180 Ω? • DTCP064712: Circuit remains short to power
– If no, replace the fuel pump relay. supply for 0.5s.
– If yes, go to the next test. Action Taken When the DTC Sets
4. Measure the resistance between the following • DTC is recorded and the engine malfunction
fuel pump relay terminals respectively. Is it indicator lamp does not illuminate.
infinite? Conditions for Clearing the DTC
○ 5 and 2 • A history DTC will clear after 40 fault - free ignition
○ 5 and 3 cycles.
○ 1 and 3 • The body control module receives an order to
○ 2 and 3 clear the DTC sent by the scan tool.
– If no, replace the fuel pump relay. Reference Information Schematic Reference
– If yes, go to the next test. 4.11.1B A/C System Schematics (Compressor,
Pressure Switch, Evaporator Temperature Sensor,
5. Install a 2A fused jumper wire between terminal 2 A/C Request Signal - B1.5T)
of the fuel pump relay and the 12 V power supply.
Install a jumper wire between terminal 1 of the Connector End View Reference
fuel pump relay and the ground. Measure the K20engine control moduleX1
resistance between terminal 3 and terminal 5 Electrical Information Reference
terminal. Is it less than 1 Ω?
• Circuit Testing
– If no, replace the fuel pump relay.
• Connector Repairs
– If yes, perform “circuit system testing”.
• Testing for Intermittent Conditions and Poor
Repair Instructions Connections
• Engine Control Module Replacement • Wiring Repairs
• Engine Control Module Programming and Setup
9.2.3.40 DTCP064513, P064611 or P064712
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
DTC Description
DTCP064513: A/C compressor relay control circuit
open
DTCP064611: A/C compressor relay control circuit
short to ground
DTCP064712: A/C compressor relay control circuit
short to power supply
Circuit System Description
After the ignition main relay is electrified, the A/C
compressor clutch relay coil can be activated. The
engine control module controls the relay coil to fully
grounded as an A/C ON request is received.
Conditions for Running the DTC
9-117 Engine/Propulsion

Scan Tool Reference A/C compressor clutch relay base and the ground.
Refer to “6.1.1.1 Control Module References” for Is it infinite?
scan tool information. - If no, test the circuit for short to ground.
Circuit/System Inspection – If yes, go to the next diagnostic step.
1. Clear the DTC. Does the DTC reoccur? 9. Connect the battery negative cable and turn the
– Yes, an intermittent condition; refer to ignition switch to ON position.
11.3.4.7 Testing for Intermittent 10. Measure the voltage between terminal 1 of the
Conditions and Poor Connections. A/C compressor clutch relay base and the ground.
– If no, go to the next check. Is it 0 V?
2. Check the system. Are other DTCs set up? - If no, test the circuit for short to power supply.
– If no, perform the corresponding fault – If yes, go to the next diagnostic step.
diagnosis according to the DTC. 11. Turn the ignition switch to OFF position and
– If no, go to the next check. disconnect the battery negative cable.
3. Check the harness connectors or components. 12. Replace the engine control module. Refer to
Does breakage, poor contact, aging or looseness Engine Control Module Programming and Setup.
exist? Operate the vehicle under conditions for running
the DTC. Is the DTC set?
– If yes, inspect and remove the fault.
– If no, diagnosis ends.
– If no, perform “Circuit/System Testing”.
– If yes, install the original module back and
4. Operate the vehicle under the conditions for contact the technician.
running the DTC and confirm that the DTC is not
set again.
Circuit/System Testing
1. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
2. Perform A/C compressor clutch relay component
testing. Is it normal?
– If no, replace the A/C compressor clutch
relay.
– If yes, go to the next diagnostic step.
3. Connect the battery negative cable and turn the
ignition switch to ON position.
4. Check control supply circuit of the A/C
compressor clutch relay. Measure the voltage
between terminal 2 of the A/C compressor clutch
relay base and the ground. Is it the battery
voltage?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
5. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
6. Disconnect K20 engine control module harness
connector X2.
7. Measure the resistance between terminal K4 of
K20 engine control module harness connector X2
and terminal 1 of the A/C compressor clutch relay
base. Is it less than 1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
8. Measure the resistance between terminal 1 of the
 9-118 Engine/Propulsion

Component Testing • DTCP068891: System sampling voltage is < 3 V.

1. Turn the ignition switch to OFF position and • DTCP068892: System sampling voltage is ≥ 3 V
disconnect the battery negative cable. and the engine control module monitoring level
2. Remove the A/C compressor clutch relay. detects that the voltage after the main relay is
abnormal.
3. Measure the resistance between terminal 1 and
terminal 2 of the relay. Is it about 130 Ω? Action Taken When the DTC Sets
– If no, replace the A/C compressor clutch • The engine malfunction indicator lamp does not
relay. illuminate.
– If yes, go to the next test. Conditions for Clearing the DTC
4. Measure the resistance between the following • A history DTC will clear after 40 fault - free ignition
relay terminals respectively. Is it infinite? cycles.
○ 3 and 5 • The body control module receives an order to
clear the DTC sent by the scan tool.
○ 1 and 5
Reference Information
○ 2 and 5
Schematic Reference
○ 1 and 3
4.10.10 Engine Controls Schematics (Module Power,
– If no, replace the A/C compressor clutch Ground, Serial Data, and MIL) - 1.5 T
relay.
Connector End View Reference
– If yes, go to the next test.
K20engine control moduleX2
5. Install a 2A fused jumper wire between terminal 2
of the relay and the 12 V power supply. Install a Electrical Information Reference
jumper wire between terminal 1 of the relay and • Circuit Testing
the ground. Measure the resistance between • Connector Repairs
terminal 3 and terminal 5 terminal. Is it less than 1
Ω? • Testing for Intermittent Conditions and Poor
Connections
– If no, replace the A/C compressor clutch
relay. • Wiring Repairs
– If yes, perform “circuit system testing”.
Repair Instructions
• Engine Control Module Replacement
• Engine Control Module Programming and Setup
9.2.3.41 DTCP068891 or P068892
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
DTC Description
DTCP068891: Main relay output voltage signal not
plausible
DTCP068892: Main relay output voltage signal fault
Circuit System Description
The main relay turns on as the ignition switch is turned
to ON position or START position. The ground signal
at control end of the main relay is provided by the
engine control module.
Conditions for Running the DTC
• The engine control module is electrified.
Conditions for Setting the DTC
9-119 Engine/Propulsion

Scan Tool Reference – If no, test the circuit for open circuit/high
Refer to “6.1.1.1 Control Module References” for resistance.
scan tool information. – If yes, go to the next diagnostic step.
Circuit/System Inspection 8. Measure the resistance between terminal 86 of
1. Clear the DTC. Does the DTC reoccur? the ignition main relay base and the ground. Is it
infinite?
– Yes, an intermittent condition; refer to
11.3.4.7 Testing for Intermittent - If no, test the circuit for short to ground.
Conditions and Poor Connections. – If yes, go to the next diagnostic step.
– If no, go to the next check. 9. Check switch circuit of the ignition main relay.
2. Check the system. Are other DTCs set up? Measure the resistance between terminal 87 of
the ignition main relay base and terminal P1 and
– If no, perform the corresponding fault terminal Q1 of K20 engine control module
diagnosis according to the DTC. harness connector X2 respectively. Is it less than
– If no, go to the next check. 1 Ω?
3. Check the harness connectors or components. – If no, test the circuit for open circuit/high
Does breakage, poor contact, aging or looseness resistance.
exist? – If yes, go to the next diagnostic step.
– If yes, inspect and remove the fault. 10. Measure the resistance between terminal 87 of
– If no, go to the next check. the ignition main relay base and the ground. Is it
4. Check fuse F9UA. Has it blown? infinite?
– If yes, replace the fuse and check and - If no, test the circuit for short to ground.
remove the power circuit short to ground – If yes, go to the next diagnostic step.
fault. 11. Connect the battery negative cable and turn the
– If no, perform “Circuit/System Testing”. ignition switch to ON position.
5. Operate the vehicle under the conditions for 12. Measure the voltage between terminal 86 of the
running the DTC and confirm that the DTC is not ignition main relay base and the ground. Is it 0 V?
set again. - If no, test the circuit for short to power supply.
Circuit/System Testing – If yes, go to the next diagnostic step.
1. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
2. Perform ignition main relay component testing. Is
it normal?
– If no, replace the ignition main relay.
– If yes, go to the next diagnostic step.
3. Connect the battery negative cable and turn the
ignition switch to ON position.
4. Check power circuit of the ignition main relay.
Measure the voltage between terminal 85 or
terminal 30 of the ignition main relay base and the
ground. Is it the battery voltage?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
5. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
6. Disconnect the engine control module harness
connector X2.
7. Check control circuit of the ignition main relay.
Measure the resistance between terminal 86 of
the ignition main relay base and terminal E1 of
K20 engine control module harness connector X2.
Is it less than 1 Ω?
 9-120 Engine/Propulsion

13. Measure the voltage between terminal 87 of the provides an overview of each diagnostic category
ignition main relay base and the ground. Is it 0 V? DTC Description
- If no, test the circuit for short to power supply. DTCP155929: Electronic throttle mechanical bottom
– If yes, go to the next diagnostic step. dead center second - time self - learning fault
14. Turn the ignition switch to OFF position and DTCP156400: System voltage not satisfying electronic
disconnect the battery negative cable. throttle adaptive learning condition
15. Replace the engine control module. Refer to DTCP156500: Electronic throttle mechanical bottom
Engine Control Module Programming and Setup. dead center initial self - learning fault
Operate the vehicle under conditions for running DTCP156800: Electronic throttle spring check fault
the DTC. Is the DTC set?
DTCP157900: Electronic throttle self - learning
– If no, diagnosis ends. conditions not satisfied
– If yes, install the original module back and DTCP210612: Electronic throttle power drive stage
contact the technician. fault (short - circuited)
Component Testing DTCP210613: Electronic throttle power drive stage
1. Turn the ignition switch to OFF position and fault (open circuit)
disconnect the battery negative cable. DTCP210619: Electronic throttle power drive stage
2. Remove the ignition main relay. fault (overheat or overcurrent)
3. Measure the resistance between terminal 86 and DTCP210629: Load monitoring fault
terminal 85 of the ignition main relay. Is it about DTCP210692: Electronic throttle power drive stage
60~180 Ω? fault (SPI bus or signal)
– If no, replace the ignition main relay.
– If yes, go to the next test.
4. Measure the resistance between the following
relay terminals respectively. Is it infinite?
○ 30 and 87
○ 85 and 87
○ 86 and 87
○ 85 and 30
– If no, replace the ignition main relay.
– If yes, go to the next test.
5. Install a 2A fused jumper wire between terminal
86 of the relay and the 12 V power supply. Install
a jumper wire between terminal 85 of the relay
and the ground. Measure the resistance between
terminal 30 and terminal 87 terminal. Is it less
than 1 Ω?
– If no, replace the ignition main relay.
– If yes, perform “circuit system testing”.
Repair Instructions
• Engine Control Module Replacement
• Engine Control Module Programming and Setup
9.2.3.42 DTCP155929, P156400, P156500, P156800,
P157900, P210612, P210613, P210619,
P210629 or P210692
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
9-121 Engine/Propulsion

Circuit System Description cycles.

The electronic throttle includes two potentiometers
which are used to provide analog voltage. The voltage
is connected to the engine harness via connectors and
converted to throttle position information by the engine
control module. The electronic throttle determines the
butterfly valve position which is monitored by the
position sensor integrated in the throttle based on the
signal from the accelerator pedal. In this way, it can be
guaranteed that the engine can receive the correct air
and fuel amount whatever the engine load condition is.
As a result, the vehicle driveability is improved and
emission is reduced.
Conditions for Running the DTC
• DTCP155929, P156500: No starting after
electrification and self - learning activated.
• DTCP156400, P157900: No starting after
electrification.
• DTCP156800: Ignition switch ON and engine
speed ≤250 rpm.
• DTCP210612, P210613, P210619, P210629,
P210692: Ignition switch ON.
Conditions for Setting the DTC
• DTCP155929: Bottom dead center signal voltage
TPS1 < 0.2124 [V] or > 0.8655 [V]; bottom dead
center signal voltage TPS2 < 4.1418 [V] or >
4.8413 [V].
• DTCP156400: Self - learning failed as the battery
voltage is lower than 10 V at the time of self -
learning.
• DTCP156500: Throttle bottom dead center self -
learning failed or self - learning conditions not
satisfied.
• DTCP156800: Valve plate return time > 0.56s at
return spring check.
• DTCP157900: Self - learning failed as the self -
learning conditions not satisfied (including engine
speed < 250 rpm, 105°C ≥ coolant temperature ≥
5.3°C, intake air temperature ≥ 5.3°C, pedal
opening = 0, vehicle speed = 0 km/h).
• DTCP210612, P210613, P210619, P210629,
P210692: Internal logic check fault.
Action Taken When the DTC Sets
• DTCP155929, P156400, P157900: None; the
engine malfunction indicator lamp does not
illuminate.
• DTCP156500, P156800, P210612, P210613,
P210619, P210629, P210692: Limp home mode
is activated; throttle is turned off, the maximum
engine speed is only 2,000~4,000 rpm with an
idle speed of about 1,000 rpm; the engine
malfunction indicator lamp illuminates.
Conditions for Clearing the DTC
• A history DTC will clear after 40 fault - free ignition
• The body control module receives an order to
clear the DTC sent by the scan tool.
Reference Information
Schematic Reference
4.10.13 Engine Controls Schematics (Accelerator
Pedal Position Sensor, Electronic Throttle Control) -
1.5 T
Connector End View Reference
Q38 Throttle, and K20 Engine Control Module X1
Electrical Information Reference
• Circuit Testing
• Connector Repairs
• Testing for Intermittent Conditions and Poor
Connections
• Wiring Repairs
Scan Tool Reference
Refer to “6.1.1.1 Control Module References” for
scan tool information.
Circuit/System Inspection
1. Clear the DTC. Does the DTC reoccur?
– Yes, an intermittent condition; refer to
11.3.4.7 Testing for Intermittent
Conditions and Poor Connections.
– If no, go to the next check.
2. Check the system. Are other DTCs set up?
– If no, perform the corresponding fault
diagnosis according to the DTC.
– If no, go to the next check.
3. Check the harness connectors or components.
Does breakage, poor contact, aging or looseness
exist?
– If yes, inspect and remove the fault.
– If no, go to the next check.
 9-122 Engine/Propulsion

4. Check the throttle. Is it with carbon deposit or V?

does it bind? - If no, test the circuit for short to power supply.
– If yes, clean the carbon deposit and check for – If yes, go to the next diagnostic step.
throttle internal binding.
12. Turn the ignition switch to OFF position and
– If no, perform “Circuit/System Testing”. disconnect the battery negative cable.
5. Operate the vehicle under the conditions for 13. Replace the throttle and the engine control
running the DTC and confirm that the DTC is not module. Refer to Engine Control Module
set again. Programming and Setup. Operate the vehicle
Circuit/System Testing under conditions for running the DTC. Is the DTC
1. Turn the ignition switch to OFF position and set?
disconnect the battery negative cable. – If no, diagnosis ends.
2. Disconnect Q38 throttle harness connector and – If yes, install the original module back and
K20 engine control module harness connector contact the technician.
X1. Repair Instructions
3. Measure the resistance between terminal 3 of • Throttle Matching/Self - learning
Q38 throttle harness connector and terminal 11 of
K20 engine control module harness connector X1. • Throttle Replacement
Is it less than 1 Ω? • Engine Control Module Replacement
– If no, test the circuit for open circuit/high • Engine Control Module Programming and Setup
resistance. 9.2.3.43 DTCP212216, P212317, P212716, P212817,
– If yes, go to the next diagnostic step. P213800 or P213829
4. Measure the resistance between terminal 3 of Diagnostic Instructions
Q38 throttle harness connector and the ground. Is • Perform “6.2.2.7 Diagnostic System Check -
it infinite? Vehicle” prior to using this diagnostic procedure.
- If no, test the circuit for short to ground. • Review “6.2.2.5 Strategy Based Diagnosis” for
– If yes, go to the next diagnostic step. an overview of the diagnostic approach.
5. Connect the battery negative cable and turn the • “6.2.2.6 Diagnostic Procedure Instructions”
ignition switch to ON position. provides an overview of each diagnostic category
6. Measure the voltage between terminal 3 of Q38
throttle harness connector and the ground. Is it 0
V?
- If no, test the circuit for short to power supply.
– If yes, go to the next diagnostic step.
7. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
8. Measure the resistance between terminal 6 of
Q38 throttle harness connector and terminal 23 of
K20 engine control module harness connector X1.
Is it less than 1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
9. Measure the resistance between terminal 6 of
Q38 throttle harness connector and the ground. Is
it infinite?
- If no, test the circuit for short to ground.
– If yes, go to the next diagnostic step.
10. Connect the battery negative cable and turn the
ignition switch to ON position.
11. Measure the voltage between terminal 6 of Q38
throttle harness connector and the ground. Is it 0
9-123 Engine/Propulsion

DTC Description • DTCP213800: Torque - limiting mode is activated,

DTCP212216: Electronic accelerator pedal position the maximum engine speed at neutral gear does
sensor 1 signal voltage too low not exceed 5,500 rpm, the maximum vehicle
speed is about 80~120 km/h, the vehicle
DTCP212317: Electronic accelerator pedal position acceleration performance decreases a little, the
sensor 1 signal voltage too high engine malfunction indicator lamp does not
DTCP212716: Electronic accelerator pedal position illuminate.
sensor 2 signal voltage too low Conditions for Clearing the DTC
DTCP212817: Electronic accelerator pedal position • A history DTC will clear after 40 fault - free ignition
sensor 2 signal voltage too high cycles.
DTCP213800: Electronic accelerator pedal position • The body control module receives an order to
sensor signal not plausible (pedal displacement clear the DTC sent by the scan tool.
detection at approximate idle speed)
Reference Information
DTCP213829: Electronic accelerator pedal position
sensor signal not plausible Schematic Reference
Circuit System Description 4.10.13 Engine Controls Schematics (Accelerator
Pedal Position Sensor, Electronic Throttle Control) -
The electronic accelerator pedal module, i.e. The 1.5 T
accelerator pedal module is provided with two
independent ohmmeter sensors, each is grounded Connector End View Reference
and provided with a 5 V power supply. These two B107 Accelerator Pedal Position Sensor, and K20
sensors output two sensor signals to the engine Engine Control Module X2
control module synchronously. Different voltage value Electrical Information Reference
is output, depending on the accelerator pedal position.
• Circuit Testing
Conditions for Running the DTC
• Connector Repairs
• The ignition switch is turned to ON position.
• Testing for Intermittent Conditions and Poor
Conditions for Setting the DTC Connections
DTCP212216: Electronic accelerator pedal position • Wiring Repairs
sensor 1 signal voltage remains higher than 4.824
V for 0.35s. Scan Tool Reference
DTCP212317: Electronic accelerator pedal position Refer to “6.1.1.1 Control Module References” for
sensor 1 signal voltage remains lower than 0.586 scan tool information.
V for 0.35s. Circuit/System Inspection
DTCP212716: Electronic accelerator pedal position 1. Clear the DTC. Does the DTC reoccur?
sensor 2 signal voltage remains higher than – Yes, an intermittent condition; refer to
2.412V for 0.35s. 11.3.4.7 Testing for Intermittent
DTCP212817: Electronic accelerator pedal position Conditions and Poor Connections.
sensor 2 signal voltage remains lower than – If no, go to the next check.
0.215V for 0.35s.
• DTCP213800: One circuit signal of the
accelerator pedal is under idle state and the other
out of idle state.
• DTCP213829: Difference between half signal
voltage of electronic accelerator pedal position
sensor 1 and sensor 2 signal voltage under
different pedal openings exceeds [0.156 V~0.546
V] and this lasts for 0.35s.
Action Taken When the DTC Sets
• DTCP212216, P212317, P212716, P212817,
P213829: Torque - limiting mode is activated, the
maximum engine speed at neutral gear does not
exceed 5,500 rpm, the maximum vehicle speed is
about 80~120 km/h, the vehicle acceleration
performance decreases a little, the engine
malfunction indicator lamp illuminates.
 9-124 Engine/Propulsion

2. Check the system. Are other DTCs set up? and disconnect the battery negative cable.
– If no, perform the corresponding fault (8) Replace the engine control module. Refer to
diagnosis according to the DTC. Engine Control Module Programming and
– If no, go to the next check. Setup. Operate the vehicle under conditions
for running the DTC. Is the DTC set?
3. Check the harness connectors or components.
Does breakage, poor contact, aging or looseness – If no, diagnosis ends.
exist? – If yes, install the original module back
– If yes, inspect and remove the fault. and contact the technician.
– If no, go to the next check. – If yes, perform the following test:
4. Operate the vehicle under the conditions for (1) Turn the ignition switch to the OFF position
running the DTC and confirm that the DTC is not and disconnect the battery negative cable.
set again. (2) Disconnect K20 engine control module
Circuit/System Testing harness connector X2.
1. Turn the ignition switch to OFF position and (3) Check ground circuit of the accelerator pedal
disconnect the battery negative cable. position sensor 1. Measure the resistance
between terminal 3 of B107 accelerator pedal
2. Disconnect B107 accelerator pedal position position sensor harness connector and
sensor harness connector. terminal G1 of K20 engine control module
3. Connect the battery negative cable and turn the harness connector X2. Is it less than 1 Ω?
ignition switch to ON position. – If no, test the circuit for open circuit/high
4. Check power circuit of the accelerator pedal resistance.
position sensor 1. Measure the voltage between – If yes, go to the next diagnostic step.
terminal 2 of B107 accelerator pedal position
sensor harness connector and the ground. Is it (4) Connect the battery negative cable and turn
about 5 V? the ignition switch to ON position.
– If no, perform the following test:
(1) Turn the ignition switch to the OFF position
and disconnect the battery negative cable.
(2) Disconnect K20 engine control module
harness connector X2.
(3) Measure the resistance between terminal 2
of B107 accelerator pedal position sensor
harness connector and terminal E3 of K20
engine control module harness connector X2.
Is it less than 1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
(4) Measure the resistance between terminal 2
of B107 accelerator pedal position sensor
harness connector and the ground. Is it
infinite?
– If no, test the circuit for short to ground.
– If yes, go to the next diagnostic step.
(5) Connect the battery negative cable and turn
the ignition switch to ON position.
(6) Measure the voltage between terminal 2 of
B107 accelerator pedal position sensor
harness connector and the ground. Is it 0 V?
– If no, test the circuit for short to power supply.
– If yes, go to the next diagnostic step.
(7) Turn the ignition switch to the OFF position
9-125 Engine/Propulsion

(5) Measure the voltage between terminal 3 of harness connector and terminal D3 of K20
B107 accelerator pedal position sensor engine control module harness connector X2.
harness connector and the ground. Is it 0 V? Is it less than 1 Ω?
– If no, test the circuit for short to power – If no, test the circuit for open circuit/high
supply. resistance.
– If yes, go to the next diagnostic step. – If yes, go to the next diagnostic step.
(6) Turn the ignition switch to the OFF position (4) Measure the resistance between terminal 1
and disconnect the battery negative cable. of B107 accelerator pedal position sensor
(7) Check signal circuit of the accelerator pedal harness connector and the ground. Is it
position sensor 1. Measure the resistance infinite?
between terminal 4 of B107 accelerator pedal – If no, test the circuit for short to ground.
position sensor harness connector and – If yes, go to the next diagnostic step.
terminal N3 of K20 engine control module
harness connector X2. Is it less than 1 Ω? (5) Connect the battery negative cable and turn
the ignition switch to ON position.
– If no, test the circuit for open circuit/high
resistance. (6) Measure the voltage between terminal 1 of
B107 accelerator pedal position sensor
– If yes, go to the next diagnostic step. harness connector and the ground. Is it 0 V?
(8) Measure the resistance between terminal 4 – If no, test the circuit for short to power
of B107 accelerator pedal position sensor supply.
harness connector and the ground. Is it
infinite? – If yes, go to the next diagnostic step.
– If no, test the circuit for short to ground. (7) Turn the ignition switch to the OFF position
and disconnect the battery negative cable.
– If yes, go to the next diagnostic step.
(8) Replace the engine control module. Refer to
(9) Connect the battery negative cable and turn Engine Control Module Programming and
the ignition switch to ON position. Setup. Operate the vehicle under conditions
(10) Measure the voltage between terminal 4 of for running the DTC. Is the DTC set?
B107 accelerator pedal position sensor – If no, diagnosis ends.
harness connector and the ground. Is it 0 V?
– If yes, install the original module back
– If no, test the circuit for short to power and contact the technician.
supply.
– If yes, perform the following test:
– If yes, go to the next diagnostic step.
(1) Turn the ignition switch to the OFF position
(11) Turn the ignition switch to the OFF position and disconnect the battery negative cable.
and disconnect the battery negative cable.
(12) Replace the accelerator pedal position
sensor and the engine control module.
Operate the vehicle under conditions for
running the DTC. Is the DTC set?
– If no, diagnosis ends.
– If yes, install the original module back
and contact the technician.
5. Check power circuit of the accelerator pedal
position sensor 2. Measure the voltage between
terminal 1 of B107 accelerator pedal position
sensor harness connector and the ground. Is it
about 5 V?
– If no, perform the following test:
(1) Turn the ignition switch to the OFF position
and disconnect the battery negative cable.
(2) Disconnect K20 engine control module
harness connector X2.
(3) Measure the resistance between terminal 1
of B107 accelerator pedal position sensor

(2) Disconnect K20 engine control module
harness connector X2.
(3) Check signal circuit of the accelerator pedal
position sensor 2. Measure the resistance
between terminal 6 of B107 accelerator pedal
position sensor harness connector and
terminal O2 of K20 engine control module
harness connector X2. Is it less than 1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
(4) Measure the resistance between terminal 6
of B107 accelerator pedal position sensor
harness connector and the ground. Is it
infinite?
– If no, test the circuit for short to ground.
– If yes, go to the next diagnostic step.
(5) Connect the battery negative cable and turn
the ignition switch to ON position.
(6) Measure the voltage between terminal 6 of
B107 accelerator pedal position sensor
harness connector and the ground. Is it 0 V?
– If no, test the circuit for short to power
supply.
– If yes, go to the next diagnostic step.
(7) Turn the ignition switch to the OFF position
and disconnect the battery negative cable.
(8) Check ground circuit of the accelerator pedal
position sensor 2. Measure the resistance
between terminal 5 of B107 accelerator pedal
position sensor harness connector and
terminal L4 of K20 engine control module
harness connector X2. Is it less than 1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
(9) Connect the battery negative cable and turn
the ignition switch to ON position.
(10) Measure the voltage between terminal 5 of
B107 accelerator pedal position sensor
harness connector and the ground. Is it 0 V?
– If no, test the circuit for short to power
supply.
– If yes, go to the next diagnostic step.
(11) Turn the ignition switch to the OFF position
and disconnect the battery negative cable.
(12) Replace the accelerator pedal position
sensor and the engine control module.
Operate the vehicle under conditions for
running the DTC. Is the DTC set?
– If no, diagnosis ends.
– If yes, install the original module back
9-126 Engine/Propulsion
and contact the technician.
Repair Instructions
• Accelerator Pedal Position Sensor Replacement
• Engine Control Module Replacement
• Engine Control Module Programming and Setup
9.2.3.44 DTCP217700, P217800, P218700 or
P218800
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
DTC Description
DTCP217700: Air - fuel ratio closed - loop control self -
learning value over upper limit
DTCP217800: Air - fuel ratio closed - loop control self -
learning value over lower limit
DTCP218700: Air - fuel ratio closed - loop control self -
learning value over upper limit (low load area)
DTCP218800: Air - fuel ratio closed - loop control self -
learning value over lower limit (low load area)
Circuit System Description
The engine control module adopts a closed - loop
control fuel supply system as part of the whole
strategy. That whether the three - way catalytic
converter can work efficiently depends on whether the
engine control module can carry out rich - to - lean air -
fuel ratio adjustment. The oxygen sensor compares
the oxygen content (passing the sensor probe) in the
exhaust and that in the ambient air, and then it
generates a reversely proportional voltage. The
engine control module processes the voltage it
receives from the sensor and calculates the air - fuel
ratio accordingly. If the engine control module receives
a voltage that corresponds to the rich - to - lean limit
value, the fuel supply will increase. As the lean - to -
rich limit value is reached, the fuel supply decreases
until the rich - to - lean limit value is reached.
9-127 Engine/Propulsion
Conditions for Running the DTC
• DTCP217700, P217800: Air - fuel ratio self -
learning is activated, and the engine speed, load
and exhaust flow are shown on the diagnostic
window.
• DTCP218700, P218800: Air - fuel ratio
multiplication self - learning testing passed; idle
speed
Conditions for Setting the DTC
• DTCP217700: Multiplication correction
factor >1.23.
• DTCP217800: Multiplication correction factor <
0.77.
• DTCP218700: Addition correction factor > 8.016.
• DTCP218800: Addition correction factor < -
8.016.
Action Taken When the DTC Sets
• DTC is recorded and the engine malfunction
indicator lamp illuminates.
Conditions for Clearing the DTC
• A history DTC will clear after 40 fault - free ignition
cycles.
• The body control module receives an order to
clear the DTC sent by the scan tool.
Reference Information
Electrical Information Reference
• Circuit Testing
• Connector Repairs
• Testing for Intermittent Conditions and Poor
Connections
• Wiring Repairs
Scan Tool Reference
Refer to “6.1.1.1 Control Module References” for
scan tool information.
Circuit/System Inspection
1. Clear the DTC. Does the DTC reoccur?
– Yes, an intermittent condition; refer to
11.3.4.7 Testing for Intermittent
Conditions and Poor Connections.
– If no, go to the next check.
2. Check the system. Are other DTCs set up?
– If no, perform the corresponding fault
diagnosis according to the DTC.
– If no, go to the next check.
3. Check the harness connectors or components.
Does breakage, poor contact, aging or looseness
exist?
– If yes, inspect and remove the fault.
– If no, go to the next check.
4. Check for the following conditions:
○ Wrong fuel.
○ Ignition system fault.
○ Intake air system leakage.
○ Vacuum hose cracks, torts or is not
connected properly.
○ Vacuum leakage from intake manifold,
throttle and fuel injection nozzle.
○ The crankshaft ventilation system leaks.
○ Insufficient fuel in the fuel tank.
○ Too lean fuel injected from the fuel injection
nozzle.
○ Evaporative emission canister crack.
○ Evaporative emission pipe blockage or
leakage.
– If yes, inspect and remove the fault.
– If no, go to the next check.
5. With the engine not started, confirm the “Intake
Air Pressure” displayed real - time on the scan
tool. Check to see if the parameter greatly
deviates from the ambient pressure which is
about 101 kpa (the specific value depends on the
current air pressure).
– If the pressure is not shown as normal, check
the intake manifold pressure and air
temperature sensor to see if a fault exists.
6. With the engine starting, confirm the “Intake Air
Temperature” and “Intake Air Temperature
Voltage Original Value” displayed real - time on
the scan tool. The reading should be between -
39~149°C according to the current ambient
temperature and the vehicle operation condition.
– If the pressure is not shown as normal, check
the intake manifold pressure and air
temperature sensor to see if a fault exists.
 9-128 Engine/Propulsion

7. With the engine starting, confirm the “Coolant Conditions for Running the DTC
Temperature Sensor Measured Value” displayed • Ignition switch ON and starting 1,000 ms later.
real - time on the scan tool. The measured value
should be between - 39~120°C according to the Conditions for Setting the DTC
current ambient temperature and the vehicle • No message received in 10 successive cycles.
operation condition. Action Taken When the DTC Sets
– If the measured value is not shown as normal, • The DTC is recorded.
check the engine coolant temperature sensor
Conditions for Clearing the DTC
to see if a fault exists.
• A history DTC will clear after 40 fault - free ignition
8. With the engine idling, confirm the “Upstream
cycles.
Oxygen Sensor Voltage” and “Upstream Oxygen
Sensor Voltage Original Value” displayed real - • The body control module receives an order to
time on the scan tool (the reading should fluctuate clear the DTC sent by the scan tool.
within 0.1 - 0.9 V); the “Downstream Oxygen Reference Information
Sensor Voltage” and “Downstream Oxygen Schematic Reference
Sensor Voltage Original Value” displayed real -
time on the scan tool (the reading should fluctuate 4.12.3 Data Communication Schematics (CAN Bus -
within 0.4 - 0.5 V). LV3)
– If the reading is not shown as normal, check Connector End View Reference
the oxygen sensor to see if a fault exists. K20 Engine Control Module X2, X84 Data Link
9. Replace the engine control module. Refer to Connector, and K102 Vehicle Stability Control Module
Engine Control Module Programming and Setup. Electrical Information Reference
Operate the vehicle under conditions for running • Circuit Testing
the DTC. Is the DTC set?
• Connector Repairs
– If yes, replace the engine control module,
and set and program the theft deterrent • Testing for Intermittent Conditions and Poor
system. Connections
– If no, diagnosis ends. • Wiring Repairs
Repair Instructions Scan Tool Reference
• Intake Manifold Pressure and Air Temperature Refer to “6.1.1.1 Control Module References” for
Sensor Replacement scan tool information.
• Engine Coolant Temperature Sensor
Replacement
• Oxygen Sensor Replacement
• Engine Control Module Replacement
• Engine Control Module Programming and Setup
9.2.3.45 DTCU012900 or U041500
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
DTC Description
DTCU041500: ECU–ABS communication abnormal
DTCU012900: ECU–ABS control module
communication missing
Circuit System Description
The engine control module communicates with
ABS/ESP (Antilock Brake System/Electronic Stability
Program) control module via CAN BUS.
9-129 Engine/Propulsion

Circuit/System Inspection resistance.

1. Clear the DTC. Does the DTC reoccur? – If yes, go to the next diagnostic step.
– Yes, an intermittent condition; refer to 7. Measure the resistance between terminal 49 of
11.3.4.7 Testing for Intermittent K20 engine control module harness connector X2
Conditions and Poor Connections. and the ground. Is it infinite?
– If no, go to the next check. - If no, test the circuit for short to ground.
2. Check the system. Are other DTCs set up? – If yes, go to the next diagnostic step.
– If no, perform the corresponding fault 8. Connect the battery negative cable and turn the
diagnosis according to the DTC. ignition switch to ON position.
– If no, go to the next check. 9. Measure the voltage between terminal 49 of K20
3. Check the harness connectors or components. engine control module harness connector X2 and
Does breakage, poor contact, aging or looseness the ground. Is it 2.7 ± 0.1 V?
exist? - If no, test the circuit for short to power supply.
– If yes, inspect and remove the fault. – If yes, go to the next diagnostic step.
– If no, perform “Circuit/System Testing”. 10. Turn the ignition switch to OFF position and
Circuit/System Testing disconnect the battery negative cable.
Confirm the following conditions: 11. Check the CAN network L circuit. Measure the
• Control module and local interconnect network resistance between terminal 33 of K20 engine
device equipped for vehicle control module harness connector X2 and
terminal 14 of K102 vehicle stability control
• Control module position on CAN serial data circuit module harness connector. Is it less than 1 Ω?
• Power supply+, ignition, ground, communication – If no, test the circuit for open circuit/high
enabling and serial data circuit terminals of resistance.
control module
– If yes, go to the next diagnostic step.
1. Before diagnosis, it should be confirmed that
there is no DTC in communication among other
modules. If there is a DTC, diagnose it first.
2. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
3. Measure the resistance between terminal 3
(CANH) and terminal 11 (CANL) of X84 data link
connector under the following conditions:
Condition A: Measure the resistance under the
connection state of all connectors. Is it 60±5 Ω?
Condition B: Measure the resistance with 1
control module separated from the engine control
module or body control module. Is it 120±5 Ω?
Condition C: Measure the resistance with
connectors of engine control module and body
control module being separated. Is it infinite?
4. If the above - mentioned resistance does not
meet the standard value, disconnect the harness
connector at the control module which cannot
communicate.
5. Disconnect K20 engine control module harness
connector X2 and K102 vehicle stability control
module harness connector.
6. Check the CAN network H circuit. Measure the
resistance between terminal 49 of K20 engine
control module harness connector X2 and
terminal 26 of K102 vehicle stability control
module harness connector. Is it less than 1 Ω?
– If no, test the circuit for open circuit/high
 9-130 Engine/Propulsion

12. Measure the resistance between terminal 33 of controller “load signals” based on the difference
K20 engine control module harness connector X2 between the barometric pressure and the intake
and the ground. Is it infinite? manifold pressure; the engine control module provides
- If no, test the circuit for short to ground. 5 V voltage for the sensor and the sensor gives a 0~5
V voltage feedback to the controller as the intake air
– If yes, go to the next diagnostic step. pressure changes. The pressure ratio is directly
13. Connect the battery negative cable and turn the proportional to the output voltage and the temperature
ignition switch to ON position. is reversely proportional to the output resistance.
14. Measure the voltage between terminal 33 of K20 Conditions for Running the DTC
engine control module harness connector X2 and • The ignition switch is turned to ON position.
the ground. Is it 2.3 ± 0.1 V?
Conditions for Setting the DTC
- If no, test the circuit for short to power supply.
• Circuit check is conducted and the voltage goes
– If yes, go to the next diagnostic step. beyond the range (0.098 V–4.902 V).
15. Turn the ignition switch to OFF position and Action Taken When the DTC Sets
disconnect the battery negative cable.
• The engine malfunction indicator lamp does not
16. Replace the engine control module and the illuminate.
vehicle stability control module. Refer to engine
control module and vehicle stability control Conditions for Clearing the DTC
module programming and setup. Operate the • A history DTC will clear after 40 fault - free ignition
vehicle under conditions for running the DTC. Is cycles.
the DTC set? • The body control module receives an order to
– If no, diagnosis ends. clear the DTC sent by the scan tool.
– If yes, install the original module back and Reference Information
contact the technician. Schematic Reference
Repair Instructions 4.10.11 Engine Controls Schematics (Intake Air
• Engine Control Module Replacement Pressure & Temperature Sensor) - 1.5 T
• Engine Control Module Programming and Setup Connector End View Reference
• Vehicle Stability Control Module Replacement K20 Engine Control Module X2, B65 Intake Manifold
• Vehicle Stability Control Module Programming Pressure and Air Temperature Sensor
and Setup
9.2.3.46 DTCP012B21, P012B22, P012C11 or
P012D15
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
DTC Description
DTCP012B21: Supercharger upstream pressure
sensor voltage range not plausible (low)
DTCP012B22: Supercharger upstream pressure
sensor voltage range not plausible (high)
DTCP012C11: Supercharger upstream pressure
sensor circuit voltage too low
DTCP012D15: Supercharger upstream pressure
sensor circuit voltage too high
Circuit System Description
Intake air pressure sensor measures the pressure at
the air filter. The part used to measure the intake air
pressure is a piezoelectric sensor which sends to the
9-131 Engine/Propulsion

Electrical Information Reference resistance.

• Circuit Testing – If yes, go to the next diagnostic step.
• Connector Repairs (4) Measure the resistance between terminal 3 of
• Testing for Intermittent Conditions and Poor B65 intake manifold pressure and air temperature
Connections sensor harness connector and the ground. Is it
infinite?
• Wiring Repairs
– If no, test the circuit for short to ground.
Scan Tool Reference
– If yes, go to the next diagnostic step.
Refer to “6.1.1.1 Control Module References” for
scan tool information. (5) Connect the battery negative cable and turn the
ignition switch to ON position.
Circuit/System Inspection
(6) Measure the voltage between terminal 3 of B65
1. Clear the DTC. Does the DTC reoccur? intake manifold pressure and air temperature
– Yes, an intermittent condition; refer to sensor harness connector and the ground. Is it 0
11.3.4.7 Testing for Intermittent V?
Conditions and Poor Connections. – If no, test the circuit for short to power supply.
– If no, go to the next check. – If yes, go to the next diagnostic step.
2. Check the system. Are other DTCs set up? (7) Turn the ignition switch to the OFF position and
– If no, perform the corresponding fault disconnect the battery negative cable.
diagnosis according to the DTC. (8) Replace the engine control module. Refer to
– If no, go to the next check. Engine Control Module Programming and Setup.
3. Check the harness connectors or components. Operate the vehicle under conditions for running
Does breakage, poor contact, aging or looseness the DTC. Is the DTC set?
exist? – If no, diagnosis ends.
– If yes, inspect and remove the fault. – If yes, install the original module back and
– If no, perform “Circuit/System Testing”. contact the technician.
4. Operate the vehicle under the conditions for – If yes, perform the following test:
running the DTC and confirm that the DTC is not (1) Turn the ignition switch to the OFF position and
set again. disconnect the battery negative cable.
Circuit/System Testing (2) Check ground circuit of the intake manifold
1. Turn the ignition switch to OFF position and pressure and air temperature sensor. Measure
disconnect the battery negative cable. the resistance between terminal 1 of B65 intake
manifold pressure and air temperature sensor
2. Disconnect B65 intake manifold pressure and air
harness connector and the ground. Is it less than
temperature sensor harness connector.
1 Ω?
3. Connect the battery negative cable and turn the
– If no, test the circuit for open circuit/high
ignition switch to ON position.
resistance.
4. Check power circuit of the intake manifold
– If yes, go to the next diagnostic step.
pressure and air temperature sensor. Measure
the voltage between terminal 3 of B65 intake
manifold pressure and air temperature sensor
harness connector and the ground. Is it about 5
V?
– If no, perform the following test:
(1) Turn the ignition switch to the OFF position and
disconnect the battery negative cable.
(2) Disconnect K20 engine control module harness
connector X2.
(3) Measure the resistance between terminal 3 of
B65 intake manifold pressure and air temperature
sensor harness connector and terminal C2 of K20
engine control module harness connector X2. Is it
less than 1 Ω?
– If no, test the circuit for open circuit/high
 9-132 Engine/Propulsion

(3) Disconnect K20 engine control module harness DTCP065000: MIL drive circuit short to power
connector X2. supply/MIL drive circuit short to ground
(4) Check voltage signal circuit of the intake manifold DTCP070000: External request for MIL illumination
pressure and air temperature sensor. Measure Circuit System Description
the resistance between terminal 4 of B65 intake
manifold pressure and air temperature sensor When the engine control module detects a fault, the
harness connector and terminal M4 of K20 engine ground controlling MIL picks up and MIL on the
control module harness connector X2. Is it less instrument cluster illuminates.
than 1 Ω? Conditions for Running the DTC
– If no, test the circuit for open circuit/high • Engine is running and the battery voltage is
resistance. higher than 9 V.
– If yes, go to the next diagnostic step. Conditions for Setting the DTC
(5) Measure the resistance between terminal 4 of • Circuit short to ground/open/short to power supply
B65 intake manifold pressure and air temperature is detected.
sensor harness connector and the ground. Is it Action Taken When the DTC Sets
infinite?
• DTC is recorded and the engine malfunction
– If no, test the circuit for short to ground. indicator lamp does not illuminate.
– If yes, go to the next diagnostic step. Conditions for Clearing the DTC
(6) Connect the battery negative cable and turn the • A history DTC will clear after 40 fault - free ignition
ignition switch to ON position. cycles.
(7) Measure the voltage between terminal 4 of B65 • The body control module receives an order to
intake manifold pressure and air temperature clear the DTC sent by the scan tool.
sensor harness connector and the ground. Is it 0
V?
– If no, test the circuit for short to power supply.
– If yes, go to the next diagnostic step.
(8) Turn the ignition switch to the OFF position and
disconnect the battery negative cable.
(9) Replace the intake manifold pressure and air
temperature sensor and the engine control
module. Refer to Engine Control Module
Programming and Setup. Operate the vehicle
under conditions for running the DTC. Is the DTC
set?
– If no, diagnosis ends.
– If yes, install the original module back and
contact the technician.
Repair Instructions
• Intake Manifold Pressure and Air Temperature
Sensor Replacement
• Engine Control Module Replacement
• Engine Control Module Programming and Setup
9.2.3.47 DTCP065000 or P070000
Diagnostic Instructions
• Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
DTC Description
9-133 Engine/Propulsion

Reference Information - If no, test the circuit for short to ground.

Schematic Reference – If yes, go to the next diagnostic step.
4.10.10 Engine Controls Schematics (Module Power, 5. Connect the battery negative cable and turn the
Ground, Serial Data, and MIL) - 1.5 T ignition switch to ON position.
Connector End View Reference 6. Measure the voltage between terminal J4 of K20
K20 Engine Control Module X2, and P16 Instrument engine control module harness connector X2 and
Cluster the ground. Is it 0 V?
Electrical Information Reference - If no, test the circuit for short to power supply.
• Circuit Testing – If yes, go to the next diagnostic step.
• Connector Repairs 7. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
• Testing for Intermittent Conditions and Poor
Connections 8. Replace the instrument cluster and the engine
control module. Refer to Engine Control Module
• Wiring Repairs Programming and Setup. Operate the vehicle
Scan Tool Reference under conditions for running the DTC. Is the DTC
Refer to “6.1.1.1 Control Module References” for set?
scan tool information. – If no, diagnosis ends.
Circuit/System Inspection – If yes, install the original module back and
1. Clear the DTC. Does the DTC reoccur? contact the technician.
– Yes, an intermittent condition; refer to Repair Instructions
11.3.4.7 Testing for Intermittent • Instrument Cluster Replacement
Conditions and Poor Connections. • Engine Control Module Replacement
– If no, go to the next check. • Engine Control Module Programming and Setup
2. Check the system. Are other DTCs set up? 9.2.3.48 DTCP152300 or P168300
– If no, perform the corresponding fault Diagnostic Instructions
diagnosis according to the DTC.
• Perform “6.2.2.7 Diagnostic System Check -
– If no, go to the next check. Vehicle” prior to using this diagnostic procedure.
3. Check the harness connectors or components. • Review “6.2.2.5 Strategy Based Diagnosis” for
Does breakage, poor contact, aging or looseness an overview of the diagnostic approach.
exist?
• “6.2.2.6 Diagnostic Procedure Instructions”
– If yes, inspect and remove the fault. provides an overview of each diagnostic category
– If no, perform “Circuit/System Testing”.
4. Operate the vehicle under the conditions for
running the DTC and confirm that the DTC is not
set again.
Circuit/System Testing
1. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
2. Disconnect K20 engine control module harness
connector X2 and P16 instrument cluster harness
connector.
3. Measure the resistance between terminal J4 of
K20 engine control module harness connector X2
and terminal 9 of P16 instrument cluster harness
connector. Is it less than 1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
4. Measure the resistance between terminal J4 of
K20 engine control module harness connector X2
and the ground. Is it infinite?
 9-134 Engine/Propulsion

DTC Description the theft deterrent system has been installed.

DTCP152300: Fuel cutoff mode in case of collision – If yes, remove the additionally installed
activated equipment.
DTCP168300: Airbag signal not plausible – If no, go to the next check.
Circuit System Description 5. Turn the ignition switch to ON position, connect a
The engine control module communicates with SRS scan tool to clear the DTCs and then program and
(Supplemental Restraint System) via CAN bus and it set the engine control module. Observe the DTCs
receives collision and airbag signals. shown on the scan tool. Is any DTC set?
Conditions for Running the DTC – If yes, replace the engine control module.
• Ignition switch ON and starting 1,000 ms later. – If no, diagnosis ends.
Conditions for Setting the DTC Repair Instructions
• DTCP152300: Collision sensor response • Engine Control Module Replacement
abnormal • Engine Control Module Programming and Setup
DTCP168300: Airbag signal interrupted 9.2.3.49 DTCP161000, P161100, P161200, P161300,
Action Taken When the DTC Sets P161400, P161500, P161600, P161700,
P161800, P161900 or P163000
• DTC is recorded and the fault indicator does not
illuminate. Diagnostic Instructions
Conditions for Clearing the DTC • Perform “6.2.2.7 Diagnostic System Check -
Vehicle” prior to using this diagnostic procedure.
• A history DTC will clear after 40 fault - free ignition
cycles. • Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach.
• The body control module receives an order to
clear the DTC sent by the scan tool. • “6.2.2.6 Diagnostic Procedure Instructions”
provides an overview of each diagnostic category
Reference Information
Electrical Information Reference
• Circuit Testing
• Connector Repairs
• Testing for Intermittent Conditions and Poor
Connections
• Wiring Repairs
Scan Tool Reference
Refer to “6.1.1.1 Control Module References” for
scan tool information.
Circuit/System Inspection
1. Clear the DTC. Does the DTC reoccur?
– Yes, an intermittent condition; refer to
11.3.4.7 Testing for Intermittent
Conditions and Poor Connections.
– If no, go to the next check.
2. Check the system. Are other DTCs set up?
– If no, perform the corresponding fault
diagnosis according to the DTC.
– If no, go to the next check.
3. Check the harness connectors or components.
Does breakage, poor contact, aging or looseness
exist?
– If yes, inspect and remove the fault.
– If no, go to the next check.
4. Perform visual /physical inspection to see if any
additional equipment that may affect operation of
9-135 Engine/Propulsion

DTC Description Reference Information

DTCP161000: ECM not learning SecretKey Electrical Information Reference
DTCP161100: PIN code input error • Circuit Testing
DTCP161200: ECM receiving error (received • Connector Repairs
response data frame incomplete) • Testing for Intermittent Conditions and Poor
DTCP161300: BCM gives BUSY responses for over 6 Connections
times • Wiring Repairs
DTCP161400: BCM and EMS certification failure Scan Tool Reference
DTCP161500: Status byte of BCM response not within Refer to “6.1.1.1 Control Module References” for
definition range scan tool information.
DTCP161600: BCM and key certification failure Circuit/System Inspection
DTCP161700: No certification response received from 1. Clear the DTC. Does the DTC reoccur?
theft deterrent
– Yes, an intermittent condition; refer to
DTCP161800: EEPROM offline configuration 11.3.4.7 Testing for Intermittent
password failure Conditions and Poor Connections.
DTCP161900: ECM theft deterrent matching not – If no, go to the next check.
performed
2. Check the system. Are other DTCs set up?
DTCP163000: VIN not written to EEPROM (offline)
– If no, perform the corresponding fault
Circuit System Description diagnosis according to the DTC.
Information certification must be conducted between – If no, go to the next check.
the engine control module and any other modules. The
engine can be started only after the certification 3. Check the harness connectors or components.
succeeds. The certification information is transmitted Does breakage, poor contact, aging or looseness
via CAN bus. exist?
Conditions for Running the DTC – If yes, inspect and remove the fault.
• The ignition switch is turned to ON position. – If no, go to the next check.
Conditions for Setting the DTC 4. Perform visual /physical inspection to see if any
additional equipment that may affect operation of
• DTCP161000: Internal logic check fault. the theft deterrent system has been installed.
• DTCP161100: Internal logic check fault. – If yes, remove the additionally installed
• DTCP161200: Internal logic check fault. equipment.
• DTCP161300: Internal logic check fault. – If no, go to the next check.
• DTCP161400: Internal logic check fault.
• DTCP161500: ECMeeprom (Engine Control
Module electrical erasable programmable read -
only memory) status error
• DTCP161600: Wrong theft deterrent certification
response received
• DTCP161700: Internal logic check fault.
• DTCP161800: Internal logic check fault.
• DTCP161900: Internal logic check fault.
• DTCP163000: Internal logic check fault.
Action Taken When the DTC Sets
• DTC is recorded and the engine malfunction
indicator lamp does not illuminate.
Conditions for Clearing the DTC
• A history DTC will clear after 40 fault - free ignition
cycles.
• The body control module receives an order to
clear the DTC sent by the scan tool.
 9-136 Engine/Propulsion

5. Turn the ignition switch to ON position, connect a Diagnostic Interfaces, and K71 Transmission Control
scan tool to clear the DTCs and then program and Module
set the engine control module and the theft Electrical Information Reference
deterrent system respectively. Observe the DTCs
shown on the scan tool. Is any DTC set? • Circuit Testing
– If yes, replace the engine control module, • Connector Repairs
and set and program the theft deterrent • Testing for Intermittent Conditions and Poor
system. Connections
– If no, diagnosis ends. • Wiring Repairs
Repair Instructions Scan Tool Reference
• Theft Deterrent System Setup and Matching Refer to “6.1.1.1 Control Module References” for
• Engine Control Module Replacement scan tool information.
• Engine Control Module Programming and Setup Circuit/System Inspection
9.2.3.50 DTCU010100 1. Clear the DTC. Does the DTC reoccur?
Diagnostic Instructions – Yes, an intermittent condition; refer to
11.3.4.7 Testing for Intermittent
• Perform “6.2.2.7 Diagnostic System Check - Conditions and Poor Connections.
Vehicle” prior to using this diagnostic procedure.
– If no, go to the next check.
• Review “6.2.2.5 Strategy Based Diagnosis” for
an overview of the diagnostic approach. 2. Check the system. Are other DTCs set up?
• “6.2.2.6 Diagnostic Procedure Instructions” – If no, perform the corresponding fault
provides an overview of each diagnostic category diagnosis according to the DTC.
DTC Description – If no, go to the next check.
DTCU010100: ECU–TCU communication missing 3. Check the harness connectors or components.
Does breakage, poor contact, aging or looseness
Circuit System Description exist?
The engine control module communicates with TCU – If yes, inspect and remove the fault.
(Transmission Control Module) via CAN bus.
– If no, perform “Circuit/System Testing”.
Conditions for Running the DTC
• Ignition switch ON and starting 1,000 ms later.
Conditions for Setting the DTC
• No message received in 10 successive cycles.
Action Taken When the DTC Sets
• The DTC is recorded.
Conditions for Clearing the DTC
• A history DTC will clear after 40 fault - free ignition
cycles.
• The body control module receives an order to
clear the DTC sent by the scan tool.
Reference Information
Schematic Reference
4.12.1 Data Communication Schematics (OBD
Diagnostic Interface)
4.12.2 Data Communication Schematics (CAN Bus -
LV1/LV2)
4.12.3 Data Communication Schematics (CAN Bus -
LV3)
4.12.4 Data Communication Schematics (CAN Bus -
LV3, cont’d)
Connector End View Reference
K20 Engine Control Module X2, X84 Complete Vehicle
9-137 Engine/Propulsion

Circuit/System Testing X1 and the ground. Is it 2.7±0.1 V?

LV1/LV2 iAMT - If no, test the circuit for short to power supply.
Confirm the following conditions: – If yes, go to the next diagnostic step.
• Control module and local interconnect network 10. Turn the ignition switch to OFF position and
device equipped for vehicle disconnect the battery negative cable.
• Control module position on CAN serial data circuit 11. Check the CAN network L circuit. Measure the
• Power supply+, ignition, ground, communication resistance between terminal 1 of K71
enabling and serial data circuit terminals of transmission control module harness connector
control module X1 and terminal A2 of K20 engine control module
harness connector X2. Is it less than 1 Ω?
1. Before diagnosis, it should be confirmed that
there is no DTC in communication among other – If no, test the circuit for open circuit/high
modules. If there is a DTC, diagnose it first. resistance.
2. Turn the ignition switch to OFF position and – If yes, go to the next diagnostic step.
disconnect the battery negative cable. 12. Measure the resistance between terminal 1 of
3. Measure the resistance between terminal 6 K71 transmission control module harness
(CANH) and terminal 14 (CANL) of X84 whole connector X1 and the ground. Is it infinite?
vehicle diagnostic interface under the following - If no, test the circuit for short to ground.
conditions: – If yes, go to the next diagnostic step.
○ Condition A: Measure the resistance under 13. Connect the battery negative cable and turn the
the connection state of all connectors. Is it ignition switch to ON position.
60±5 Ω?
14. Measure the voltage between terminal 1 of K71
○ Condition B: Measure the resistance with 1 transmission control module harness connector
control module separated from the engine X1 and the ground. Is it 2.3±0.1 V?
control module or body control module. Is it
120±5 Ω? - If no, test the circuit for short to power supply.
○ Condition C: Measure the resistance with – If yes, go to the next diagnostic step.
connectors of engine control module and 15. Turn the ignition switch to OFF position and
body control module being separated. Is it disconnect the battery negative cable.
infinite?
4. If the above - mentioned resistance does not
meet the standard value, disconnect the harness
connector at the control module which cannot
communicate.
5. Disconnect K20 engine control module harness
connector and K71 transmission control module
harness connector.
6. Check the CAN network H circuit. Measure the
resistance between terminal 2 of K71
transmission control module harness connector
X1 and terminal A1 of K20 engine control module
harness connector X2. Is it less than 1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
7. Measure the resistance between terminal 2 of
K71 transmission control module harness
connector X1 and the ground. Is it infinite?
- If no, test the circuit for short to ground.
– If yes, go to the next diagnostic step.
8. Connect the battery negative cable and turn the
ignition switch to ON position.
9. Measure the voltage between terminal 2 of K71
transmission control module harness connector
 9-138 Engine/Propulsion

16. Replace the transmission control module and the – If yes, go to the next diagnostic step.
engine control module. Operate the vehicle under 8. Connect the battery negative cable and turn the
conditions for running the DTC. Is the DTC set? ignition switch to ON position.
– If no, diagnosis ends. 9. Measure the voltage between terminal 18 of K71
– If yes, install the original module back and transmission control module harness connector
contact the technician. and the ground. Is it within 2.7±0.1 V?
LV1/LV2DCT - If no, test the circuit for short to power supply.
Confirm the following conditions: – If yes, go to the next diagnostic step.
• Control module and local interconnect network 10. Turn the ignition switch to OFF position and
device equipped for vehicle disconnect the battery negative cable.
• Control module position on CAN serial data circuit 11. Check the CAN network L circuit. Measure the
• Power supply+, ignition, ground, communication resistance between terminal 17 of K71
enabling and serial data circuit terminals of transmission control module harness connector
control module and terminal A2 of K20 engine control module
harness connector X2. Is it less than 1 Ω?
1. Before diagnosis, it should be confirmed that
there is no DTC in communication among other – If no, test the circuit for open circuit/high
modules. If there is a DTC, diagnose it first. resistance.
2. Turn the ignition switch to OFF position and – If yes, go to the next diagnostic step.
disconnect the battery negative cable. 12. Measure the resistance between terminal 17 of
3. Measure the resistance between terminal 6 K71 transmission control module harness
(CANH) and terminal 14 (CANL) of X84 whole connector and the ground. Is it infinite?
vehicle diagnostic interface under the following - If no, test the circuit for short to ground.
conditions: – If yes, go to the next diagnostic step.
○ Condition A: Measure the resistance under 13. Connect the battery negative cable and turn the
the connection state of all connectors. Is it ignition switch to ON position.
60±5 Ω?
14. Measure the voltage between terminal 17 of K71
○ Condition B: Measure the resistance with 1 transmission control module harness connector
control module separated from the engine and the ground. Is it within 2.3±0.1 V?
control module or body control module. Is it
120±5 Ω? - If no, test the circuit for short to power supply.
○ Condition C: Measure the resistance with – If yes, go to the next diagnostic step.
connectors of engine control module and
body control module being separated. Is it
infinite?
4. If the above - mentioned resistance does not
meet the standard value, disconnect the harness
connector at the control module which cannot
communicate.
5. Disconnect K20 engine control module harness
connector and K71 transmission control module
harness connector.
6. Check the CAN network H circuit. Measure the
resistance between terminal 18 of K71
transmission control module harness connector
and terminal A1 of K20 engine control module
harness connector X2. Is it less than 1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
7. Measure the resistance between terminal 18 of
K71 transmission control module harness
connector and the ground. Is it infinite?
- If no, test the circuit for short to ground.
9-139 Engine/Propulsion

15. Turn the ignition switch to OFF position and connector and the ground. Is it infinite?
disconnect the battery negative cable. - If no, test the circuit for short to ground.
16. Replace the transmission control module and the – If yes, go to the next diagnostic step.
engine control module. Operate the vehicle under
conditions for running the DTC. Is the DTC set? 8. Connect the battery negative cable and turn the
ignition switch to ON position.
– If no, diagnosis ends.
9. Measure the voltage between terminal 18 of K71
– If yes, install the original module back and transmission control module harness connector
contact the technician. and the ground. Is it within 2.7±0.1 V?
LV3DCT - If no, test the circuit for short to power supply.
Confirm the following conditions: – If yes, go to the next diagnostic step.
• Control module and local interconnect network 10. Turn the ignition switch to OFF position and
device equipped for vehicle disconnect the battery negative cable.
• Control module position on CAN serial data circuit 11. Check the CAN network L circuit. Measure the
• Power supply+, ignition, ground, communication resistance between terminal 17 of K71
enabling and serial data circuit terminals of transmission control module harness connector
control module and terminal A2 of K20 engine control module
1. Before diagnosis, it should be confirmed that harness connector X2. Is it less than 1 Ω?
there is no DTC in communication among other – If no, test the circuit for open circuit/high
modules. If there is a DTC, diagnose it first. resistance.
2. Turn the ignition switch to OFF position and – If yes, go to the next diagnostic step.
disconnect the battery negative cable. 12. Measure the resistance between terminal 17 of
3. Measure the resistance between terminal 3 K71 transmission control module harness
(CANH) and terminal 11 (CANL) of X84 whole connector and the ground. Is it infinite?
vehicle diagnostic interface under the following - If no, test the circuit for short to ground.
conditions:
– If yes, go to the next diagnostic step.
○ Condition A: Measure the resistance under
the connection state of all connectors. Is it 13. Connect the battery negative cable and turn the
60±5 Ω? ignition switch to ON position.
○ Condition B: Measure the resistance with 1
control module separated from the engine
control module or body control module. Is it
120±5 Ω?
○ Condition C: Measure the resistance with
connectors of engine control module and
body control module being separated. Is it
infinite?
4. If the above - mentioned resistance does not
meet the standard value, disconnect the harness
connector at the control module which cannot
communicate.
5. Disconnect K20 engine control module harness
connector and K71 transmission control module
harness connector.
6. Check the CAN network H circuit. Measure the
resistance between terminal 18 of K71
transmission control module harness connector
and terminal A1 of K20 engine control module
harness connector X2. Is it less than 1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
7. Measure the resistance between terminal 18 of
K71 transmission control module harness
 9-140 Engine/Propulsion

14. Measure the voltage between terminal 17 of K71 Diagnostic Interface)

transmission control module harness connector 4.12.2 Data Communication Schematics (CAN Bus -
and the ground. Is it within 2.3±0.1 V? LV1/LV2)
- If no, test the circuit for short to power supply. 4.12.3 Data Communication Schematics (CAN Bus -
– If yes, go to the next diagnostic step. LV3)
15. Turn the ignition switch to OFF position and 4.12.4 Data Communication Schematics (CAN Bus -
disconnect the battery negative cable. LV3, cont’d)
16. Replace the transmission control module and the Connector End View Reference
engine control module. Operate the vehicle under K20 Engine Control Module, X84 Complete Vehicle
conditions for running the DTC. Is the DTC set? Diagnostic Interfaces, and K102 Vehicle Stability
– If no, diagnosis ends. Control Module
– If yes, install the original module back and Electrical Information Reference
contact the technician. • Circuit Testing
Repair Instructions • Connector Repairs
• Engine Control Module Replacement • Testing for Intermittent Conditions and Poor
• Engine Control Module Programming and Setup Connections
• Transmission Control Module Replacement • Wiring Repairs
• Transmission Control Module Programming and Scan Tool Reference
Setup Refer to “6.1.1.1 Control Module References” for
9.2.3.51 DTCU012800, U012900 or U041500 scan tool information.
Diagnostic Instructions Circuit/System Inspection
• Perform “6.2.2.7 Diagnostic System Check - 1. Clear the DTC. Does the DTC reoccur?
Vehicle” prior to using this diagnostic procedure. – Yes, an intermittent condition; refer to
• Review “6.2.2.5 Strategy Based Diagnosis” for 11.3.4.7 Testing for Intermittent
an overview of the diagnostic approach. Conditions and Poor Connections.
• “6.2.2.6 Diagnostic Procedure Instructions” – If no, go to the next check.
provides an overview of each diagnostic category
DTC Description
DTCU012800: Communication with EPB missing or
signal abnormal
DTCU012900: ECU–ABS control module
communication missing
DTCU041500: ECU–ABS communication abnormal
Circuit System Description
The engine control module communicates with EPB
(Electronic Park Brake) via CAN BUS.
Conditions for Running the DTC
• Ignition switch ON and starting 1,000 ms later.
Conditions for Setting the DTC
• No message received in 10 successive cycles.
Action Taken When the DTC Sets
• The DTC is recorded.
Conditions for Clearing the DTC
• A history DTC will clear after 40 fault - free ignition
cycles.
• The body control module receives an order to
clear the DTC sent by the scan tool.
Reference Information Schematic Reference
4.12.1 Data Communication Schematics (OBD
9-141 Engine/Propulsion

2. Check the system. Are other DTCs set up? 7. Measure the resistance between terminal A1 of
– If no, perform the corresponding fault K20 engine control module harness connector X2
diagnosis according to the DTC. and the ground. Is it infinite?
– If no, go to the next check. - If no, test the circuit for short to ground.
3. Check the harness connectors or components. – If yes, go to the next diagnostic step.
Does breakage, poor contact, aging or looseness 8. Connect the battery negative cable and turn the
exist? ignition switch to ON position.
– If yes, inspect and remove the fault. 9. Measure the voltage between terminal A1 of K20
– If no, perform “Circuit/System Testing”. engine control module harness connector X2 and
the ground. Is it 2.7 ± 0.1 V?
Circuit/System Testing
- If no, test the circuit for short to power supply.
LV1/LV2 (Bosch)
– If yes, go to the next diagnostic step.
Confirm the following conditions:
10. Turn the ignition switch to OFF position and
• Control module and local interconnect network disconnect the battery negative cable.
device equipped for vehicle
11. Check the CAN network L circuit. Measure the
• Control module position on CAN serial data circuit resistance between terminal A2 of K20 engine
• Power supply+, ignition, ground, communication control module harness connector X2 and
enabling and serial data circuit terminals of terminal 14 of K102 vehicle stability control
control module module harness connector. Is it less than 1 Ω?
1. Before diagnosis, it should be confirmed that – If no, test the circuit for open circuit/high
there is no DTC in communication among other resistance.
modules. If there is a DTC, diagnose it first. – If yes, go to the next diagnostic step.
2. Turn the ignition switch to OFF position and 12. Measure the resistance between terminal A2 of
disconnect the battery negative cable. K20 engine control module harness connector X2
3. Measure the resistance between terminal 6 and the ground. Is it infinite?
(CANH) and terminal 14 (CANL) of X84 whole - If no, test the circuit for short to ground.
vehicle diagnostic interface under the following
conditions: – If yes, go to the next diagnostic step.
○ Condition A: Measure the resistance under 13. Connect the battery negative cable and turn the
the connection state of all connectors. Is it ignition switch to ON position.
60±5 Ω?
○ Condition B: Measure the resistance with 1
control module separated from the engine
control module or body control module. Is it
120±5 Ω?
○ Condition C: Measure the resistance with
connectors of engine control module and
body control module being separated. Is it
infinite?
4. If the above - mentioned resistance does not
meet the standard value, disconnect the harness
connector at the control module which cannot
communicate.
5. Disconnect K20 engine control module harness
connector X2.
6. Check the CAN network H circuit. Measure the
resistance between terminal A1 of K20 engine
control module harness connector X2 and
terminal 26 of K102 vehicle stability control
module harness connector. Is it less than 1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
 9-142 Engine/Propulsion

14. Measure the voltage between terminal A2 of K20 harness connector. Is it less than 1 Ω?
engine control module harness connector X2 and – If no, test the circuit for open circuit/high
the ground. Is it 2.3 ± 0.1 V? resistance.
- If no, test the circuit for short to power supply. – If yes, go to the next diagnostic step.
– If yes, go to the next diagnostic step. 7. Measure the resistance between terminal A1 of
15. Turn the ignition switch to OFF position and K20 engine control module harness connector X2
disconnect the battery negative cable. and the ground. Is it infinite?
16. Replace the engine control module and the - If no, test the circuit for short to ground.
vehicle stability control module. Operate the – If yes, go to the next diagnostic step.
vehicle under conditions for running the DTC. Is
the DTC set? 8. Connect the battery negative cable and turn the
ignition switch to ON position.
– If no, diagnosis ends.
9. Measure the voltage between terminal A1 of K20
– If yes, install the original module back and engine control module harness connector X2 and
contact the technician. the ground. Is it 2.7 ± 0.1 V?
LV1/LV2 (Autoliv) - If no, test the circuit for short to power supply.
Confirm the following conditions: – If yes, go to the next diagnostic step.
• Control module and local interconnect network 10. Turn the ignition switch to OFF position and
device equipped for vehicle disconnect the battery negative cable.
• Control module position on CAN serial data circuit 11. Check the CAN network L circuit. Measure the
• Power supply+, ignition, ground, communication resistance between terminal A2 of K20 engine
enabling and serial data circuit terminals of control module harness connector X2 and
control module terminal 19 of K102 vehicle stability control
1. Before diagnosis, it should be confirmed that module harness connector. Is it less than 1 Ω?
there is no DTC in communication among other – If no, test the circuit for open circuit/high
modules. If there is a DTC, diagnose it first. resistance.
2. Turn the ignition switch to OFF position and – If yes, go to the next diagnostic step.
disconnect the battery negative cable. 12. Measure the resistance between terminal A2 of
3. Measure the resistance between terminal 6 K20 engine control module harness connector X2
(CANH) and terminal 14 (CANL) of X84 whole and the ground. Is it infinite?
vehicle diagnostic interface under the following - If no, test the circuit for short to ground.
conditions:
– If yes, go to the next diagnostic step.
○ Condition A: Measure the resistance under
the connection state of all connectors. Is it
60±5 Ω?
○ Condition B: Measure the resistance with 1
control module separated from the engine
control module or body control module. Is it
120±5 Ω?
○ Condition C: Measure the resistance with
connectors of engine control module and
body control module being separated. Is it
infinite?
4. If the above - mentioned resistance does not
meet the standard value, disconnect the harness
connector at the control module which cannot
communicate.
5. Disconnect K20 engine control module harness
connector X2 and K102 vehicle stability control
module harness connector.
6. Check the CAN network H circuit. Measure the
resistance between terminal A1 of K20 engine
control module harness connector X2 and
terminal 5 of K102 vehicle stability control module
9-143 Engine/Propulsion

13. Connect the battery negative cable and turn the control module harness connector X2 and
ignition switch to ON position. terminal 26 of K102 vehicle stability control
14. Measure the voltage between terminal A2 of K20 module harness connector. Is it less than 1 Ω?
engine control module harness connector X2 and – If no, test the circuit for open circuit/high
the ground. Is it 2.3 ± 0.1 V? resistance.
- If no, test the circuit for short to power supply. – If yes, go to the next diagnostic step.
– If yes, go to the next diagnostic step. 7. Measure the resistance between terminal A1 of
15. Turn the ignition switch to OFF position and K20 engine control module harness connector X2
disconnect the battery negative cable. and the ground. Is it infinite?
16. Replace the engine control module and the - If no, test the circuit for short to ground.
vehicle stability control module. Operate the – If yes, go to the next diagnostic step.
vehicle under conditions for running the DTC. Is 8. Connect the battery negative cable and turn the
the DTC set? ignition switch to ON position.
– If no, diagnosis ends. 9. Measure the voltage between terminal A1 of K20
– If yes, install the original module back and engine control module harness connector X2 and
contact the technician. the ground. Is it 2.7 ± 0.1 V?
LV3 (Bosch) - If no, test the circuit for short to power supply.
Confirm the following conditions: – If yes, go to the next diagnostic step.
• Control module and local interconnect network 10. Turn the ignition switch to OFF position and
device equipped for vehicle disconnect the battery negative cable.
• Control module position on CAN serial data circuit 11. Check the CAN network L circuit. Measure the
• Power supply+, ignition, ground, communication resistance between terminal A2 of K20 engine
enabling and serial data circuit terminals of control module harness connector X2 and
control module terminal 14 of K102 vehicle stability control
module harness connector. Is it less than 1 Ω?
1. Before diagnosis, it should be confirmed that
there is no DTC in communication among other – If no, test the circuit for open circuit/high
modules. If there is a DTC, diagnose it first. resistance.
2. Turn the ignition switch to OFF position and – If yes, go to the next diagnostic step.
disconnect the battery negative cable.
3. Measure the resistance between terminal 3
(CANH) and terminal 11 (CANL) of X84 whole
vehicle diagnostic interface under the following
conditions:
○ Condition A: Measure the resistance under
the connection state of all connectors. Is it
60±5 Ω?
○ Condition B: Measure the resistance with 1
control module separated from the engine
control module or body control module. Is it
120±5 Ω?
○ Condition C: Measure the resistance with
connectors of engine control module and
body control module being separated. Is it
infinite?
4. If the above - mentioned resistance does not
meet the standard value, disconnect the harness
connector at the control module which cannot
communicate.
5. Disconnect K20 engine control module harness
connector X2 and K102 vehicle stability control
module harness connector.
6. Check the CAN network H circuit. Measure the
resistance between terminal A1 of K20 engine
 9-144 Engine/Propulsion

12. Measure the resistance between terminal A2 of communicate.

K20 engine control module harness connector X2 5. Disconnect K20 engine control module harness
and the ground. Is it infinite? connector X2 and K102 vehicle stability control
- If no, test the circuit for short to ground. module harness connector.
– If yes, go to the next diagnostic step. 6. Check the CAN network H circuit. Measure the
13. Connect the battery negative cable and turn the resistance between terminal A1 of K20 engine
ignition switch to ON position. control module harness connector X2 and
terminal 5 of K102 vehicle stability control module
14. Measure the voltage between terminal A2 of K20 harness connector. Is it less than 1 Ω?
engine control module harness connector X2 and
the ground. Is it 2.3 ± 0.1 V? – If no, test the circuit for open circuit/high
resistance.
- If no, test the circuit for short to power supply.
– If yes, go to the next diagnostic step.
– If yes, go to the next diagnostic step.
7. Measure the resistance between terminal A1 of
15. Turn the ignition switch to OFF position and K20 engine control module harness connector X2
disconnect the battery negative cable. and the ground. Is it infinite?
16. Replace the engine control module and the - If no, test the circuit for short to ground.
vehicle stability control module. Operate the
vehicle under conditions for running the DTC. Is – If yes, go to the next diagnostic step.
the DTC set? 8. Connect the battery negative cable and turn the
– If no, diagnosis ends. ignition switch to ON position.
– If yes, install the original module back and 9. Measure the voltage between terminal A1 of K20
contact the technician. engine control module harness connector X2 and
the ground. Is it 2.7 ± 0.1 V?
LV3 (Autoliv)
- If no, test the circuit for short to power supply.
Confirm the following conditions:
– If yes, go to the next diagnostic step.
• Control module and local interconnect network
device equipped for vehicle 10. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
• Control module position on CAN serial data circuit
• Power supply+, ignition, ground, communication
enabling and serial data circuit terminals of
control module
1. Before diagnosis, it should be confirmed that
there is no DTC in communication among other
modules. If there is a DTC, diagnose it first.
2. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
3. Measure the resistance between terminal 3
(CANH) and terminal 11 (CANL) of X84 whole
vehicle diagnostic interface under the following
conditions:
○ Condition A: Measure the resistance under
the connection state of all connectors. Is it
60±5 Ω?
○ Condition B: Measure the resistance with 1
control module separated from the engine
control module or body control module. Is it
120±5 Ω?
○ Condition C: Measure the resistance with
connectors of engine control module and
body control module being separated. Is it
infinite?
4. If the above - mentioned resistance does not
meet the standard value, disconnect the harness
connector at the control module which cannot
9-145 Engine/Propulsion

11. Check the CAN network L circuit. Measure the

resistance between terminal A2 of K20 engine
control module harness connector X2 and
terminal 19 of K102 vehicle stability control
module harness connector. Is it less than 1 Ω?
– If no, test the circuit for open circuit/high
resistance.
– If yes, go to the next diagnostic step.
12. Measure the resistance between terminal A2 of
K20 engine control module harness connector X2
and the ground. Is it infinite?
- If no, test the circuit for short to ground.
– If yes, go to the next diagnostic step.
13. Connect the battery negative cable and turn the
ignition switch to ON position.
14. Measure the voltage between terminal A2 of K20
engine control module harness connector X2 and
the ground. Is it 2.3 ± 0.1 V?
- If no, test the circuit for short to power supply.
– If yes, go to the next diagnostic step.
15. Turn the ignition switch to OFF position and
disconnect the battery negative cable.
16. Replace the engine control module and the
vehicle stability control module. Operate the
vehicle under conditions for running the DTC. Is
the DTC set?
– If no, diagnosis ends.
– If yes, install the original module back and
contact the technician.
Repair Instructions
• Engine Control Module Replacement
• Engine Control Module Programming and Setup
• Vehicle Stability Control Module Replacement
• Vehicle Stability Control Module Programming
and Setup
 9-146 Engine/Propulsion

9.2.4 Repair Instructions

9.2.4.1 Engine Control Module Replacement (1.5 T) (208535)

Engine Control Module Replacement

Callout Component Name
Preliminary Procedure
1. Disconnect the battery negative cable. Refer to “9.1.4.2 Battery Negative Cable Disconnection and
Connection”.
1 Engine control module electrical connector
Bolt (Qty.: 4)
Caution: Refer to “0.2.1.30 Fastener Caution”.
2
Tighten
8±2 N·m
Engine Control Module
3 Procedure
1. Program the new engine control module.
9-147 Engine/Propulsion

9.2.4.2 Engine Coolant Temperature Sensor Replacement (1.5T) (208536)

Engine Coolant Temperature Sensor Replacement

Callout Component Name
Preliminary Procedure
1. 1. Drain the cooling system. Refer to “9.4.4.16 Cooling System Draining and Filling”.
2. Disconnect the battery negative cable. Refer to “9.1.4.2 Battery Negative Cable Disconnection and
Connection”.
3. Disconnect the connector plug.
Engine coolant temperature sensor
Caution: Refer to “0.2.1.30 Fastener Caution”.
1
Tighten
18±2 N·m
 9-148 Engine/Propulsion

9.2.4.3 Fuel Injector Replacement (1.5T) (208556)

Fuel Injector Replacement

Callout Component Name
Preliminary Procedure
1. Disconnect the battery negative cable. Refer to “9.1.4.2 Battery Negative Cable Disconnection and
Connection”.
Fuel rail assembly fastening bolt (Qty.: 2)
Caution: Refer to “0.2.1.30 Fastener Caution”.
1
Tighten
18±2 N·m
Intake manifold mounting bolt (Qty.: 1)
Procedure
1. Loosen the intake manifold mounting nut.
2 2. Remove the fuel rail electrostatic ground wire.
Caution: Refer to “0.2.1.30 Fastener Caution”.
Tighten
25±2 N·m
9-149 Engine/Propulsion

Fuel Injector Replacement (Cont’d)

Callout Component Name
Preliminary Procedure
1. Disconnect the battery negative cable. Refer to “9.1.4.2 Battery Negative Cable Disconnection and
Connection”.
Fuel rail assembly
Procedure
1. Relieve the fuel pressure. Refer to “0.2.1.35 Fuel Pressure Caution”.
3
2. Remove the fuel filler tube.
3. Disconnect the electrical connector.
4. Remove the fuel rail assembly.
4 Fuel injector clip
5 Fuel injector
 9-150 Engine/Propulsion

9.2.4.4 Evaporative Emission Canister Replacement (1.5T) (208558)

Canister Assembly Replacement

Callout Component Name
Preliminary Procedure
Warning: Refer to “0.2.1.17 Actions to Take When Working with Fuel Warning”
Warning: Refer to “0.2.1.34 Fuel and Evaporative Emission Pipe Warning”.
Note: Ensure the joint is seated properly. A slight click sound can be heard as the quick - connect joint snaps in. After
installation, pull both ends of the joint gently to ensure it is connected firmly without falling off.
1. Lift the vehicle. Refer to “1.1.1.4 Lifting and Jacking the Vehicle”.
1 Absorption tube assembly
2 Desorption tube assembly II
Bolt cluster–canister assembly
Caution: Refer to “0.2.1.30 Fastener Caution”.
3
Tighten
Tighten the bolt to 5±1 N·m
4 Canister - to - air pipe
5 Canister assembly
9-151 Engine/Propulsion

9.2.4.5 Evaporative Emission Canister Purge Solenoid Valve Replacement (1.5T)

Canister Solenoid Valve Assembly Replacement

Callout Component Name
Canister solenoid valve assembly
Procedure
1 1. Disconnect the electrical connector.
2. Disconnect the evaporation emission loop hose.
3. Remove the canister solenoid valve assembly.
 9-152 Engine/Propulsion

9.2.4.6 Air Cleaner Element Replacement (1.5T) (208570)

Air Cleaner Element Replacement

Callout Component Name
Bolt (Qty.: 2)
Caution: Refer to “0.2.1.30 Fastener Caution”.
1
Tighten
1~2 N·m
2 Air cleaner upper housing
3 Air cleaner element
4 Air cleaner lower housing
9-153 Engine/Propulsion

9.2.4.7 Air Cleaner Assembly Replacement (1.5T) (208571)

Air Cleaner Replacement

Callout Component Name
Preliminary Procedure
1. Remove the intake air temperature/pressure sensor assembly (low pressure). Refer to “Intake Air Pressure
and Temperature Sensor Replacement”.
Air cleaner outlet duct clamp
1 Procedure
1. Loosen the clamp and disconnect it from the air cleaner.
Bolt (Qty.: 2)
Caution: Refer to “0.2.1.30 Fastener Caution”.
2
Tighten
9±1 N·m
Air cleaner assembly
Procedure
3
1. Move the air cleaner upwards with great effort to separate it from the holder and then take it out
from the inlet duct.
 9-154 Engine/Propulsion

9.2.4.8 Fuel Level Sensor Replacement (212024)

Removal Steps
1. Remove the fuel pump. Refer to “9.2.4.25 Fuel Tank Fuel Pump
Module Replacement”.
2. Disconnect the fuel level sensor electrical connector and the
harness strap.
3. Press the snapper (1) and move the fuel level sensor (2) upwards
to remove it.

Removal Steps
Note: If the sensor assembly is not installed properly, incorrect fuel
gauge reading can result.
1. Install the sensor assembly (2) to the fuel pump assembly.
2. Move the fuel level sensor downwards until the snapper (1) seats in
place.
3. Connect the fuel level sensor electrical connector and fix the
harness strap.
4. Install the fuel pump. Refer to “9.2.4.25 Fuel Tank Fuel Pump
Module Replacement”.
9-155 Engine/Propulsion

9.2.4.9 Throttle Body Assembly Replacement (1.5T) (208543)

Throttle Body Assembly Replacement

Callout Component Name
Preliminary Procedure
1. Disconnect the battery negative cable. Refer to “9.1.4.2 Battery Negative Cable Disconnection and
Connection”.
2. Disconnect the connector plug.
1 Clamp
Intercooler air outlet hose
Procedure
2
1. Loosen the clamp.
2. Pull out the intercooler air outlet hose.
Throttle body bolt (Qty.: 4)
Caution: Refer to “0.2.1.30 Fastener Caution”.
3
Tighten
10±2 N·m
4 Throttle body
 9-156 Engine/Propulsion

9.2.4.10 Crankshaft Position Sensor Replacement (1.5T) (208563)

Crankshaft Position Sensor Replacement

Callout Component Name
Crankshaft position sensor bolt
Caution: Refer to “0.2.1.30 Fastener Caution”.
Procedure
1
1. Remove the crankshaft position sensor bolt.
Tighten
10±2 N·m
Crankshaft position sensor
2 Tip
1. Disconnect all the electrical connectors when necessary.
9-157 Engine/Propulsion

9.2.4.11 Camshaft Position Sensor Replacement (1.5T) (208564)

Camshaft Position Sensor Replacement

Callout Component Name
Preliminary Procedure
1. Disconnect the battery negative cable. Refer to “9.1.4.2 Battery Negative Cable Disconnection and
Connection”.
2. Disconnect the connector plug.
Camshaft position sensor bolt (Qty.: 2)
1 Tighten
10±2 N·m
Camshaft position sensor
Procedure
2
1. Loosen and remove the bolt.
2. Take down the camshaft position sensor carefully.
 9-158 Engine/Propulsion

9.2.4.12 Fuel Filter Replacement (1.5T) (212302)

Fuel Filter Replacement

Callout Component Name
Preliminary Procedure
1.
Warning: Refer to “0.2.1.17 Actions to Take When Working with Fuel Warning”
Warning: Refer to “0.2.1.34 Fuel and Evaporative Emission Pipe Warning”.
Release the fuel system pressure. Refer to “0.2.1.35 Fuel Pressure Caution”.
2. Lift the vehicle. Refer to “0.2.1.14 Vehicle Lifting and Jacking Position Caution”.
Warning: Refer to “0.2.1.17 Actions to Take When Working with Fuel Warning”
Note: Ensure the joint is seated properly. After installation, pull both ends of the joint gently to ensure it
is connected firmly without falling off.
1
Fuel return hose assembly joint
Procedure
1. Disconnect the fuel return hose joint.
Fuel feed pipe assembly I joint
2 Procedure
1. Disconnect fuel feed pipe I joint.
9-159 Engine/Propulsion

Fuel Filter Replacement (Cont’d)

Callout Component Name
Preliminary Procedure
1.
Warning: Refer to “0.2.1.17 Actions to Take When Working with Fuel Warning”
Warning: Refer to “0.2.1.34 Fuel and Evaporative Emission Pipe Warning”.
Release the fuel system pressure. Refer to “0.2.1.35 Fuel Pressure Caution”.
2. Lift the vehicle. Refer to “0.2.1.14 Vehicle Lifting and Jacking Position Caution”.
Fuel feed pipe assembly II joint
3 Procedure
1. Disconnect fuel feed pipe II joint.
Fuel filter retaining bolt
Caution: Refer to “0.2.1.12 Fastener Caution”.
4
Tighten
1~2 N·m
5 Fuel filter
 9-160 Engine/Propulsion

9.2.4.13 Accelerator Pedal Replacement (1.5T)

Electronic Accelerator Pedal Assembly Replacement

Callout Component Name
1 Electronic accelerator pedal assembly electrical connector
Accelerator pedal retaining nut (Qty.: 3)
Caution: Refer to “0.2.1.12 Fastener Caution”.
2
Tighten
10±1 N·m
3 Electronic accelerator pedal assembly
9-161 Engine/Propulsion

9.2.4.14 Intake Air Pressure and Temperature Sensor Replacement (1.5T low - pressure)

Intake Air Temperature and Pressure Sensor Assembly (Low Pressure) Replacement
Callout Component Name
Bolt
Caution: Refer to “0.2.1.12 Fastener Caution”.
1
Tighten
2±0.5 N·m
2 Intake air temperature/pressure sensor assembly (low pressure)
 9-162 Engine/Propulsion

9.2.4.15 Intake Air Pressure and Temperature Sensor Replacement (1.5T high - pressure)

Intake Air Temperature/Pressure Sensor Assembly (High Pressure) Replacement

Callout Component Name
Bolt
Caution: Refer to “0.2.1.12 Fastener Caution”.
1
Tighten
10±2 N·m
2 Intake air temperature/pressure sensor assembly (high pressure)
9-163 Engine/Propulsion

9.2.4.16 Camshaft Position Actuator Solenoid Valve Replacement (1.5T) (249903)

Camshaft Position Phase Actuator Solenoid Valve Replacement

Callout Component Name
Preliminary Procedure
1. Disconnect the battery negative cable. Refer to “9.1.4.2 Battery Negative Cable Disconnection and
Connection”.
2. Disconnect the connector plug.
Camshaft phase actuator solenoid valve bolt (Qty.: 2)
1 Tighten
10±2 N·m
Camshaft phase actuator solenoid valve assembly (Qty.: 2)
Procedure
2
1. Loosen and remove the bolt.
2. Remove the camshaft phase actuator solenoid valve assembly carefully.
 9-164 Engine/Propulsion

9.2.4.17 Fuel Feed Pipe and Return Hose Replacement (1.5T)

Fuel Feed Pipe, Return Hose and Absorption Rubber Tube Replacement
Callout Component Name
Preliminary Procedure
Warning: Refer to “0.2.1.17 Actions to Take When Working with Fuel Warning” Warning: Refer to “0.2.1.34 Fuel
and Evaporative Emission Pipe Warning”.
Note: Ensure the joint is seated properly. A slight click sound can be heard as the quick - connect joint snaps in. After
installation, pull both ends of the joint gently to ensure it is connected firmly without falling off.
1. Remove the fuel tank. Refer to “9.2.4.26 Fuel Tank Replacement”.
1 Fuel feed pipe
2 Fuel return hose
3 Adsorption rubber tube
9-165 Engine/Propulsion

9.2.4.18 Spark Plug Inspection (1.5T) (208573)

Spark Plug Usage or water. A spark plug boot that is saturated
causes arcing to ground.
1. Ensure the correct spark plug is installed. An
incorrect spark plug can result in a driveability
fault, so confirm that the spark plug is correct.
2. Ensure that the spark plug is of the correct heat
range. An incorrect heat range can lead to the
following conditions:
○ Spark plug contamination—low spark plug
temperature
○ Damage to the spark plug and/or engine due
to advance ignition—high spark plug
temperature
Spark Plug Inspection
3. Inspect the insulator (2) for cracks. All or part of
the electrical charge may arc through the crack
instead of the electrodes (3, 4).

1. Inspect the terminal post (1) for damage.

○ Inspect for a bent or broken terminal post
(1).
○ Test for a loose terminal post (1) by twisting
and pulling the post. The terminal post (1)
should not move.

2. Inspect the insulator (2) for flashover or carbon

tracking (soot). This is caused by the electrical
charge traveling across the insulator (2) between
the terminal post (1) and ground. Inspect for the
following conditions:
○ Inspect the spark plug boot for damage.
○ Inspect the spark plug recess area of the
cylinder head for moisture, such as oil,
coolant,
 9-166 Engine/Propulsion

○ Incorrect combustion
○ Reduced ignition system voltage output
○ Weak coils
○ Worn ignition wires
○ Incorrect spark plug gap
○ Excessive idling or slow speeds under light
loads can keep spark plug temperatures so
low that normal combustion deposits may not
burn off.
3. Deposit fouling—oil, coolant, or additives that
include substances such as silicone (very white
coating) reduce the spark intensity. Most powdery
4. Inspect for evidence of improper arcing.
deposits will not affect spark intensity unless they
○ Measure the gap between the center form into a glazing over the electrode.
electrode (4) and the side electrode (3)
terminals. An excessively wide electrode gap
can prevent correct spark plug operation.
○ Inspect for the correct spark plug torque.
Insufficient torque can prevent correct spark
plug operation. An over torqued spark plug
can cause the insulator (2) to crack.
○ Inspect for signs of electrical leakage that
occurred near the insulator tip instead of the
center electrode (4).
○ Inspect for a broken or worn side electrode
(3).
○ Inspect for a broken, worn, or loose center
electrode (4) by shaking the spark plug.
5. A rattling sound indicates internal damage.
6. A loose center electrode (4) reduces the spark
intensity.
○ Inspect for bridged electrodes (3, 4). Carbon
deposits on the electrodes (3, 4) reduce or
even eliminate the gap.
○ Inspect for worn or missing platinum pads (if
equipped) on the electrodes (3, 4).
○ Inspect the electrodes for excessive fouling.
○ Inspect the spark plug recess area of the
cylinder head for debris. Dirty or damaged
threads can cause the spark plug not to seat
correctly during installation.
Spark Plug Visual Inspection
1. Normal operation—brown to grayish - tan with
small amounts of white powdery deposits are
normal combustion by - products from fuels with
additives.
2. Carbon fouled—dry, fluffy black carbon, or soot
caused by the following conditions:
○ Rich fuel mixtures
○ Leaking fuel injectors
○ Excessive fuel pressure
○ Restricted air cleaner element
9-167 Engine/Propulsion

9.2.4.19 Knock Sensor Replacement (1.5T) (208565)

Knock Sensor Replacement

Callout Component Name
Preliminary Procedure
1.
Warning: Refer to “0.2.1.9 Knock Sensor Service Warning”.
Disconnect the battery negative cable. Refer to “9.1.4.2 Battery Negative Cable Disconnection and
Connection”.
Knock sensor bolt
Caution: Refer to “0.2.1.12 Fastener Caution”.
1
Tighten
20±5 N·m
2 Knock sensor
 9-168 Engine/Propulsion

9.2.4.20 Fuel Tank Filler Pipe Replacement (208550)

Fuel Tank Filler Pipe Replacement

Callout Component Name
Preliminary Procedure
Caution: Refer to “0.2.1.30 Fastener Caution”.
1. Lift the vehicle. Refer to “1.1.1.4 Lifting and Jacking the Vehicle”.
1 Fuel filler pipe cover
Bolt (Qty.: 3)
2 Tighten
7.5±1.5 N·m
3 Strap
4 Retainer
5 Air pipe clamp
6 Fuel filler pipe clamp
7 Air pipe
8 Fuel filler pipe
9-169 Engine/Propulsion

9.2.4.21 Air Cleaner Outlet Duct Replacement (1.5T) (208569)

Air Cleaner Outlet Duct Replacement

Callout Component Name
1 Clamp
2 Clamp
3 Air cleaner outlet duct
 9-170 Engine/Propulsion

9.2.4.22 Fuel Pressure Relief (1.5T) (208545)

Warning: Remove the fuel tank cap and relieve the
fuel system pressure before servicing the fuel system
in order to reduce the risk of personal injury. After you
relieve the fuel system pressure, a small amount of
fuel may be released when servicing the fuel lines, the
fuel injection pump, or the connections. In order to
reduce the risk of personal injury, cover the fuel
system components with a shop towel before
disconnection. This will catch any fuel that may leak
out. After disconnection, place a cloth in an approved
container.
1. Loosen the fuel filler cap to release the vapor
pressure in the fuel tank.
2. Remove the fuel pump fuse from the engine
compartment fuse block.
3. Turn the ignition switch to ON position and allow
the engine to idle until the engine stops.
4. Turn the ignition switch to OFF position and use
the ignition key to start the engine again for 3
minutes to verify that there is no fuel.
5. Tighten the fuel filler cap.
9-171 Engine/Propulsion

9.2.4.23 Fuel System Cleaning (1.5T) (208554)

Note: If the fuel filter is blocked, inspect and clean
inside of the fuel tank when necessary.
Drain the fuel tank. Refer to “9.2.4.24 Fuel Tank
Draining”.
2. Remove the fuel pump module assembly. Refer
to “9.2.4.25 Fuel Tank Fuel Pump Module
Replacement”.
3. Inspect the fuel pump module filter screen. If the
fuel filter screen is contaminated, replace the fuel
pump assembly.
Note: When cleaning the fuel tank, handle the fuel -
water mixture as dangerous goods. When handling the
fuel - water mixture, follow all regional applicable laws
and regulations.
4. Flush the fuel tank with warm water.
5. Discharge the water from the fuel conveyor
assembly opening in the fuel tank. Shake the fuel
tank to confirm that water in the fuel tank has
been fully discharged.
6. Wait until the fuel tank fully dries before
assembling again.
7. Disconnect the fuel feed pipe on engine fuel
distribution pipe. Refer to “9.2.4.17 Fuel Feed
Pipe and Return Hose Replacement”.
Note: Use oil - free compressed air to blow the fuel
pipe dry only.
8. Clean the fuel pipe by blowing compressed air in
the direction opposite to the fuel flow.
Warning: Refer to “0.2.1.34 Fuel and Evaporative
Emission Pipe Warning”.
Note: Ensure the joint is seated properly. After
installation, pull both ends of the joint gently to ensure
it is connected firmly without falling off.
9. Connect the fuel feed pipe to the engine fuel
distribution pipe. Refer to “9.2.4.17 Fuel Feed
Pipe and Return Hose Replacement”.
10. Install the fuel pump assembly. Refer to “9.2.4.25
Fuel Tank Fuel Pump Module Replacement”.
 9-172 Engine/Propulsion

9.2.4.24 Fuel Tank Draining (1.5T) (208547)

Warning: Refer to “0.2.1.33 Gasoline/Gasoline Vapors Warning”.
Caution: Never drain or store fuel in an open container. Do use an
appropriate fuel storage container to reduce the risk of fire and
explosion.
1. Remove the fuel filler cap.
2. Use a long screwdriver to open the fuel filler cap and stretch a hose
out to bottom of the fuel tank.
3. Use a pneumatic pump to drain the fuel to an appropriate gasoline
container.
4. Turn and pull the fuel suction pipe at the same time to take it out
from the fuel tank.
9-173 Engine/Propulsion

9.2.4.25 Fuel Tank Fuel Pump Module Replacement (1.5T) (208552)

Removal Steps
1. Release the fuel system pressure. Refer to “0.2.1.35 Fuel Pressure
Caution”.
Warnings: Refer to “0.2.1.42 Battery Disconnect Warning”.
2. Disconnect the battery negative cable.
3. Remove the second - row seats.
4. Cut the carpet along the die marks at the fuel pump view port.

5. Remove the fuel pump access cover carefully to prevent

deformation.
6. Disconnect fuel pump assembly electrical connector.
Warnings: Refer to “0.2.1.42 Battery Disconnect Warning”.
7. Disconnect fuel feed pipe I.
8. Disconnect the fuel tank fuel return hose.
9. Remove the bolts diagonally connecting the fuel pump and the fuel
tank.

10. Remove the fuel tank fuel pump module.

 9-174 Engine/Propulsion

Installation Procedure
1. Install the fuel pump assembly and tighten the fuel pump bolts
diagonally to 4±1 N·m.

Note: Ensure the joint is seated properly. After installation, pull both
ends of the joint gently to ensure it is connected firmly without falling off.
2. Connect fuel feed pipe I.
3. Connect the fuel tank fuel return hose.
4. Connect fuel pump assembly electrical connector.
5. Apply adhesive and then install the fuel pump access cover.

6. Glue the cut carpet with foam glue or double faced adhesive tape
that is applicable to knitwear.
7. Install the second - row seats.
8. Connect the battery negative cable.
9-175 Engine/Propulsion

9.2.4.26 Fuel Tank Replacement (1.5T) (208548)

Removal Steps
Caution: If the vehicle is lift by a jack, an additional support should be
used to replace the fuel tank. Neglecting the above caution can lead to
vehicle damage and serious personal injuries or even death.
Note: Do not try to straighten a twisted fuel pipe in case the vehicle is
damaged. Replace it instead.
Do not try to repair any fuel pipe section. Replace the whole pipe as
one.
To prevent dust and other foreign materials from entering through the
open pipeline or other passages, cover the pipe fittings and all holes
while working with the fuel system.
Keep the fuel system clean while servicing any fuel system part. While
servicing any gasoline - related component, allow no contact of any fire
or heat source with it.
1. Release the fuel system pressure. Refer to “9.2.4.22 Fuel Pressure
Relief”.
2. Drain the fuel remaining in the fuel tank. Refer to “9.2.4.24 Fuel
Tank Draining”.
3. Lift the vehicle. Refer to “1.1.1.4 Lifting and Jacking the Vehicle”.
4. Loosen the fuel filler hose clamp (1) and draw fuel filler hose (2)
out.
5. Disconnect the fuel feed pipe (3), fuel return hose (4) and
desorption tube (5) which are connected to the canister and the
absorption tube (6) and desorption tube (7) which are connected to the
oil filter.
6. Support the fuel tank with the hydraulic jack or an appropriate
device. Remove the four fuel tank retaining bolts and lower down the
fuel tank.
7. Disconnect the fuel pump assembly wiring plug. Lower down the
hydraulic jack and take the fuel tank out.
 9-176 Engine/Propulsion

8. Remove the fuel tank assembly (1). Refer to “Use a Hand Pump to
Extract Fuel Remaining in Fuel Tank”.
9. Remove the fuel filter.
9-177 Engine/Propulsion

Installation Procedure
1. Install the fuel filter.
2. Install the fuel pump assembly. Refer to “9.2.4.25 Fuel Tank Fuel
Pump Module Replacement”.
3. Jack the fuel tank up with the hydraulic jack or an appropriate
device and connect the fuel pump wiring plug.
Caution: Refer to “0.2.1.30 Fastener Caution”.

4. Install the 4 fuel tank fastening bolts and tighten them to 23±3 N·m.

4. Connect the fuel feed pipe (6), fuel return hose (7) and desorption
tube (5) to the oil filter and connect the absorption tube (5) and
desorption tube (7) to the canister respectively.
Note: Ensure the joint is seated properly. A slight click sound can be
heard as the quick - connect joint snaps in. After installation, pull both
ends of the joint gently to ensure it is connected firmly without falling off.
5. Install the fuel filler hose (2) to the fuel tank and tighten clamp (1).
6. Connect the fuel feed pipe (3), fuel return hose (4) and desorption
tube (5) to the canister and connect the absorption tube (6) and
desorption tube (7) to the oil filter.
7. Lower the vehicle and add fuel.
8. Inspect for fuel leakage.
 9-178 Engine/Propulsion

9.2.4.27 Heated Oxygen Sensor Replacement - Sensor 1 (1.5T) (208541)

Front Oxygen Sensor Replacement

Callout Component Name
Preliminary Procedure
1. Disconnect the battery negative cable. Refer to “9.1.4.2 Battery Negative Cable Disconnection and
Connection”.
Front oxygen sensor
Procedure
Note: Causes of a fouled oxygen sensor can be incorrect use of room temperature vulcanizing (RTV)
sealant (unsafe for the oxygen sensor) or excessive consumption of engine coolant or engine oil.
Remove the heated oxygen sensor and inspect the area exposed to the exhaust flow for
contaminants. If the sensor is fouled, the area exposed to the exhaust flow will have a white powdery
coating. If the heated oxygen sensor is silicon - fouled, a high but false signal voltage which gives a
rich exhaust
1 indication can result. In this case, the control module reduces the amount of fuel delivered to the
engine, causing a driveability fault. First eliminate the source of pollutants before replacing the
oxygen sensor.
Special Tools
PT - 0070/PT - 0098 Oxygen Sensor Remover
1. Disconnect the front oxygen sensor electrical connector.
Caution: Refer to “0.2.1.30 Fastener Caution”.
Tighten
50±10 N·m.
9-179 Engine/Propulsion

9.2.4.28 Heated Oxygen Sensor Replacement - Sensor 2 (1.5T) (208541)

Rear Oxygen Sensor Replacement

Callout Component Name
Preliminary Procedure
1. Disconnect the battery negative cable. Refer to “9.1.4.2 Battery Negative Cable Disconnection and
Connection”.
Rear oxygen sensor
Procedure
Note: Causes of a fouled oxygen sensor can be incorrect use of room temperature vulcanizing (RTV)
sealant (unsafe for the oxygen sensor) or excessive consumption of engine coolant or engine oil.
Remove the heated oxygen sensor and inspect the area exposed to the exhaust flow for contaminants.
If the sensor is fouled, the area exposed to the exhaust flow will have a white powdery coating. If the
heated oxygen sensor is silicon - fouled, a high but false signal voltage which gives a rich exhaust

indication can result. In this case, the control module reduces the amount of fuel delivered to the
2 engine, causing a driveability fault. First eliminate the source of pollutants before replacing the oxygen
sensor.
Special Tools
PT - 0070/PT - 0098 Oxygen Sensor Remover
Procedure
1. Lift the vehicle. Refer to “1.1.1.4 Lifting and Jacking the Vehicle”.
2. Disconnect the electrical connector.
Caution: Refer to “0.2.1.30 Fastener Caution”.
Tighten
50±10 N·m.
 9-180 Engine/Propulsion

9.2.4.29 Ignition Coil Replacement (1.5T) (208560)

Ignition Coil Replacement

Callout Component Name
Preliminary Procedure
1. Disconnect the battery negative cable. Refer to “9.1.4.2 Battery Negative Cable Disconnection and
Connection”.
Ignition coil bolt (Qty.: 4)
Procedure
1. Disconnect the ignition coil wiring harness.
1 2. Screw off the ignition coil bolts.
Caution: Refer to “0.2.1.30 Fastener Caution”.
Tighten
10±2 N·m
Ignition coil
2 Procedure
1. Pull the ignition coil upwards and out with great effort.
9-181 Engine/Propulsion

9.2.4.30 Spark Plug Replacement (1.5T) (208562)

Spark Plug Replacement

Callout Component Name
Preliminary Procedure
1. Disconnect the battery negative cable. Refer to “9.1.4.2 Battery Negative Cable Disconnection and
Connection”.
2. Remove the ignition coil. Refer to “9.2.4.29 Ignition Coil Replacement”.
Spark plug (Qty.: 4)
Caution: Refer to “0.2.1.30 Fastener Caution”.
1
Tighten
23±3 N·m
 9-182 Engine/Propulsion

9.2.5 Description and Operation in the crankcase is absorbed into the intake system
and burned during the normal combustion process.
9.2.5.1 Air Intake System Description (1.5T)
The blown - by gas volume flowing into the intake
(210571)
manifold is accurately controlled to keep the idling
The positive crankcase ventilation (PCV) system is quality. Be sure to use the correct positive crankcase
used to make full use of the vapor in the crankcase. ventilation valve which has been calibrated properly.
Fresh air from the air cleaner enters the crankcase. The relationship between the blown - by gas flow and
The fresh air mixes with the blow - by gases and then engine manifold vacuum degree is shown in the
enters the intake manifold via the vacuum hose. following table:
Inspect the hose and clip regularly. Replace the
Positive crankcase ventilation valve operation:
crankcase ventilation component if necessary.
Restricted or blocked positive crankcase ventilation Positive
hose may cause the following conditions: Manifold vacuum crankcase Blown - by gas
1. Rough idle degree ventilation valve flow
opening
2. Stalling or slow idle speed
Low Large High
3. Oil leaks High Small Low
4. Oil in the air cleaner
Consequence of abnormal operation:
5. Sludge in the engine
A plugged valve or hose may cause the following
Positive crankcase ventilation hose leakage may conditions:
cause the following conditions:
1. Rough idle
1. Rough idle
2. Stalling or slow idle speed
2. Engine stalling
3. Extremely high engine crankcase pressure
3. High idle speed
4. Oil leaks
9.2.5.2 Crankcase Ventilation System
Description (1.5T) (210572) 5. Oil in the air cleaner
The compressed combustion gas which has entered 6. Sludge in the engine
the crankcase through the piston ring is called the 7. Oil consumption
blown - by gas. The blow - by gas contains a large 8. Excessive exhaust emission
amount of carbon monoxide and hydrocarbons. The
positive crankcase ventilation (PCV) system prevents
the blown - by gas from being discharged into the
atmosphere. The positive crankcase ventilation
system leads blow - by gas from the crankcase back to
the intake system, so that the blown - by gas enters
the combustion chamber for combustion. The positive
crankcase ventilation system consists of the following
components:
1. Positive crankcase ventilation valve
2. Crankcase vent pipe or air inlet duct
3. Intake air filter or separator (if used)
4. Hose and joint
Operation
The main control device for blown - by gas from the
engine crankcase is the positive crankcase ventilation
valve. The positive crankcase ventilation valve
calculates the blown - by gas flow according to the
manifold vacuum signal.
The positive crankcase ventilation valve part below the
lower O - ring is exposed in the manifold vacuum; the
part between the lower and upper O - rings is exposed
in the crankcase gas. The positive crankcase
ventilation valve allows some vacuum pressure to
pass through the orifice in the valve, forming a low -
pressure state in the crankcase. Then, blown - by gas
9-183 Engine/Propulsion
A leaking valve or hose may cause the following
conditions:
1. Rough idle
2. Stalling
3. High idle speed
4. Abnormal engine crankcase pressure
5. Excessive exhaust emission
9.2.5.3 Engine Control Components Description
(1.5T)
Coolant Temperature Sensor Description
Function: Measure the coolant temperature and sends
corresponding electric signal to ECU. ECU judges the
engine operating condition based on this signal and
corrects the basic fuel injection quantity accordingly.
Working principle: As the resistance of the
temperature sensor changes as the coolant
temperature changes, the voltage on the signal line
changes accordingly. The lower the temperature, the
higher the resistance and the output voltage.
Canister Solenoid Valve Description
Working principle: After the engine stalls, the gasoline
vapor and fresh air mix and remains in the canister; as
the engine restarts, the solenoid valve installed
between the canister and the intake manifold opens,
the gasoline vapor in the canister is brought to the
cylinder by the clean air under the function of the
vacuum in the intake pipe and participates in
combustion there. In this way, not only emission but
also fuel consumption are reduced.
Camshaft Position Sensor Description
The sensor collects valving camshaft position signal
and inputs it to ECU so that ECU identifies the
compression top dead center of cylinder 1 and carries
out sequential fuel injection control, ignition timing
control and knock control.
Crankshaft Position Sensor Description
Function: The sensor detects crankshaft rotation
speed and crankshaft angle signals and it inputs such
signals to ECU so that ECU can decide the ignition
and injection time.
Working principle: Hall voltage control is realized via
control of the magnetic field intensity and
corresponding frequency signals are output. The
existence of signals depends on continuity of the
magnetic field.
Intake Air Pressure Sensor Description
The intake air pressure sensor detects the absolute
pressure change in the intake manifold according to
the engine speed and load, converts the speed and
load to a signal voltage and then sends it to the
electronic control unit (ECU) which controls the basic
fuel injection quantity based on such voltage. As a
result, fuel is saved.
Intake Air Temperature Sensor Description
The sensor detects the intake air temperature based
on which ECM calculates the true intake air quantity
and corrects the basic fuel injection quantity
accordingly.
Working principle: The temperature - sensing element
is a NTC (negative temperature coefficient) thermistor
the resistance of which decreases as the temperature
increases and vice versa. ECM corrects the basic fuel
injection quantity based on the intake air temperature
signal. Correction is reversely proportional to the
temperature.
Oxygen Sensor Description
The oxygen sensor is designed to monitor the oxygen
content in the exhaust and sends information on the
air - fuel ratio to the electronic control module (ECM).
As the mixture becomes rich, data is sent to ECM and
ECM reduces the fuel injection quantity; on the
contrary, as the mixture becomes lean, the ECM
increases the fuel injection quantity.
VVT System Description
VVT is designed to adjust the intake (exhaust) volume,
valve opening and closing time so that the entered
airflow reaches the optimum value to improve the
combustion efficiency.
Knock Sensor Description
The sensor converts engine knock signal to electric
signal and sends it to ECU. ECU corrects the ignition
advance angle based on this knock signal. In this way,
the ignition advance angle is kept optimum, greatly
promoting the fuel combustion efficiency and driving
safety.
ECU detects knocking while the engine is running and
adjusts the ignition timing according to the signal it
receives from the knock sensor so that the engine is
working in the critical detonation state.
9.2.5.4 Throttle Actuator Control (TAC) System
Description
Electronic Throttle Description
The accelerator pedal position sensor produces a
corresponding voltage signal and inputs it to the
throttle control unit. The unit calculates the best
throttle opening and in this way, the throttle opening is
accurately controlled, fuel economy is improved and
emission is reduced.
 9-184 Engine/Propulsion

9.2.6 Special Tools and Equipment

9.2.6.1 Special Tools (1.5T) (208572)
Illustration Tool Number/Description

PT - 0070
PT - 0098
Oxygen sensor
remover/installer
9-185 Engine/Propulsion

9.4 Engine Cooling System

9.4.1 Specifications
9.4.1.1 Fastener Tightening Specifications
Fastener Specifications
Specification
Application
Metric
Electric coolant fan retaining bolt (/B15T) 4.5±0.5 N·m
Radiator bolt (/B15T) 7.5±1.5 N·m
Surge tank retaining bolt (/B15T) 4.5±0.5 N·m
Surge tank bracket bolt (B15T) 8±1 N·m
 9-186 Engine/Propulsion

9.4.1.2 Approximate Fluid Capacities (258271)

Engine Cooling System Capacity
Application Specification
Coolant specifications Ethylene glycol antifreezing fluid Engine model
Coolant capacity 7.35±0.25 L /B15T
9-187 Engine/Propulsion

9.4.1.3 Temperature Versus Resistance (210513)

Temperature Resistance
150°C (302°F) 42 to 44 Ω
140°C (284°F) 53 to 57 Ω
130°C (266°F) 68 to 72 Ω
120°C (248°F) 88 to 92 Ω
110°C (230°F) 114 to 120 Ω
100°C (212°F) 151 to 159 Ω
90°C (194°F) 203 to 215 Ω
80°C (176°F) 275 to 293 Ω
70°C (158°F) 379 to 405 Ω
60°C (140°F) 532 to 572 Ω
50°C (122°F) 762 to 824 Ω
45°C (113°F) 921 to 997 Ω
40°C (104°F) 1118 to 1212 Ω
35°C (95°F) 1366 to 1484 Ω
30°C (86°F) 1683 to 1829 Ω
25°C (77°F) 2088 to 2266 Ω
20°C (68°F) 2608 to 2828 Ω
15°C (59°F) 3289 to 3567 Ω
10°C (50°F) 4182 to 4532 Ω
5°C (41°F) 5356 to 5800 Ω
0°C (32°F) 6914 to 7484 Ω
- 5°C (23°F) 8994 to 9732 Ω
- 10°C (14°F) 11796 to 12762 Ω
- 15°C (5°F) 15589 to 16871 Ω
- 20°C ( - 4°F) 20791 to 22517 Ω
- 30°C ( - 22°F) 37991 to 41273 Ω
- 40°C ( - 40°F) 72230 to 78834 Ω
 9-188 Engine/Propulsion

9.4.2 Schematic and Routing Diagrams

9.4.2.2 B15T Engine Cooling System Schematics
9-189 Engine/Propulsion

9.4.3 Diagnostic Information and Procedures

9.4.3.1 Engine Fails to Reach Normal Operating Temperature (37221)
Engine Fails to Reach Normal Operating Temperature
Procedure Operation Yes No
Check the coolant level in the radiator surge tank.
1 Refer to “9.4.4.16 Cooling System Draining and Go to Step 3. Go to Step 2.
Filling”. Is the coolant at the correct level?
Add coolant into the radiator surge tank if
2 necessary. Does the engine still fail to reach Go to Step 3.
normal operating temperature?
Check the coolant passage for blockage. Is any
3 Go to Step 4. Go to Step 5.
coolant passage blocked?
Flush the cooling system or check the radiator flow.
4 Does the engine still fail to reach normal operating Go to Step 5.
temperature?
Check the thermostat to see if it is installed
incorrectly, or caught or stuck open.
5 Go to Step 6.
Is the thermostat installed incorrectly, or caught or
stuck open?
Replace the thermostat.
6 Does the engine still fail to reach normal operating The system is normal.
temperature?
 9-190 Engine/Propulsion

9.4.3.2 Engine Overheating (37218)

Engine Overheating
Procedure Operation Yes No
Definition: Either of the following conditions indicate a probable engine overheat condition: the engine temperature
indicator keeps ON; the engine temperature gauge is in the red (overheat) zone; engine coolant overflows from the
surge tank onto the ground while the engine is running.
Check for coolant loss. Refer to “9.4.3.3 Loss of
1 Coolant”. Go to Step 2. Go to Step 3.
Is coolant loss discovered?
Add coolant to the system until the coolant reaches
2 Go to Step 3. The system is normal.
the specified level. Does the engine still overheat?
Check the surge tank hose for twisting or pinching,
3 especially that at the radiator. Go to Step 4. Go to Step 5.
Is the surge tank hose twisted or pinched?
1. Rearrange the hose to straighten the twist.
4 2. Replace the hose if necessary. Go to Step 5. The system is normal.
Does the engine still overheat?
Check the radiator air seal or deflector for
5 looseness, missing or damage. Is the radiator air Go to Step 6. Go to Step 7.
seal or deflector loose, missing or damaged?
Repair the loose, missing or damaged radiator air
6 seal or deflector. Go to Step 7. The system is normal.
Does the engine still overheat?
Check the coolant concentration.
7 Go to Step 9. Go to Step 8.
Is the coolant concentration test result correct?
Replace the coolant if necessary.
8 Go to Step 9. The system is normal.
Does the engine still overheat?
Note: Use the correct pressure cap.
9 Check the system for pressure loss. Go to Step 10. Go to Step 11.
Does pressure loss exist?
Repair all leaks if necessary.
10 Go to Step 11. The system is normal.
Does the engine still overheat?
Check the engine coolant temperature sensor for
faults.
11 Go to Step 12. Go to Step 13.
Does any engine coolant temperature sensor fault
exist?
12 Replace the engine coolant temperature sensor. Go to Step 13. The system is normal.
Check the radiator for flow blockage or bent
13 cooling fins. Go to Step 14. Go to Step 15.
Does flow blockage or bent cooling fins exist?
9-191 Engine/Propulsion

Engine Overheating (Cont’d)

Procedure Operation Yes No
1. Remove or relocate the aftermarket
component that obstructs air flow to the radiator.
14 Go to Step 15. The system is normal.
2. Clean the debris on the radiator core. Does
the engine still overheat?
Check the cooling system passage for blockage. Is
15 Go to Step 16. Go to Step 17.
the cooling system passage blocked?
1. Remove all the obstructions.
2. Flush the cooling system if necessary.
16 Go to Step 17. The system is normal.
3. Fill the coolant again. Does the engine still
overheat?
Check the coolant fan to see if it does not operate.
17 Go to Step 18. Go to Step 19.
Doesn’t the coolant fan operate?
Replace the coolant fan. Refer to “Engine Coolant
18 Fan Replacement”. Go to Step 19. The system is normal.
Does the engine still overheat?
Check the thermostat to see if it is stuck closed.
19 Go to Step 20. Go to Step 21.
Is the thermostat stuck closed?
20 Replace the thermostat. Go to Step 21. The system is normal.
Inspect the water pump for a fault. The impeller
21 blade may have been corroded and broken. Go to Step 22. The system is normal.
Does any water pump fault exist?
Replace the water pump.
22 - The system is normal.
Does the engine still overheat?
 9-192 Engine/Propulsion

9.4.3.3 Loss of Coolant (37222)

Loss of Coolant
Procedure Operation Yes No
Definition: Loss of coolant in the coolant system internally or externally.
Go to “9.4.3.4
Is the diagnosis performed according to
1 Go to Step 2. Symptoms - Engine
“Symptoms” or the instructions on other scam tool?
Cooling”.
Repair all the existing DTCs. Refer to “6.2.2.7
2 Diagnostic System Check - Vehicle”. Is the Go to Step 3. -
operation completed?
Check the coolant level.
3 Go to Step 5. Go to Step 4.
Is the coolant at the correct level?
Fill the cooling system to the correct level. Refer to
4 “9.4.4.16 Cooling System Draining and Filling”. Go to Step 5. -
Is the operation completed?
Engine overheating can cause loss of coolant.
5 Go to Step 18. Go to Step 6.
Does the engine overheat?
1. Idle the engine at the normal operation
temperature.
2. Inspect for heavy white smoke coming out of
6 Go to Step 7. Go to Step 8.
the exhaust
pipe. Is heavy white smoke present from the
exhaust pipe?
1. Coolant in the exhaust system creates a
distinctive, burning coolant odor in the exhaust
pipe.
2. Condensation in the exhaust system can
7 cause an odorless Go to Step 20. Go to Step 8.

white smoke during engine warm up.

Does the white smoke have a burning coolant type
odor?
Visually inspect the hose, pipe and hose clamp.
8 Go to Step 20. Go to Step 9.
Does the hose, clamp or pipe leak?
Visually inspect the following components:
Cylinder block heater
Coolant pressure cap
Cast hole plug
Throttle valve
9 Engine block Go to Step 20. Go to Step 10.
Intake manifold
Radiator
Thermostat housing
Water pump
Is any of the listed components leaking?
9-193 Engine/Propulsion

Loss of Coolant (Cont’d)

Procedure Operation Yes No
Pressure test the coolant pressure cap.
10 Go to Step 11. Go to Step 15.
Does the coolant pressure cap hold pressure?
Inspect for the following conditions:
A coolant smell inside the vehicle.
Coolant in the HVAC module drain tube.
11 Go to Step 20. Go to Step 12.
Coolant on the vehicle floor covering near the
HVAC module.
Is coolant present?
Inspect the underside of the engine oil filler cap for
12 a gray/white milky substance. Go to Step 13. Go to Step 15.
Is there a milky substance under the oil filler cap?
Inspect the engine oil level indicator for a
gray/white milky substance.
13 Go to Step 16. Go to Step 14.
Is there a milky substance on the engine oil level
indicator?
Inspect the automatic transmission fluid level
indicator (if equipped) for a gray/white milky
14 substance. Go to Step 17. Go to Step 21.
Is there a milky substance on the automatic
transmission fluid level indicator?
Replace the coolant pressure cap.
15 Go to Step 21. -
Is repair completed?
1. Replace the radiator. Refer to “9.4.4.20
Radiator Replacement”.
16 Go to Step 21. -
2. Replace the engine oil and the oil filter. Is
repair completed?
1. Replace the radiator. Refer to “9.4.4.20
Radiator Replacement”.
17 Go to Step 21. -
2. Repair the automatic transmission. Is repair
completed?
Repair the engine overheating condition. Refer to
18 “9.4.3.2 Engine Heating”. Go to Step 21. -
Is repair completed?
Repair the engine internal coolant leak. Refer to
“9.5.3.6 Coolant in Combustion Chamber” or
19 Go to Step 21. -
“9.5.3.7 Coolant in Engine Oil”. Is repair
completed?
 9-194 Engine/Propulsion

Loss of Coolant (Cont’d)

Procedure Operation Yes No
Repair or replace the leaking component. Refer to
20 Go to Step 21. -
the appropriate repair.
Run the system and verify the repair result.
21 The system is normal. Go to Step 2.
Is any fault found and removed?
9.4.3.4 Symptoms - Engine Cooling (37429) pavement, vibration or physical movements of a
Important Preparations before Starting component. Refer to the following for a list of
issues that may cause an intermittent condition:
Perform the following steps before using the
“Symptoms” diagnosis: 2. Moisture and water intrusion in connectors,
terminals, and components
1. Perform “6.2.2.7 Diagnostic System Check -
Vehicle” and confirm all the following items: 3. Incomplete connector mating
– Ensure that the engine control module (ECM) 4. Poor terminal contact
and the malfunction indicator lamp (MIL) are 5. High circuit or component resistance—High
operating correctly. resistance can include any resistance, regardless
– Ensure that there are no DTCs stored. of the amount, which can interrupt the operation
of the component.
– The scan tool data is within the normal
operating range. Refer to “6.1.1.1 Control 6. Harness that is too short or tight
Module References” for scan tool 7. High or low ambient temperature
information. 8. High or low engine coolant temperature
2. Verify the customer concern. 9. High underhood temperature
3. Perform “Visual/Physical Inspection” in this 10. Heat buildup in component or circuit due to circuit
resistance, poor terminal contact, or high
section. “Visual/Physical Inspection” is extremely electrical load
important, and can lead to correcting a condition
without additional testing. It may also help
determine the cause of an intermittent condition.
4. Confirm the correct symptoms. Perform symptom
- related testing and inspection.
Visual/Physical Inspection
Many symptom procedures require careful visual and
physical inspection. This can help correct a condition
without additional testing and save time. The
inspection should include the following locations:
1. Ensure that the control module grounds are clean,
tight, and correctly located.
2. Inspect the cooling system hose for cracks, kinks
and correct connection. Thoroughly inspect for
any type of leakage or blockage.
3. Inspect the radiator and HVAC condenser for dirt
or blockage.
4. Inspect for aftermarket devices which could
affect the operation of the cooling system.
5. Inspect the accessible system components or the
visible system components for obvious damage
or for obvious conditions which can cause the
symptom.
6. Inspect the surge tank for the proper coolant
level.
Identifying Intermittent Conditions
1. Many intermittent conditions occur as the harness
or connector moves due to engine torque, rough
9-195 Engine/Propulsion

11. High or low system voltage

12. High vehicle load conditions
13. Rough road surfaces
14. Electromagnetic interference (EMI)/circuit
interference from relays, solenoid valves or other
electrical surge
15. Incorrect installation of aftermarket, add on

accessories. If the condition is determined to be

intermittent, refer to “11.3.4.7 Testing for
Intermittent Conditions and Poor
Connections”.
Symptom List
Refer to a symptom diagnostic procedure from the
following list in order to diagnose the symptom:
1. Engine overheating
2. Loss of coolant
3. Engine fails to reach normal operating
temperature
4. Pressure cap test
 9-196 Engine/Propulsion

9.4.4 Repair Instructions

9.4.4.1 Engine Coolant Fan Replacement (B15T) (37302)

Engine Coolant Fan Replacement (B15T)

Callout Component Name
Preliminary Procedure
1. Disconnect the radiator water inlet hose from the radiator. Refer to “Radiator Inlet Hose Replacement”.
2. Disconnect the surge tank overflow hose. Refer to “Radiator Surge Tank Overflow Hose Replacement
(B15T)”.
Coolant fan retaining bolt (Qty.: 4)
Caution: Refer to “0.2.1.30 Fastener Caution”.
1
Tighten
4.5±0.5 N·m
Electric coolant fan assembly
2 Procedure
Disconnect the electric coolant fan harness connector.
9-197 Engine/Propulsion

9.4.4.3 Radiator Air Side Baffle and Deflector Replacement (B15T) (69785)

Radiator Air Side Baffle and Deflector Replacement (B15T)

Callout Component Name
Preliminary Procedure
1. Remove the front grille upper cover. Refer to “2.1.2.16 Front Grille Upper Cover Replacement”.
Radiator air deflector ejector pin (Qty.: 4)
Procedure
1 1. For removal, first remove the upper ejector pins, and then turn the deflector to the middle direction
and finally remove the lower ejector pins.
2. For installation, install the lower ejector pins first and then install the upper ones.
2 Radiator air deflector (left)
3 Radiator air deflector (right)
 9-198 Engine/Propulsion

9.4.4.5 Radiator Surge Tank Overflow Hose Replacement (B15T)

Radiator Surge Tank Overflow Hose Replacement (B15T)

Callout Component Name
Preliminary Procedure
1. Remove the cover plate assembly at left side of engine compartment. Refer to “2.1.2.17 Engine Compartment
Side Cover Replacement”.
1 Oveflow hose clip (Qty.: 2)
Surge tank overflow hose
2
Note: Add appropriate amount of coolant after installation.
9-199 Engine/Propulsion
 9-200 Engine/Propulsion

9.4.4.7 Water Pump Belt Replacement (1.5T)

Removal Steps
Caution: Refer to “0.2.1.45 Moving Parts and Hot Surfaces Warning”.
1. Lift the vehicle. Refer to “1.1.1.4 Lifting and Jacking the Vehicle”.
2. Remove the engine lower cover plate.
3. Remove the compressor belt. Refer to “9.5.4.3 Compressor Belt
Replacement”.
4. Loosen tensioner (1) and remove drive belt (2).

Installation Procedure
1. Loosen tensioner (1) and install drive belt (2).
2. Install the compressor belt. Refer to “9.5.4.3 Compressor Belt
Replacement”.
3. Install the engine lower cover plate.
4. Lower the vehicle. Refer to “1.1.1.4 Lifting and Jacking the Vehicle”.
9-201 Engine/Propulsion

9.4.4.11 Engine Coolant Temperature Sensor Replacement (1.5T) (208536)

Coolant Temperature Sensor Replacement

Callout Component Name
Preliminary Procedure
1. Drain the cooling system. Refer to “9.4.4.16 Cooling System Draining and Filling”.
2. Disconnect the battery negative cable. Refer to “9.1.4.2 Battery Negative Cable Disconnection and
Connection”.
3. Disconnect the connector plug.
Engine coolant temperature sensor
Caution: Refer to “0.2.1.30 Fastener Caution”.
1
Tighten
18±2 N·m
 9-202 Engine/Propulsion

9.4.4.12 Radiator Inlet Hose Replacement (B15T)

Radiator Inlet Hose Replacement (B15T)

Callout Component Name
Preliminary Procedure
1. Drain the cooling system. Refer to “9.4.4.16 Cooling System Draining and Filling”.
1 Radiator inlet hose clip (Qty.: 2)
2 Radiator inlet hose
9-203 Engine/Propulsion

9.4.4.14 Radiator Outlet Hose Replacement (B15T)

Radiator Outlet Hose Replacement (B15T)

Callout Component Name
Preliminary Procedure
1. Drain the cooling system. Refer to “9.4.4.16 Cooling System Draining and Filling”.
1 Radiator outlet hose clip (Qty.: 2)
2 Radiator outlet hose
 9-204 Engine/Propulsion

9.4.4.18 Engine Coolant Thermostat Replacement (1.5T) (37212)

Removal Steps
1. Loosen and remove thermostat housing retaining bolt (3).
2. Remove thermostat housing (1).
3. Remove thermostat (2).

Installation Procedure
1. Install thermostat (1) to thermostat housing. Seat the seal ring in
the thermostat housing locating slot and take care to ensure correct
mating.
Caution: Refer to “0.2.1.30 Fastener Caution”.
2. Install thermostat housing (2) to the water pump with the thermostat
housing locating slot facing upward.
Tighten
Thermostat housing bolt: 10±2 N·m
9-205 Engine/Propulsion

9.4.4.19 Flushing
Note: Do not use any chemical cleaning agent.
Store used coolant in a proper manner, such as in a
used engine coolant holding tank. Do not pour used
coolant down a drain. Ethylene glycol antifreeze is a
highly toxic chemical. Do not dispose of coolant into
the sewer system or ground water. This is illegal and
ecologically unsound.
Various methods and equipment can be used to flush
the cooling system. If special equipment is used, such
as a back flusher, follow the

manufacturer’s instructions. Always remove the

thermostat before back flushing the system. If the
cooling system is contaminated, flush it thoroughly to
remove all the pollutants before serious engine
damage occurs.
1. Drain the cooling system. Refer to “9.4.4.16
Cooling System Draining and Filling”.
2. Remove the radiator surge tank. Refer to
“Radiator Surge Tank Replacement”.
3. Clean and flush the radiator surge tank with clean
drinking water.
4. Install the radiator surge tank. Refer to “Radiator
Surge Tank Replacement”.
5. Use clean drinking water only when performing
the draining and filling procedures. Refer to
“9.4.4.16 Cooling System Draining and Filling”.
6. Keep the engine running for 20 minutes.
7. Turn off the engine.
8. Drain the cooling system. Refer to “9.4.4.16
Cooling System Draining and Filling”.
9. Repeat this procedure until the fluid is nearly
colorless if necessary.
10. Fill the cooling system. Refer to “9.4.4.16
Cooling System Draining and Filling”.
 9-206 Engine/Propulsion

9.4.4.20 Radiator Replacement (37191)

Radiator Replacement
Callout Component Name
Preliminary Procedure
1. Drain the cooling system. Refer to “9.4.4.16 Cooling System Draining and Filling”.
2. Remove the engine coolant fan. Refer to “Engine Coolant Fan Replacement”.
3. Disconnect the radiator inlet hose from the radiator. Refer to “Radiator Inlet Hose Replacement”.
4. Disconnect the radiator outlet hose from the radiator. Refer to “Radiator Outlet Hose Replacement”.
5. Disconnect the radiator surge tank overflow hose from the radiator. Refer to “Radiator Surge Tank Overflow
Hose Replacement (B15T)”.
6. Disconnect the radiator to surge tank connection hose from the radiator. Refer to “Radiator Surge Tank Outlet
Hose Replacement (1.8L)”.
7. Disconnect the condenser fastening bolt from the radiator. Refer to “10.1.5.15 Air Conditioning Condenser
Replacement”.
Radiator fastening bolt
Caution: Refer to “0.2.1.30 Fastener Caution”.
1
Tighten
7.5±1.5 N·m
2 Radiator upper bracket
3 Radiator shock pad (Qty.: 4)
4 Radiator
9-207 Engine/Propulsion

9.4.4.21 Radiator Surge Tank Inlet Hose Replacement (B15T) (37409)

Radiator Surge Tank Inlet Hose Replacement (B15T)

Callout Component Name
Preliminary Procedure
1. Remove the cover plate assembly at left side of engine compartment. Refer to “2.1.2.17 Engine Compartment
Side Cover Replacement”.
2. Drain the cooling system. Refer to “9.4.4.16 Cooling System Draining and Filling”.
1 Radiator surge tank inlet hose clip (Qty.: 2)
2 Radiator surge tank inlet hose
 9-208 Engine/Propulsion

9.4.4.22 Radiator Surge Tank Outlet Hose Replacement (B15T) (37410)

Radiator Surge Tank Outlet Hose Replacement (B15T)

Callout Component Name
Preliminary Procedure
1. Remove the cover plate assembly at left side of engine compartment. Refer to “2.1.2.17 Engine Compartment
Side Cover Replacement”.
2. Drain the coolant in the cooling system. Refer to “9.4.4.16 Cooling System Draining and Filling”.
1 Radiator surge tank outlet hose clip (Qty.: 2)
2 Radiator surge tank outlet hose
9-209 Engine/Propulsion

9.4.4.24 Radiator Surge Tank Replacement (B15T) (37297)

Radiator Surge Tank Replacement (B15T)

Callout Component Name
Preliminary Procedure
1. Remove the cover plate assembly at left side of engine compartment. Refer to “2.1.2.17 Engine Compartment
Side Cover Replacement”.
2. Remove the radiator surge tank fastening bolts and discharge the coolant in the surge tank into a clean bottle.
3. Disconnect the radiator surge tank overflow hose from the radiator and hold the hose head high to prevent the
fluid from flowing out. Refer to “Radiator Surge Tank Overflow Hose Replacement (B15T)”.
4. Disconnect the radiator surge tank inlet hose from the radiator and hold the hose head high to prevent the fluid
from flowing out. Refer to “9.4.4.21 Radiator Surge Tank Inlet Hose Replacement (B15T)”.
5. Disconnect the radiator surge tank outlet hose from the surge tank and hold the hose head high to prevent the
fluid from flowing out. Refer to “Radiator Surge Tank Outlet Hose Replacement (B15T)”.
Radiator surge tank fastening bolt (Qty: 2)
Caution: Refer to “0.2.1.30 Fastener Caution”.
1
Tighten
4.5±0.5 N·m
Radiator surge tank
Caution: Refer to “0.2.1.30 Fastener Caution”.
Surge tank cap tightening
2
4±1 N·m
Note: Add appropriate amount of coolant after installation. Refer to “9.4.1.2 Approximate Fluid
Capacities”.
 9-210 Engine/Propulsion

Radiator Surge Tank Replacement (B15T) (Cont’d)

Callout Component Name
Radiator surge tank bracket fastening bolt (Qty: 3)
Caution: Refer to “0.2.1.30 Fastener Caution”.
3
Tighten
8±1 N·m
4 Radiator surge tank bracket
9-211 Engine/Propulsion

9.4.4.26 Engine Oil Cooler Replacement (1.5T)

Engine Oil Cooler Replacement

Callout Component Name
Preliminary Procedure
1. Remove the oil filter and the oil filter mounting stud. Refer to “9.5.4.1 Engine Oil and Oil Filter Replacement”.
Engine oil cooler mounting bolt (Qty.: 2)
Caution: Refer to “0.2.1.30 Fastener Caution”.
1
Tighten
10±2 N·m
2 Engine oil cooler
 9-212 Engine/Propulsion

9.4.4.27 Engine Oil Cooler Outlet Hose Replacement (1.5T) (211067)

Removal Steps
1. Remove the three - way catalytic converter assembly. Refer to
“Catalytic Converter Replacement”.
2. Remove the engine oil cooler adapter if necessary. Refer to
“9.4.4.28 Engine Oil Cooler Base Replacement”.
3. Remove engine oil cooler outlet hose assembly bolt (1) from the
adapter.
4. Remove the 2 engine oil cooler outlet hose assembly bolts (2) from
the front cover water pump.
5. Remove engine oil cooler outlet hose assembly (3).

Removal Steps
Caution: Refer to “0.2.1.30 Fastener Caution”.
1. Apply grease on the engine oil cooler outlet hose O - ring, install the
O - ring to the engine oil cooler adapter and then install them together
with the engine oil cooler to the cylinder block. Refer to “9.4.4.28 Engine
Oil Cooler Base Replacement” for installation of the adapter.
2. Connect the other end of the engine oil cooler outlet hose to the
front cover.
3. Tighten the engine oil cooler outlet hose bolt (2) at the front cover
and bolt (1) at the adapter.
Tighten
Front cover end engine oil cooler outlet hose bolt (Qty.: 2): 10±2 N·m
Adapter end engine oil cooler outlet hose bolt (Qty.: 1): 10±2 N·m
9-213 Engine/Propulsion

9.4.4.28 Engine Oil Cooler Base Replacement (1.5T)

Removal Steps
1. Raise the vehicle. Refer to “0.2.1.14 Vehicle Lifting and Jacking
Caution”.
2. Remove the oil filter and the mounting stud. Refer to “9.5.4.1
Engine Oil and Oil Filter Replacement”.
3. Remove the engine oil cooler. Refer to “9.4.4.26 Engine Oil Cooler
Replacement”.
4. Remove bolt (1) to disconnect the turbocharger oil feed pipe from
the adapter.
5. Remove bolt (2) to disconnect the engine oil cooler outlet hose from
the adapter.

6. Remove engine oil cooler adapter mounting bolt (1) to remove

adapter (4).
7. If necessary, remove 2 oil outlet O - rings (2), 2 water outlet O -
rings (3), 1 water inlet O - ring (5) and 1 oil inlet O - ring (6) from the
adapter.
 9-214 Engine/Propulsion

Installation Procedure
Caution: Refer to “0.2.1.30 Fastener Caution”.
1. If the O - rings have been removed, install them first to the adapter.
2. Install the engine oil cooler adapter to the cylinder block and tighten
the mounting bolt to 22±2 N·m.

1. Lubricate the engine oil cooler water outlet hose O - ring,

install the engine oil cooler adapter and tighten bolt (1) to 10±2
N·m.
2. Connect the turbocharger oil feed pipe and the adapter,
place gaskets at both ends of the engine oil cooling end oil
feed pipe joint and tighten with bolt (2) to 32±2 N·m.
3. Install the engine oil cooler. Refer to “9.4.4.26 Engine Oil Cooler
Replacement”.
4. Install the engine oil filter. Refer to “9.5.4.1 Engine Oil and Oil Filter
Replacement”.
5. Lower the vehicle slowly.
9-215 Engine/Propulsion

9.4.4.29 Turbocharger Oil Feed Pipe Replacement

Removal Steps
1. Remove oil feed pipe bolt (1) from the turbocharger, remove the 2
gaskets at oil feed pipe to turbocharger joint and discard them.
2. Raise the vehicle, remove oil feed pipe bolt (2) from the engine oil
cooler adapter, remove the 2 gaskets at the joint and discard them.
3. Remove turbocharger oil feed pipe bracket bolt (3).
4. Remove turbocharger oil feed pipe (4).
Note: Take caution not to contaminate the parts around with the oil.

Installation Procedure
1. Install turbocharger oil feed pipe (4), place new gaskets at both
ends of the turbocharger end joint and pre - tighten with bolt (1), place
new gaskets at both ends of the engine oil cooling end joint and pre -
tighten with bolt (2).
2. Lower the vehicle, and tighten turbocharger oil feed pipe bolt (1) at
the turbocharger end, oil feed pipe bolt (2) at engine oil cooler adapter
end and oil feed pipe bracket bolt (3).
Tighten
Oil feed pipe bolt (1) at turbocharger end: 32±2 N·m
Oil feed pipe bolt (2) at adapter end: 32±2 N·m
Oil feed pipe bracket bolt (3): 10±2 N·m
 9-216 Engine/Propulsion

9.4.4.30 Radiator Cleaning (37291)

Warning: Never spray water on a hot heat exchanger.
Otherwise, the resulting steam could cause personal
injuries.
Caution: The heat exchanger fins are essential for
good heat transfer. Do not brush the fins. This may
cause damage to the fins, reducing heat transfer.
Note: Blow compressed air through the engine side of
the radiator to remove any foreign material, such as
insects, leaves, and dust.
• Warm water and mild soap may be needed in
some conditions.
• Wash the A/C condenser fin.
• Wash the area between A/C condenser and
radiator.
• Wash the radiator cooling fin.
9-217 Engine/Propulsion
9.4.5 Description and Operation
9.4.5.1 Cooling System Description and
Operation (37455)
Cooling System
The cooling system maintains the engine operating
temperature at the efficient level under any speed and
operating condition. It is designed to discharge
approximately 1/3 heat generated from air - fuel
mixture combustion. When the engine is cold, the
coolant does not pass the radiator until the thermostat
opens. In this way, the engine can be warmed up
quickly.
Cooling Cycle
The coolant flows out from the radiator outlet and into
the water pump inlet. Some coolant flows from the
water pump to the heater core and then returns to the
water pump. As the coolant warms up, heating and
defrosting in the passenger compartment is provided.
The coolant also flows out from the water pump outlet
and into the engine block. The coolant in the engine
block circulates through water
jackets around the cylinder and absorbs heat.
Afterwards, the coolant passes the cylinder head
gasket hole and enters the cylinder head. In the
cylinder head, the coolant passes through the water
jackets around the combustion chamber and the valve
and absorbs the additional heat.
The coolant is also led to the throttle body. It circulates
through the water passages within the cast parts. At
the beginning of starting, the coolant helps warm up
the throttle body. It flows from the cylinder head to the
thermostat. As the engine warms up to the normal
operating temperature, coolant flow stops at the
thermostat, or the coolant passes the thermostat and
enters the radiator where it cools. At this time, the
coolant flow circulation ends.
All system components must function properly in order
for the cooling system to operate efficiently. The
cooling system consists of the following components.
Radiator
The radiator is a heat exchanger. It consists of a core
and 2 tanks. The aluminum core is a tube and fin cross
- flow design that extends from the inlet tank to the
outlet tank. Fins are placed around the outside of the
tubes to improve heat transfer to the atmosphere.
The inlet and outlet tanks are molded with a high
temperature and nylon reinforced plastic material. A
high temperature rubber gasket seals the tank flange
edge to the aluminum core. The tanks are clamped to
the core with clinch tabs The tabs are part of the
aluminum header at each end of the core.
The radiator is also provided with a drain valve and it is
installed at bottom of the left tank. The drain valve unit
consists of a drain valve and a drain valve seal ring.
The radiator removes heat from the coolant passing
through it. The fins on the core transfer heat from the
coolant passing through the tubes. As air passes
between the fins, it absorbs heat and cools the
coolant.
Pressure Cap
The pressure cap seals and pressurizes the cooling
system. It consists of one vent valve or pressure valve
and one vacuum valve or air valve.
As the temperature increases, the pressure cap
pressurizes the cooling system. The coolant boiling
point increases as a result of the pressurization. In this
way, the engine coolant can work safety under a
temperature higher than its boiling point under the
barometric pressure. The hotter the coolant, the faster
the heat transfer from the radiator to the comparatively
cooler air.
It is possible that the cooling system pressure
becomes excessively high. If the pressure exceeds the
spring tension, the pressure valve lifts and as a result,
pressure is dissipated.
As the engine cools, the coolant temperature
decreases, forming vacuum in the cooling system.
Vacuum forces the vacuum valve to open. As a result,
the cooling system keeps in balance with the
barometric pressure and no radiator hose collapse will
occur.
Coolant Recovery System
The coolant recovery system consists of a plastic
coolant recovery reservoir and an overflow hose. The
recovery reservoir is also called recovery tank or surge
tank. The reservoir is partially filled with coolant and
connected to the radiator filler neck via an overflow
hose. The coolant can flow back and forth between the
radiator and the reservoir.
The cooling system with a coolant recovery reservoir
is actually a closed system. As the cooling system
pressure becomes excessively high, the pressure
valve on the pressure cap will be pressurized to open.
This makes the coolant which has expanded under
high temperature pass the overflow hose and enters
the recovery reservoir. As the engine cools, the
coolant temperature decreases, forming vacuum in the
cooling system. The vacuum valve on the pressure
cap opens as a function of vacuum and as a result,
some coolant in the reservoir is syphoned back to the
radiator. No loss of coolant occurs under the normal
operating condition. Though the coolant level
increases and decreases in the recovery reservoir, the
radiator and the cooling system are always fully filled.
The advantage of the coolant recovery reservoir is that
almost all bubbles in the engine cooling system can be
eliminated. Coolant without air bubbles absorbs heat
much better than coolant with bubbles.
 9-218 Engine/Propulsion

Air Baffle and Seal surge tank, not passing the radiator. In this way, heat
Deflectors, air baffles and air seals are used to dissipation is reduced and the engine can be warmed
enhance the system cooling capacity. The deflector is up quickly. When the coolant temperature becomes
installed at lower of the vehicle and is used to divert higher than the thermostat begin - to - open
the air to pass the radiator so as to enhance the temperature 82±2°C (1.8L) or 87±1.5°C (1.5T), the
engine cooling effect. The baffle is also used to divert thermostat begins to open so that most coolant
the air to pass the radiator so as to enhance the circulates through the radiator. The higher the coolant
cooling capacity. The air seal can prevent the air from temperature, the large the thermostat opening. When
bypassing the radiator and the A/C condenser. It can the coolant temperature reaches 95°C(1.8L) or
also prevent hot air recirculation. In this way, the 97°C(1.5T), the thermostat fully opens and heat
cooling effect in hot weather as well as the A/C dissipation becomes faster. In this way, the coolant
condenser performance are improved. temperature is controlled. When the coolant
temperature drops to 77°C(1.8L), the thermostat will
Water pump fully close.
The water pump is a centrifugal impeller pump. It
consists of a housing with coolant inlet and outlet
passages and an impeller. The impeller is a flat plate
which is mounted on the pump shaft. It has a series of
planar or curved blades. As the impeller rotates, the
coolant between the blades is thrown out under the
centrifugal force. The impeller shaft is supported by
one or more sealed bearings which require no
lubrication. Usage of sealed bearing can prevent
grease leak as well as foreign materials and water
intrusion. The water pump drives the coolant to
circulate in the whole cooling system. It is driven by
the crankshaft via the drive belt.
Cooling Motor and Fan Assembly
After the ignition switch is turned to ON position,
operation of the motor and fan assembly is controlled
by ECU. In other words, ECU controls operation of the
motor and fan assembly behind the radiator.
(1.8L&1.5T)
Temperature Change Electric Coolant Fan State
<91°C OFF
91°C to 94°C as the
OFF
temperature increases
94°C to 98°C as the
Low speed
temperature increases
>98°C High speed
95°C to 98°C as the
High speed
temperature decreases
91°C to 95°C as the
Low speed
temperature decreases
Thermostat
The cooling system uses thermostat to control the
coolant temperature. The thermostat has the following
functions:
• To control the coolant flow;
• To warm up the engine quickly;
To adjust the coolant temperature. When the coolant
temperature is lower than the thermostat begin - to -
open temperature 82±2°C (1.8L) or 87±1.5°C (1.5T),
the thermostat keeps closed and the coolant only
circulates along the passage of engine inside <——>
9-219 Engine/Propulsion

9.5 Engine Mechanical - 1.5L

9.5.1 Specifications
9.5.1.1 Approximate Fluid Capacities (258271)
Approximate Fluid Capacities
Specification
Application
Metric English
Filtered engine oil 4L 4.23 quarts
Not filtered engine oil 3.5L 3.7 quarts
9.5.1.2 Adhesives, Fluids, Lubricants, and Sealers (208576)
Application Model Part No.
Engine oil SAE5W - 30 Refer to EPC
Oil pan sealer OXIMESILICONE polysiloxane Refer to EPC
 9-220 Engine/Propulsion

9.5.1.3 Engine Mechanical Specifications (1.5T) (208575)

Application Specifications (LL5 - B15T) ——
General data
1.5L exhaust gas turbocharged
gasoline engine, four - stroke, water -
cooled, in - line, 16 - valve, dual
overhead camshafts, DVCP (dual
Engine type ——
variable CAM phase), timing chain
drive, turbocharging, electronically
controlled gasoline injection,
electronically controlled ignition
Displacement 1.451 ——
Cylinder diameter × stroke 73.8mm×84.7mm ——
Compression ratio 9.5:1 ——
Maximum power/speed 110 kW/5500 rpm ——
Maximum net power/speed 102 kw/5500 rpm
Maximum torque 230 Nm/2000 rpm~3800 rpm ——
Maximum net torque 220Nm/2000 rpm~3800 rpm
Ignition order 1-3-4-2 ——
Spark plug gap 0.7 mm~0.8 mm ——
Idle speed (r/min) 750±50 ——
Spark plug model YR6NI302 ——
Overall dimensions (L*W*H) 594×622×637 ——
Engine mass 118 kg±2 kg (MT) ——
Cylinder block
Cylinder diameter (mm) 73.84±0.011 ——
Bore roundness (mm) 0.005 ——
Bore cylindricity (mm) 0.008 ——
Average pressure of 1.41 MPa @
Cylinder pressure (kPa) ——
200 rpm with an error range of ±3%
Camshaft
Front end: 32 ( - 0.05/ - 0.066) & 42.7
Camshaft diameter & width (mm) ——
Other: 23 ( - 0.04/ - 0.061) & 17.5
9-221 Engine/Propulsion

Journal runout (mm) 0.04

Journal cylindricity (mm) 0.007 ——
Cam parallelism (mm) 0.005 ——
Intake (24.85+17) ±0.05
Cam height (mm) ——
Exhaust (24.2+17) ±0.05
Crankshaft
Crankshaft end cap (mm) 0.08~0.29 ——
Crankshaft main bearing gap—all
0.018~0.05 ——
(mm)
Crankshaft main journal diameter &
49 ( - 0.005/ - 0.021) & 23.15±0.1 ——
width (mm)
Crankshaft main bearing journal out -
0.005 ——
of - roundness (mm)
Crankshaft main bearing journal
0.04 ——
runout (mm)
Connecting rod journal diameter
43 ( - 0.005/ - 0.021) ——
(mm)
Connecting rod journal out - of -
0.005 ——
roundness (mm)
Connecting rod journal to shell gap
0.018~0.050 ——
(mm)
Cylinder head
Overall height (mm) 121.3±0.1 ——
Total guide length: 35±0.2
Valve guide height (mm) Protrusion height as pressed into the ——
cylinder head: 13.0±0.2
Piston
Intake/exhaust side: 0.041~0.071
Distance to cylinder bore (mm) Primary/auxiliary thrush side: ——
0.038~0.074
Piston diameter (mm) 73.784±0.007
Maximum piston protrusion height
- 0.4 ——
from cylinder block (mm)
Piston top taper N/A ——
Piston pin
Piston pin to piston gap (mm) 0.003 - 0.010 ——
Piston pin diameter (mm) 19 (+0/ - 0.3) ——
Piston pin length (mm) 47±0.1 ——
Piston pin offset - toward the thrust
0.5 ——
side (mm)
 9-222 Engine/Propulsion

Piston ring
0.15~0.3
Ring I close clearance and side Intake/exhaust side: 0.766~1.074
——
clearance (mm) Primary/auxiliary thrush side:
0.765~1.076
0.35~0.5
Ring II close clearance and side Intake/exhaust side: 0.816~1.124
——
clearance (mm) Primary/auxiliary thrush side:
0.815~1.126
0.2~0.7
Oil ring close clearance and side Intake/exhaust side: 0.766~1.274
——
clearance (mm) Primary/auxiliary thrush side:
0.764~1.276
Connecting rod
Connecting rod small end to piston
0.007~0.020
pin gap (mm)
Connecting rod bending parallelism
0.017 ——
(mm)/(mm)
Connecting rod torsional parallelism
0.04 ——
(mm)/(mm)
Connecting rod large end thrust play
0.10~0.53 ——
(mm)
Valve
Valve diameter—intake (mm) 27.9±0.12 ——
Valve diameter—exhaust (mm) 24.4±0.12 ——
Valve working face angle 90°15′±15′
Valve working face runout (mm) 0.03 ——
Valve seat sealing face width—intake
1.12 ( - 0.1/+0.3) ——
(mm)
Valve seat sealing face
1.3 ( - 0.1/+0.3) ——
width—exhaust (mm)
Valve stem diameter—intake (mm) 4.972±0.007 ——
Valve stem diameter—exhaust (mm) 4.963±0.007 ——
Valve guide inner diameter (mm) ——
Valve clearance—intake (mm) 0.075~0.125 ——
Valve clearance—exhaust (mm) 0.245~0.295 ——
Valve spring
Valve spring free length (mm) 45.47 ——
Valve spring preload (N) 187±7.48 (when pressed to 34 mm) ——
Valve spring perpendicularity 2° ——
9-223 Engine/Propulsion

Oil pump
1. Pressure 100 kPa; flow rate 5.4
L/min; speed 1000 rpm; oil
temperature 100°C
Oil pump pressure ——
2. Pressure 290 kPa; flow rate 40.7
L/min; speed 6000 rpm; oil
temperature 100°C

Oil Pressure Pressure 400±40 kPa; speed 3000

rpm; oil temperature 100°C
Cooling System
Capacity (L) Engine 1.958 ——
Lubrication system
Lubrication type Spatter + pressure lubrication ——
Oil capacity with oil filter 4L ——
Sealers or adhesives
Front end cap to cylinder block and
Tianshan 1590 ——
head
Oil pan to cylinder block Tianshan 1590 ——
Crankshaft rear oil seal seat to
Tianshan 1590 ——
cylinder block
Cup plug (water plug) sealer Tianshan 1962T/Loctite 962T ——
Oil plug sealer Tianshan 1545/Loctite 545 ——
Coolant temperature sensor sealer Hubei Huitian HT2431 ——
 9-224 Engine/Propulsion

9.5.1.4 Fastener Tightening Specifications

Fastener Specifications
Specifications (N·m)
Application
LL5
Water pump bolt 22±2 ——
Water pump cover bolt 10±2
Rear engine lifting hook bolt 25±2 ——
Front engine lifting hook bolt 25±2 ——
Intake manifold stud 15±2 ——
Intake manifold bolt 25±2 ——
Intake manifold nut 25±2 ——
Water pump pulley bolt 22±2 ——
Engine shock absorber bolt 62±5 ——
Engine lift bracket to engine shock
110±10
absorber nut
Engine mount bracket to engine bolt 62±5 ——
Engine mount bracket to engine lift
110±10 ——
bracket nut
Engine mount bracket to engine lift
110±10 ——
bracket bolt
Engine mount bracket stud 72±5 ——
Intake manifold bracket bolt (to cylinder
20±2 ——
block end)
Intake manifold bracket bolt (to intake
10±2 ——
manifold end)
Exhaust manifold heat shield bolt 11±2 ——
Three - way catalytic converter mounting
50±5 ——
nut (to turbocharger end)
Exhaust manifold nut 22±2 ——
Exhaust manifold stud 20±2 ——
Ignition coil mounting bolt 10±2 ——
Oil pan bolt 10±2 ——
Lower housing mounting bolt 10±2
9-225 Engine/Propulsion

Fastener Tightening Specifications (Cont’d)

Specifications (N·m)
Application
LL5
Oil pan drain bolt 25±5 ——
Oil strainer bolt 9±1 ——
Strainer support bracket 9±1
Crankshaft pulley bolt 100 N·m + (75°±5°) ——
Front cover bolt 22±2 ——
Camshaft sprocket bolt (32±2) N·m + (50°±2°) ——
Timing tensioner bolt 10±2 ——
Timing chain exhaust side guide bolt 10±2 ——
Timing chain intake side guide bolt 10±2 ——
Camshaft bearing cap bolt 10±2 ——
Water outlet support bolt 22±2 ——
Engine water outlet pipe bolt 10±1 ——
Engine water outlet pipe support bolt 22±2 ——
Coolant temperature sensor 17.5±2.5 ——
Thermostat housing bolt 10±2 ——
Cylinder head bolt 30 N·m + 70°+ 60° ——
Flywheel to clutch bolt 25±2 ——
Flywheel fastening bolt 35 N·m + (30°~45º) ——
Crankshaft rear oil seal seat mounting bolt 10±2 ——
Main bearing cap bolt 30 N·m + (51°~59º) ——
Connecting rod bolt 20 N·m + (90°± 4°) ——
Fuel rail mounting bolt 15±2 ——
Throttle body mounting bolt 10±2 ——
Intake air temperature/pressure sensor
10±2 ——
bolt (high pressure)
Camshaft position sensor bolt 10±2 ——
Oil - gas separator bolt 10±2
Camshaft cover bolt 10±2 ——
 9-226 Engine/Propulsion

Fastener Tightening Specifications (Cont’d)

Specifications (N·m)
Application
LL5
Camshaft phase actuator solenoid valve
10±2 ——
bolt
Crankshaft position sensor bolt 10±2 ——
Crankshaft position sensor signal panel
10±1 ——
bolt
Knock sensor bolt 20±5 ——
Oil pressure switch assembly 27±3 ——
Oil pump mounting screw 10±1 ——
Oil pressure relief valve plug 42±2 ——
Oil level indicator tube support mounting
10±2 ——
bolt
Spark plug 23±3 ——
Canister solenoid valve mounting bolt 10±1 ——
Oil filter mounting stud 22±2 ——
Oil filter assembly 30±4 ——
Engine oil cooler adapter mounting bolt 22±2
Engine oil cooler mounting bolt 10±2
Piston nozzle mounting bolt 10±2
Front oxygen sensor 50±10 ——
Rear oxygen sensor 50±10 ——
Drive belt tensioner bolt 50±5 ——
Air conditioning compressor bracket bolt 22±3
Turbocharger nut 33±3
Stud (turbocharger–three - way catalytic
20±2
converter assembly)
Turbocharger heat shield bolt 11±2
Turbocharger cooling water inlet hose
22±2
support bolt
Turbocharger cooling water inlet hose bolt 32±2
Turbocharger cooling water return hose
10±2
support bolt (shield end)
9-227 Engine/Propulsion

Fastener Tightening Specifications (Cont’d)

Specifications (N·m)
Application
LL5
Turbocharger cooling water return hose
32±2
bolt (turbocharger end)
Turbocharger lubricant inlet hose bolt
32±2
(turbocharger end)
Turbocharger lubricant inlet hose bolt
32±2
(adapter end)
Turbocharger oil inlet pipe bolt 10±2
Turbocharger oil return pipe stud 6±1
Turbocharger oil return pipe nut 10±2
Turbocharger oil return pipe bolt 10±2
Turbocharger water return pipe bolt 10±2
Engine oil cooler water outlet hose bolt 10±2
Turbocharger water inlet pipe bolt 22±2
HVAC water outlet pipe assembly bolt
10±2
(front cover end)
HVAC water outlet pipe assembly bracket
30±2
bolt (cylinder block end)
Vacuum pump bolt 22±2
Air conditioning compressor bracket bolt 35±4
Generator bolt 40±5
Starter bolt 25±4
Vent valve support bolt 8±1
 9-228 Engine/Propulsion

9.5.2 Component Locator

9.5.2.1 Disassembled Views (Turbocharger Pipeline) (208602)

Turbocharger Pipeline (LL5)

1. High - load PCV pipe 7. Turbocharger water inlet pipe 13. Engine oil cooler water return
pipe gasket
2. Bolt 8. Turbocharger oil feed pipe 14. Engine oil cooler water return
gasket pipe
3. HVAC water outlet pipe 9. Turbocharger oil feed pipe 15. Bolt
4. Breather hose 10. Bolt 16. Bolt
5. Turbocharger oil feed pipe 11. Bolt
6. Turbocharger water return 12. Turbocharger oil feed pipe
pipe gasket
9-229 Engine/Propulsion

9.5.2.2 Disassembled Views (Cylinder Block LL5) (208602)

Cylinder Block (LL5)

1. Crankshaft pulley bolt 25. Cylinder head locating pin 49. Engine oil cooler mounting bolt
2. Crankshaft pulley 26. Cylinder block 50. Oil filter
3. Bolt 27. Crankshaft sprocket 51. Piston ring assembly
4. Engine front cover 28. Knock sensor 52. Piston
5. Water pump seal ring 29. Bolt 53. Piston pin
6. Bolt 30. Oil pressure switch 54. Piston pin snap ring
7. Water pump cover 31. Cylinder block plug 55. Connecting rod
8
8. Bolt 32. Crankshaft rear oil seal seat 56. Connecting rod upper bearing
shell
9. Oil pump outer rotor 33. Crankshaft rear oil seal 57. Connecting rod lower bearing
shell
10. Oil pump inner rotor 34. Bolt 58. Connecting rod bolt
11. Oil pump cover 35. Starter gear ring 59. Oil pan assembly
 9-230 Engine/Propulsion

Cylinder Block (LL5) (Cont’d)

12. Relief valve plug 36. Flywheel 60. Oil pan lower housing
13. O - ring (strainer–oil pump) 37. Bolt 61. Drain bolt gasket
14. Bolt 38. Clutch driven plate 62. Drain bolt
15. Oil strainer 39. Clutch cover 63. Bolt
16. Bolt 40. Bolt 64. Bolt
17. Timing chain exhaust side
41. Locating pin 65. Locating pin
guide
18. Timing chain 42. Piston cooling nozzle 66. Crankshaft
43. Engine oil cooler adapter oil
19. Bolt 67. Thrust washer
outlet O - ring
20. Timing chain intake side 68. Crankshaft upper main bearing
44. Engine oil cooler adapter
guide shell
45. Engine oil cooler adapter water 69. Crankshaft lower main bearing
21. Bolt
outlet O - ring shell
22. Timing chain tensioner 46. Bolt 70. Main bearing cap
23. Timing chain tensioner
47. Engine oil cooler 71. Bolt
gasket
24. Cylinder head gasket 48. Oil filter mounting stud
9-231 Engine/Propulsion

9.5.2.3 Disassembled Views (Cylinder Head LL5) (208602)

Cylinder Head (LL5)

1. Oil gallery plug 27. Canister solenoid valve 53. Cylinder head water plug
2. Bolt 28. Desorption rubber pipe 54. Cylinder head
assembly
3. Oil filler cap 29. Throttle body 55. Turbocharger
4. One - way valve 30. Bolt 56. Bolt
5. Camshaft phase actuator 31. Intake manifold bracket. 57. Turbocharger heat shield
solenoid valve
6. Bolt 32. HVAC water outlet pipe bracket 58. Turbocharger heat pad
7. Bolt 33. Bolt 59. Stud
8. Bolt 34. Bolt 60. Nut
9. Ignition coil 35. Bolt 61. Exhaust manifold
10. Camshaft cover 36. Camshaft cover seal ring 62. Nut
11. Vacuum pump oil seal 37. Camshaft front bearing cap 63. Stud
12. Camshaft cover seal ring 38. Bolt 64. Exhaust manifold heat
shield
 9-232 Engine/Propulsion

Cylinder Head (LL5) (Cont’d)

13. Camshaft cover seal ring 39. Camshaft sprocket 65. Bolt
14. Camshaft cover seal ring 40. Bolt 66. Exhaust manifold gasket
15. High - load PCV pipe 41. Camshaft bearing cap 67. Bolt
16. Oil - gas separator 42. Intake camshaft 68. Camshaft position sensor
17. Bolt 43. Intake camshaft 69. Vacuum pump gasket
18. Low - load PCV pipe 44. Cylinder head bolt 70. Vacuum pump
19. Bolt 45. Cylinder head water plug 71. Bolt
20. Fuel rail 46. Valve key 72. Water outlet support seal
ring
21. Bolt 47. Valve spring retainer 73. Water outlet support
22. Intake air temperature/pressure 48. Valve oil seal 74. Coolant temperature sensor
sensor assembly (high pressure)
23. Bolt 49. Valve guide 75. Bolt
24. Intake manifold 50. Valve spring 76. Thermostat
25. Nut 51. Intake valve 77. Bolt
26. Intake manifold stud 52. Exhaust valve 78. Thermostat housing
9-233 Engine/Propulsion

9.5.2.4 Engine Number (1.5T)

Note: The figure is for reference only.
Engine black label (2) is attached on the side of camshaft cover. The
engine number (1) is embossed or laser etched on the block at left rear
side by OEM.
1. Explanation of engine black label (2): LL5*XXXXXXXXXXX*
Meaning of the engine black label:
• LL5: 1.5L turbo
• XXXXXXXXXXX represents 11 - digit serial number
2. Explanation of seal engine number (1): LL5*XXXXXXXXXXX*
Meaning of the seal engine number:
• LL5: 1.5L turbo
• XXXXXXXXXXX represents 11 - digit serial number
3. Engine white label (3) is pasted on hood.
• Bar code
• Engine Assembly Part No.
• Engine code
• 9 - digit serial number
• Engine production plant code
• Separator
• Engine code
• Separator
• Engine Part Identification No. 10

9.5.3 Diagnostic Information and Procedures
9.5.3.1 Base Engine Misfire with Abnormal Internal Lower Engine Noises (1.5T) (208580)
Base Engine Misfire with Abnormal Internal Lower Engine Noises
Condition
Abnormalities (server cracking, bumps or missing
areas) in the drive belt
Worn, damaged, or misaligned drive components or
excessive pulley runout
Loose and/or damaged crankshaft pulley
Loose connecting bolt to the transmission
Loose and/or damaged flywheel
Excessive piston - to - cylinder bore clearance
Excessive crankshaft thrust bearing clearance
9-234 Engine/Propulsion
Actions
Abnormalities in the drive belt and/or components may
cause engine RPM variations, noises similar to faulty lower
engine and also lead to a misfire condition. A misfire code
may be present without an actual misfire condition.
1. Inspect the accessory drive components.
2. Repair or replace all damaged components.
A misfire code may be present without an actual misfire
condition.
1. Inspect the accessory drive components.
2. Repair or replace all damaged components.
A misfire code may be present without an actual misfire
condition.
1. Inspect crankshaft pulley and pulley bolt.
2. Repair or replace the damaged components.
A misfire code may be present without an actual misfire
condition.
1. Inspect the torque converter bolt and the flywheel.
2. Repair or replace all damaged components.
A misfire code may be present without an actual misfire
condition.
1. Inspect flywheel and flywheel attaching bolts.
2. Repair or replace all damaged components.
1. Perform cylinder leak down and compression tests.
2. Inspect the piston, piston rings and cylinder bore.
3. Repair or replace all damaged components.
Severely worn thrust surfaces on the crankshaft and/or
thrust bearing may permit fore and aft movement of the
crankshaft and create a misfire code without an actual
misfire condition.
1. Inspect the crankshaft end play and crankshaft thrust
bearings.
2. Repair or replace all damaged components.
9-235 Engine/Propulsion

9.5.3.2 Base Engine Misfire with Abnormal Valve Train Noise (1.5T) (208581)
Base Engine Misfire with Abnormal Valve Train Noise
Condition Actions
1. Inspect valve drive components.
Loose, worn or damaged valve drive components
2. Repair or replace all damaged components.
1. Inspect valve springs.
Soft or broken valve springs
2. Repair or replace all damaged components.
Carbon on the valve stem or valve seat may cause the valve
to stick or warp.
Sticking or warping valve
1. Inspect valves and valve guides.
2. Repair or replace all damaged components.
1. Inspect camshaft lobes.
Worn camshaft lobes
2. Repair or replace all damaged components.
1. Inspect valve lifters.
Dirty, sticking or worn valve lifter
2. Repair or replace all damaged components.

9.5.3.3 Base Engine Misfire with Coolant Consumption (208582)
Base Engine Misfire with Coolant Consumption
Inspection
Preliminary inspection
Isolate affected cylinders
Exhaust gas recirculation system inspection
Cylinder head gasket leakage
Cylinder head or engine block damage
9-236 Engine/Propulsion
Actions
Inspect and verify that there are no external coolant leaks.
Refer to “9.4.3.4 Symptoms - Engine Cooling”.
● Cylinder balance test with scan tool
● Cooling system pressurization
● Compression test
● Inspect exhaust gas recirculation valve and intake
system for evidence of coolant leakage.
● Replace the exhaust gas recirculation valve if any
problem is found.
● Remove cylinder heads of the affected cylinder bank
and inspect for damage.
● Replace components as necessary.
● Inspect the cylinder head for cracks.
● Inspect the cylinder block for damage.
● Inspect the cylinder block to head mating surface for
straightness.
● Replace components as necessary.
9-237 Engine/Propulsion

9.5.3.4 Base Engine Misfire with Excessive Oil Consumption (208583)

Base Engine Misfire with Excessive Oil Consumption
Condition Actions
1. Inspect valves and valve guides.
Worn valve guides
2. Repair or replace all damaged components.
1. Inspect the valve stem oil seals.
Worn valve stem oil seals
2. Repair or replace all damaged components.
1. Perform compression tests to determine the cause.
2. Inspect the piston rings for low ring tension, broken or
Excessive piston - to - cylinder bore clearance worn rings.
3. Inspect cylinder bore.
4. Repair or replace all damaged components.

9.5.3.5 Base Engine Misfire without Internal Engine Noises (208579)
Base Engine Misfire without Internal Engine Noises
Condition
Abnormalities (server cracking, bumps or missing
areas) in the drive belt Worn, damaged, or
misaligned drive components or excessive pulley
runout
Loose and/or damaged crankshaft pulley
Loose connecting bolt to the transmission
Loose and/or damaged flywheel
Restricted exhaust system
Air in fuel system
Bent and/or worn valve bridge and finger - follower
Sticking valve
Damaged or misaligned timing gears
Worn or faulty camshaft lobes
9-238 Engine/Propulsion
Actions
Abnormalities in the drive belt and/or components may cause
engine RPM variations, noises similar to faulty lower engine
and also lead to a misfire condition. A misfire code may be
present without an actual misfire condition.
1. Inspect the drive components.
2. Repair or replace the damaged components.
A misfire code may be present without an actual misfire
condition.
1. Inspect crankshaft pulley and pulley bolt.
2. Repair or replace the damaged components.
A misfire code may be present without an actual misfire
condition.
1. Inspect the torque converter bolt and the flywheel.
2. Repair or replace all damaged components.
A misfire code may be present without an actual misfire
condition.
1. Inspect flywheel and flywheel attaching bolts.
2. Repair or replace all damaged components.
A severe restriction in the exhaust flow can cause significant
loss of engine performance and may set a misfire code.
Possible causes of restrictions include collapsed or dented
pipes, plugged mufflers and/or catalytic converters.
Repair or replace all damaged components.
1. Inspect fuel filter, fuel system for leaks and/or restrictions.
2. Repair or replace all damaged components.
1. Inspect valve bridge and valve finger - follower.
2. Repair or replace all damaged components.
Carbon on the valve stem or valve seat may cause the valve to
stick.
1. Inspect valves and valve guides.
2. Repair or replace all damaged components.
1. Inspect timing gears.
2. Replace all damaged components.
1. Inspect camshaft lobes.
2. Repair or replace all damaged components.
9-239 Engine/Propulsion

Base Engine Misfire without Internal Engine Noises (Cont’d)

1. Perform compression tests.
Excessive piston - to - cylinder bore clearance 2. Inspect the piston, piston rings and cylinder bore.
3. Repair or replace all damaged components.
Faulty cylinder head gaskets and/or cracking or other
damage to the 1. Perform compression tests.
cylinder heads and engine block cooling system 2. Inspect the piston, piston rings and cylinder bore.
passages (Coolant consumption may or may not 3. Repair or replace all damaged components.
cause the engine to overheat.)
 9-240 Engine/Propulsion

9.5.3.6 Coolant in Combustion Chamber (208589)

Coolant in Combustion Chamber
Inspection Operation
Definition: Excessive white smoke and/or coolant type odor coming from the exhaust pipe may indicate coolant in the
combustion chamber. Low coolant levels, an inoperative cooling fan, or a faulty thermostat may lead to an
“overtemperature” condition which may cause engine component damage.
Inspect and verify that there are no external coolant leaks. Refer
Preliminary inspection
to “9.4.3.4 Symptoms - Engine Cooling”.
● Cylinder balance test with scan tool
Isolate affected cylinders ● Cooling system pressurization
● Compression test
● Inspect exhaust gas recirculation valve and intake system
for evidence of coolant leakage.
Exhaust gas recirculation system inspection
● Replace the exhaust gas recirculation valve if any problem
is found.
● Remove cylinder heads of the affected cylinder bank and
Cylinder head gasket leakage inspect for damage.
● Replace components as necessary.
● Inspect the cylinder head for cracks.
● Inspect the cylinder block for damage.
Cylinder head or engine block damage ● Inspect the cylinder block to head mating surface for
straightness.
● Replace components as necessary.
9-241 Engine/Propulsion

9.5.3.7 Coolant in Engine Oil (208590)

Coolant in Engine Oil
Condition Actions
Definition: Frothy, discolored or “excessively filled” engine oil may indicate coolant in the engine oil. Low coolant
levels, an inoperative cooling fan, or a faulty thermostat may lead to an “overtemperature” condition which may cause
engine component damage. Replace the fouled engine oil and oil filter.
1. Inspect the engine oil for much foams or excessive filling. The coolant - diluted engine oil cannot lubricate the
crankshaft bearing normally and may cause component damage. Refer to “9.5.3.13 Lower Engine Noise,
Regardless of Engine Speed” in this section.
2. Perform inspections specified in “9.5.3.9 Cylinder Leakage Test”. If much foams are found in the cooling
system during this test, it indicates a faulty gasket or component damage.
3. Perform inspections specified in “9.5.3.10 Engine Compression Test”. If compression pressure of the two
cylinders which are located in parallel at both sides of the engine block is excessively low, it may indicate a
damaged cylinder head gasket.
Replace the cylinder head gasket and affected components as
Faulty cylinder head gasket
necessary. Refer to “9.5.4.9 Cylinder Head Replacement”.
Replace cylinder head gasket. Refer to “9.5.4.9 Cylinder Head
Warping cylinder head
Replacement”.
Cracked cylinder head Replace cylinder head and gasket.
Cracked engine block Replace components as necessary.
Perforated cylinder head, cylinder block or
Replace components as necessary.
manifold
Leaking engine oil cooler Replace components as necessary.
9.5.3.8 Crankcase Ventilation System operating level;
Inspection/Diagnosis • Ensure that the throttle fully opens;
Inspection Procedure • Remove all spark plugs;
1. Check the positive crankcase ventilation (PCV) • Confirm that the battery is fully or basically fully
system, the positive crankcase ventilation hose charged.
and all pipe connections for leaks. Make repairs if
necessary. 1. Drop 3 drips of fuel onto each spark plug with a
piston oiling machine.
2. Start the engine.
3. Keep the engine idling, use fingers or a pair of
pliers to gently snap the positive crankcase
ventilation hose and hear the sound from the
ventilation valve. Repeat this test for several
times. A sound will be produced from the
ventilation valve each time the hose is snapped.
4. If no sound is heard, check PCV valve for cracks
or damage.
5. Blow air to PCV. Resistance should appear as the
air passes PCV.
6. If the clamp is protected properly, replace PCV.
9.5.3.9 Cylinder Leakage Test (208592)
Special Tools
Cylinder pressure gauge
Note: Important: Disconnect the crankshaft position
(CKP) sensor connector to prevent fuel consumption
and ignition system activation. Test and reduce
pressure of each cylinder. A failed valve or piston can
result in excessively low cylinder pressure. When
inspecting the cylinder pressure, take the following
conditions into consideration:
• Keep the engine temperature at the normal
 9-242 Engine/Propulsion

2. Insert an engine pressure gauge into each spark finally reaches the specified value.
plug. ○ Failed piston ring: The compression pressure
3. Rotate the crankshaft with the starter until each is comparatively low at the first compression
cylinder completes 4 - 5 compression strokes. stroke and increases gradually in the
4. Generally, the normal cylinder pressure value is following strokes but not reaches the normal
1.3–1.5 Mpa and the pressure difference between value. The compression pressure increases
any two cylinders does not exceed 98 Kpa. remarkably after filling oil into the oil cylinder.
5. After finishing 4 compression strokes with the ○ Faulty valve: The compression pressure is
starter, inspect the pressure gauge reading. Refer comparatively low at the first compression
to the following explanations: stroke and does not increase in the following
strokes. The compression pressure
○ Normal condition: The pressure accumulates increases remarkably after filling oil into the
quickly and evenly in all the cylinders and oil cylinder.
9.5.3.10 Engine Compression Test (1.5T) (208591)
Note: Disconnect the crankshaft position sensor connector to disable
fuel and the ignition system.
Inspect the engine compression pressure as per the following
procedure:
1. Run the engine until the coolant temperature increases to
(70°C~80°C).
2. Stop the engine and disconnect the crankshaft position sensor.
3. Remove the ignition coils. Before removal, first confirm that the
area around is clean so that no foreign materials will fall into the cylinder
block.
4. Remove all spark plugs.
5. Install cylinder pressure gauge (a) to cylinder pressure gauge
adapter (b) and then install the cylinder pressure gauge adapter (b) to
the cylinder end to be measured.
Note: Do not tighten with a tool otherwise the cylinder block is likely to
be damaged under great effort.
6. One person depresses the accelerator pedal to throttle full opening,
start the engine and rotate the crankshaft with the starter at the same
time; the other reads the maximum value shown on the pressure gauge
after the reading becomes stable.
7. Carry out data analysis:
• Average pressure is 1.41 MPa @ 200 rpm with an error range of
±3%. Besides, pressure in each cylinder increases quickly and
evenly to the normal value.
• Failed piston ring: If the compression pressure is comparatively low
at the first compression stroke and increases gradually in the
following strokes but not reaches the normal value range unless
several drips of engine oil are dropped, it indicates a piston ring
fault. Inspect the piston ring to remove the fault.
• Faulty valve: If the compression pressure is comparatively low at
the first compression stroke and increases gradually in the
following strokes but not reaches the normal value range even after
several drips of engine oil are dropped, it indicates a valve fault.
Inspect the valve to remove the fault.
8. After measurement is completed, install the spark plugs and tighten
to 23±3 N·m.
9-243 Engine/Propulsion
9.5.3.11 Engine Noise Under Load (208587)
Engine Noise Under Load
Condition
Low oil pressure
Loose connecting bolt to the transmission
Loose and/or damaged flywheel
Excessive piston - to - cylinder bore clearance
Excessive crankshaft thrust bearing clearance
Excessive crankshaft bearing clearance
Actions
Insufficient or poor oil supply to components.
1. Perform oil pressure test.
2. Repair or replace all damaged components.
1. Inspect the torque converter bolt and the flywheel.
2. Repair or replace all damaged components.
1. Inspect flywheel and flywheel attaching bolts.
2. Repair or replace all damaged components.
1. Inspect the piston rings for low ring tension, broken or
worn rings, and inspect cylinder bore.
2. Repair or replace all damaged components.
1. Inspect the crankshaft end play and crankshaft thrust
bearings.
2. Repair or replace all damaged components.
1. Inspect the crankshaft bearings and crankshaft journals.
2. Repair or replace all damaged components.
 9-244 Engine/Propulsion

9.5.3.12 Engine Will Not Crank - Crankshaft Will Not Rotate (208588)
Engine Will Not Crank - Crankshaft Will Not Rotate
Condition Actions
1. Inspect the accessory drive system components.
Seized accessory drive system component
2. Repair or replace all damaged components.
1. Inspect for broken head gasket(s).
Hydraulically locked cylinder: coolant/antifreeze in
2. Inspect for cracked engine block or cylinder head.
cylinder; oil in cylinder; fuel in cylinder
3. Inspect for a sticking fuel injector.
1. Disengage the clutch.
Seized transmission
2. Rotate crankshaft at the pulley.
Material in cylinder
● Inspect the cylinder for damaged components and/or
● Broken valve
foreign materials.
● Piston material
● Repair or replace as required.
● Foreign material
● Inspect the crankshaft and connecting rod bearings.
Seized crankshaft or connecting rod bearing
● Repair as required.
● Inspect the connecting rods.
Bent or broken connecting rod
● Repair or replace as required.
● Inspect the crankshaft.
Broken crankshaft
● Repair or replace as required.
9-245 Engine/Propulsion

9.5.3.13 Lower Engine Noise, Regardless of Engine Speed (208586)

Lower Engine Noise, Regardless of Engine Speed
Condition Actions
Worn drive components (abnormalities such as
severe
1. Inspect the drive components.
cracking, bumps or missing areas in the accessory
2. Repair or replace all damaged components.
drive belt and/or misalignment of the system
components.)
Insufficient or poor oil supply to crankshaft and connecting
rod bearings.
Low oil pressure
1. Perform oil pressure test.
2. Repair or replace all damaged components.
1. Inspect the cylinder balance with scan tool to help locate
the cylinder that is the source of the noise.
Leaking and/or sticking fuel injection nozzle (A stuck
2. If you cannot locate the cylinder that is the source of the
fuel injection nozzle can cause a noise similar to a
noise, diagnose the engine for mechanical damage.
damaged piston, rod or rod bearing.)
3. If it has been determined that the fuel injection nozzle is
causing the noise, replace the fuel injection nozzle.
1. Inspect crankshaft pulley and pulley bolt.
Loose and/or damaged crankshaft pulley
2. Repair or replace the damaged components.
1. Inspect the torque converter bolt and the flywheel.
Loose connecting bolt to the transmission
2. Repair or replace all damaged components.
1. Inspect flywheel and flywheel attaching bolts.
Loose and/or damaged flywheel
2. Repair or replace all damaged components.
1. Inspect the piston, piston pin and the connecting rod.
Excessive piston pin - to - bore clearance
2. Repair or replace all damaged components.
1. Inspect connecting rod and connecting rod bearings.
Misaligned or bent connecting rod
2. Repair or replace all damaged components.
1. Inspect the connecting rod bearings, connecting rods,
Excessive connecting rod bearing clearance crankshaft and crankshaft journals.
2. Repair or replace all damaged components.
1. Inspect the crankshaft bearings and crankshaft journals.
Excessive crankshaft bearing clearance
2. Repair or replace all damaged components.
9.5.3.14 Oil Consumption Diagnosis (208593)
Excessive oil consumption does not refer to oil
leakage, but to oil consumption of 0.9 L or more within
the range of 3,200 km (2,000 miles). The causes of
excessive oil consumption may include the following
conditions:
• External oil leaks
Tighten the bolt or replace the gasket or oil seal
as necessary.
• Incorrect oil level or improper reading of the oil
level indicator
With the vehicle on a level surface, run the engine
for a few minutes, allow adequate drain down time
and check for the correct engine oil level.
• Improper oil viscosity
Use the recommended SAE viscosity for the
prevailing temperatures.
• Continuous high speed driving and/or long - time
driving
 9-246 Engine/Propulsion

• Crankcase ventilation system restrictions or 4. Visually inspect the suspected components.

malfunctioning components Track along the leaking trace as directed by the
• Worn or leaking valve stem and/or valve stem oil white powder to locate the leak.
seal Invisible and staining method:
Reference instructions: Install a large - size A staining and invisible light tool kit can be used to
optional valve and/or new valve steam oil seal. locate the leak. Refer to the manufacturer’s
• Broken, worn, not seated properly piston rings or instructions when using the tool kit.
improperly installed valve seat 1. Pour the specified amount of dyestuff into the
Take enough time to install the piston ring. engine oil filler tube.
Replace the damaged or worn piston ring as 2. Operate the vehicle under normal operating
necessary. conditions as directed in the tool kit instructions.
• Improperly installed or miss - fitted piston 3. Illuminate the suspected area with invisible light.
9.5.3.15 Oil Leak Diagnosis (208595) A yellow passage will appear in the leak location.
You can repair most fluid leaks by first, visually Leak repair:
locating the leak, repairing or replacing the component. Once the leak location is confirmed, track along the
Sometimes it is difficult to locate the leak or make leak trace to find out the source of leak. Do confirm the
repairs. The following steps can help you locate and cause of leak so as to ensure correct repair. If only the
repair most of leaks. gasket is replaced with the bent seal flange not
Leak location.confirmation handled, the leak cannot be repaired. Also replace the
bent flange. Before repairing the leak, inspect the
1. Identify the fluid. Confirm the type of leaking fluid following items and repair them as they are probably
to be engine oil, transmission fluid, steering fluid, the causes of leak.
etc.
Gasket:
2. Confirm the source of leak.
1. Excessively high fuel level/pressure
(1) Run the vehicle at the normal operating
temperature and then park it over a large 2. Crankcase ventilation system fault
sheet of paper. 3. Improperly tightened fasteners
(2) Wait several minutes. 4. Dirty or damaged threads
(3) Find out the approximate location of leak 5. Warping flange or sealing surfaces
according to the drippings on the paper. 6. Scratched, burred or otherwise damaged sealing
3. Visually inspect the suspected components surfaces
around. Inspect all gasket mating faces around
for leakage. Use a mirror to assist in looking at the
hard - to - see area.
4. If no leak location is discovered, it is necessary to
clean the suspected area with degreaser, vapor
or solvent sprays.
(1) Clean the area thoroughly.
(2) Blow the area dry.
(3) Operate the vehicle for several kilometers at
normal operating temperature and at varying
speed.
(4) Visually inspect the suspected components
after operating the vehicle.
(5) If the leak location cannot be confirmed, use
the powder method, or the invisible light and
staining method.
Powder method:
1. Clean the suspected area.
2. Apply atomized powder to the suspected area, for
example, foot powder.
3. Operate the vehicle under normal operating
conditions.
9-247 Engine/Propulsion

7. Damaged or worn gaskets

8. Cracked or porous components
9. Usage of improper seals (if any)
Seal:
1. Excessively high fuel level/pressure
2. Crankcase ventilation system fault
3. Damaged, scratched, burred or nicked seal bores
4. Damaged or worn seals
5. Obvious improper installations
6. Cracked components
7. Scratched, nicked or damaged shaft surface
8. Excessively worn seals due to loose or worn
bearings
 9-248 Engine/Propulsion

9.5.3.16 Oil Pressure Diagnosis and Testing (208594)

Oil Pressure Diagnosis and Testing
Procedure Operation Value Yes No
Does the oil pressure indicator The system is
1 —— Go to Step 2.
illuminate? normal.
Check the oil level in the
2 crankcase. Is the oil level —— Go to Step 3. Go to Step 4.
excessively low?
Fill oil until the level reaches
3 the full mark on the indicator. Is —— Go to Step 1. ——
the repair done?
Check the idle speed. Is the
4 idle speed lower than the 775±30 r/m Go to Step 5. Go to Step 6.
specified value?
Increase the idle speed. Does
5 —— Go to Step 1. ——
the speed increase?
check the oil pressure switch.
6 Is the oil pressure switch —— Go to Step 7. Go to Step 8.
incorrect or faulty?
Install a new oil pressure
7 —— Go to Step 1. ——
switch. Is the repair done?
Check the oil pressure gauge.
8 Is the oil pressure gauge —— Go to Step 9. Go to Step 10.
incorrect or faulty?
Install a new oil pressure
9 —— Go to Step 1. ——
gauge. Is the repair done?
Check the engine oil. Is the
engine oil in the crankcase
10 —— Go to Step 11. Go to Step 12.
diluted or of an improper
viscosity?
9-249 Engine/Propulsion

Oil Pressure Diagnosis and Testing (Cont’d)

Replace with engine oil of
appropriate viscosity so as to
11 reach the expected —— Go to Step 1. ——
temperature. Is the repair
done?
Check the oil pump. Is the oil
12 —— Go to Step 13. Go to Step 14.
pump worn or contaminated?
Replace the oil pump. Is the
13 —— Go to Step 1. ——
repair done?
Check the Oil filter. Is the oil
14 —— Go to Step 15. Go to Step 16.
filter blocked?
Install a new oil filter. Is the
15 —— Go to Step 1. ——
repair done?
Check the oil strainer screen.
16 Is the oil strainer screen loose —— Go to Step 17. Go to Step 18.
or blocked?
Tighten or replace the oil
17 strainer screen as necessary. —— Go to Step 1. ——
Is the repair done?
Check the oil suction pipe. Is
18 —— Go to Step 19. Go to Step 20.
the oil suction pipe porous?
Replace the oil suction pipe. Is
19 —— Go to Step 1. ——
the repair done?
Check the bearing clearance.
Is the bearing clearance
20 0.018~0.050 mm Go to Step 21. Go to Step 22.
greater than the specified
value?
Replace the bearing as
21 —— Go to Step 1. ——
necessary. Is the repair done?
 9-250 Engine/Propulsion

Oil Pressure Diagnosis and Testing (Cont’d)

Check the oil gallery. Has the
22 oil gallery cracked or is it —— Go to Step 23. Go to Step 24.
porous or blocked?
Repair or replace the engine
23 —— Go to Step 1. ——
block. Is the repair done?
Check the oil gallery plug. Is
24 the oil gallery plug missing or —— Go to Step 25. Go to Step 26.
installed improperly?
Install or repair the plug as
25 —— Go to Step 1. ——
necessary. Is the repair done?
Check the camshaft. Is the
The system is
26 camshaft worn or with traces —— Go to Step 27.
normal.
of rough machining?
Replace the camshaft. Is the
27 —— Go to Step 1. ——
repair done?
9-251 Engine/Propulsion

9.5.3.17 Symptoms - Engine Mechanical (1.5T) 3. Check the engine lubrication system for the
(208578) following conditions:
Strategy Based Diagnosis ○ Correct oil level;
1. Review the system operations in order to ○ Proper lubricant viscosity;
familiarize yourself with the system functions. ○ Properly used oil filter;
2. Perform “6.2.2.7 Diagnostic System Check - ○ Oil contamination or combustion.
Vehicle” under engine management system.
Refer to “9.2.3.4 Symptoms - Engine Controls” 4. Verify the exact operating conditions under which
under engine controls. the concern exists. Record the following factors:
All diagnosis on a vehicle should follow a logical ○ Engine speed (r/m);
process. “6.2.2.5 Strategy Based Diagnosis” is a ○ Ambient temperature;
uniform approach for repairing all systems. The ○ Engine temperature;
diagnostic flow may always be used in order to resolve
○ Amount of engine warm - up time and vehicle
a system problem. The diagnostic flow is the place to
running speed.
start when repairs are necessary. For details about
strategy based diagnosis and relevant procedures, 5.Compare the engine sounds, if applicable, to a
refer to “9.2.3.4 Symptoms - Engine Controls” under known good engine and make sure you are not
engine controls. trying to correct a normal condition.
Visual/Physical Inspection Intermittent
1. Inspect for aftermarket devices which could affect In case of an intermittent condition, test the vehicle
the operation of the engine. under the same conditions that the customer reported
in order to verify the system
2. Inspect the easily accessible or visible system
components for obvious damage or conditions
is operating properly.
which could cause the symptom.
General Engine Diagnosis
Condition Possible Causes Actions
Fuel system fault:
Incorrect or impure fuel
Clean the fuel and the fuel line.
Insufficient fuel in the fuel tank
Fill fuel into the fuel tank.
Restricted or fouled fuel filter
Hard start (the crankshaft rotates Replace the fuel filter.
Restricted fuel line
normally) Clean the fuel line.
Fuel pump fault
Replace the fuel pump.
Fuel injector fault
Replace the fuel injector.
Water intrusion in or impure fuel in
Clean the fuel tank.
the fuel tank
 9-252 Engine/Propulsion

Compression pressure drop:

Improperly tightened fuel injector
Improperly tightened glow plug Tighten to the specified torque.
Cracked cylinder head gasket Tighten to the specified torque.
Leaking valve seat Tighten to the specified torque.
Interfered valve stem Replace the cylinder head.
Damaged valve spring or reduced Replace the valve.
spring elasticity
Replace the valve spring.
Abnormal interference with piston
Replace the piston ring.
and cylinder
Replace the cylinder block.
Excessively worn piston, ring or
cylinder
Others:
Broken timing chain Replace the timing chain.
Faulty positive crankcase ventilation Inspect and replace the positive
(PCV) valve crankcase ventilation valve.
Loose, damaged or leaking vacuum Connect the hose correctly or
hose replace it.
Leaking intake system gasket
Compression pressure drop Refer to information given above.
Fuel system fault:
Restricted fuel line Clean the fuel line.
Restricted or fouled fuel filter Replace the fuel filter.
Incorrect or impure fuel Clean the fuel and the fuel line.
Lack of engine power Others:
Clean or replace the air filter
restricted or fouled air cleaner
element.
element
Replace the intake system gasket.
Leaking intake system gasket
Repair or replace the brake.
Jammed brake
Adjust or replace the clutch.
Slipping clutch
Compression pressure drop
Refer to information given above.
Fuel system fault:
Clean the fuel line.
Restricted fuel line
Replace the fuel filter.
Restricted or fouled fuel filter
Clean the fuel and the fuel line.
Incorrect or impure fuel
Replace the fuel pump.
Fuel pump fault
Replace the fuel injector.
Fuel injector fault
Rough idle Others:
Clean or replace the air filter
restricted or fouled air cleaner
element.
element
Inspect and replace the positive
Faulty positive crankcase ventilation
crankcase ventilation valve.
(PCV) valve
Connect the hose correctly or
Loose, damaged or leaking vacuum
replace it.
hose
Replace the intake system gasket.
Leaking intake system gasket
9-253 Engine/Propulsion
Engine hesitation (the engine
responds reluctantly as the
accelerator pedal is depressed and
this condition is more obvious at
cruise or starting.)
Engine surge (the engine power
fluctuates at constant speed and the
speed changes even though the
accelerator pedal is not depressed.)
Overheating
Compression pressure drop
Refer to information given above.
Fuel system fault:
Clean the fuel line.
Restricted fuel line
Replace the fuel filter.
Restricted or fouled fuel filter
Clean the fuel and the fuel line.
Incorrect or impure fuel
Replace the fuel pump.
Fuel pump fault
Replace the fuel injector.
Fuel injector fault
Others:
Clean or replace the air filter
restricted or fouled air cleaner
element.
element
Replace the intake system gasket.
Leaking intake system gasket
Compression pressure drop
Refer to information given above.
Fuel system fault:
Clean the fuel line.
Restricted fuel line
Replace the fuel filter.
Restricted or fouled fuel filter
Clean the fuel and the fuel line.
Incorrect or impure fuel
Replace the fuel pump.
Fuel pump fault
Replace the fuel injector.
Fuel injector fault
Others:
Clean or replace the air filter
restricted or fouled air cleaner
element.
element
Replace the intake system gasket.
Leaking intake system gasket
Cooling system fault: Refill the coolant.
Insufficient coolant Replace the thermostat.
Thermostat fault Replace the coolant fan.
Coolant fan fault Replace the water pump.
Poor water pump performance Clean and repair or replace the
restricted or leaking radiator radiator.
Replace the engine oil with the
Lubricant system fault
specified oil.
Poor engine oil quality
Clean or replace the oil filter or filter
Restricted oil filter or filter screen
screen.
Insufficient engine oil
Refill the engine oil.
Poor oil pump performance
Replace or repair the oil pump.
Leakage of engine oil
Repair the affected parts.
Others:
Repair or replace the brake.
Jammed brake
Adjust or replace the clutch.
Slipping clutch
Replace the intake system gasket.
Leaking intake system gasket

High fuel consumption
Low oil pressure
Large knock noise (the engine makes
sharp metallic knocks that change
with throttle opening.)
Excessive oil consumption
9-254 Engine/Propulsion
Cooling system fault:
Replace the thermostat.
Thermostat fault
Compression pressure drop
Refer to information given above.
Fuel system fault:
Clean the fuel line.
Restricted fuel line
Replace the fuel filter.
Restricted or fouled fuel filter
Clean the fuel and the fuel line.
Incorrect or impure fuel
Replace the fuel pump.
Fuel pump fault
Replace the fuel injector.
Fuel injector fault
Others:
Repair or replace the valve.
Improperly installed valve
Repair or replace the clutch.
Slipping clutch
Adjust the tire pressure.
Low tire pressure
Lubricant system fault: Replace the engine oil with the
Insufficient oil viscosity specified oil.
Loose oil pressure switch Tighten the oil pressure switch.
Insufficient engine oil Refill the engine oil.
Restricted oil filter screen Clean the filter screen.
Poor oil pump performance Replace the oil pump.
Engine overheating
Fuel system fault: Refer to “9.4.3.2 Engine Heating”.
Restricted or fouled fuel filter Replace the fuel filter.
Leaking intake system gasket Replace the intake system gasket.
Excessive carbon deposits due to Clean the carbon deposits.
abnormal combustion
Leakage of engine oil
Tighten the drain plug.
Loose drain plug
Tighten the oil pan bolt.
Loose oil pan bolt
Clean and trim the liquid gasket.
Poor liquid gasket performance
Tighten the oil filter cap.
Loose oil filter cap
Tighten the oil pressure switch.
Loose oil pressure switch
Replace the camshaft front oil seal.
Leaking camshaft front oil seal
Replace the crankshaft front oil seal.
Leaking crankshaft front oil seal
Replace the crankshaft rear oil seal.
Leaking crankshaft rear oil seal
Replace cylinder head cover gasket.
Cylinder head cover gasket leakage
Replace cylinder head gasket.
Cylinder head gasket leakage
9-255 Engine/Propulsion
Oil in combustion chamber:
Sticking piston ring
Worn piston or cylinder
Worn piston ring or ring groove
Insufficient cut section on the piston
ring
Worn or damaged valve system
Valve noise:
Worn valve stem and valve guide
Reduced valve spring elasticity
Worn finger - follower and valve
bridge
Noise from piston, ring and cylinder
Worn piston, ring or cylinder
Connecting rod noise:
Engine noise Worn connecting rod bearing Loose
connecting rod nut
Crankshaft noise:
Worn crankshaft bearing
Worn crankshaft bearing journal
Loose bearing cap bolt
Excessive crankshaft thrust bearing
clearance
Low oil pressure
Clean the carbon deposits and
replace the piston ring.
Replace the piston or the cylinder
block.
Replace the piston or the piston ring.
Adjust the piston position.
Replace the valve system.
Replace the valve or the cylinder
head.
Replace the valve spring.
Replace the finger - follower or the
valve bridge.
Replace the piston, ring or cylinder
block.
Replace the connecting rod bearing.
Tighten the connecting rod nut to the
specified torque.
Replace the crankshaft bearing.
Replace the crankshaft bearing
journal.
Tighten the bearing cap to the
specified torque.
Adjust or replace.
Refer to “9.5.3.16 Oil Pressure
Diagnosis and Testing”.

9.5.3.18 Upper Engine Noise, Regardless of Engine Speed (208585)
Upper Engine Noise, Regardless of Engine Speed
Condition
Low oil pressure
Improperly lubricated valve drive components
Worn or damaged valve drive components
Sticking valve
Worn or faulty camshaft lobes
Damaged or misaligned timing gears
9-256 Engine/Propulsion
Actions
Insufficient or poor oil supply to the valve system
1. Perform oil pressure test.
2. Repair or replace all damaged components.
1. Inspect the valve finger - follower, valve bridge, valve finger -
follower lifter, engine oil pump and the engine block oil gallery.
2. Repair or replace all damaged components.
1. Inspect valve drive components.
2. Repair or replace all damaged components.
Carbon on the valve stem or valve seat may cause the valve to stick.
1. Inspect valves and valve guides.
2. Repair or replace all damaged components.
1. Inspect camshaft lobes.
2. If damaged, replace the camshaft.
1. Inspect timing gears.
2. Replace all damaged components.
9-257 Engine/Propulsion

9.5.3.19 Valve Clearance Testing

Measurement and Inspection
1. Remove the camshaft cover. Refer to “9.5.4.15 Camshaft Cover
Replacement”.
2. Rotate the crankshaft pulley until the timing mark on the timing
chain aligns with that on the camshaft timing gear.
3. At the same time, align the notch mark on the crankshaft pulley with
the “0” point on the engine front cover. In this way, the cylinder 1 piston
is adjusted to the top dead center.

4. Measure the valve clearance with a feeler gauge.

Intake valve: 0.075 mm~0.125 mm
Exhaust valve: 0.245 mm~0.295 mm
If the measured value is larger, replace with an appropriate valve lifter.
Refer to “9.5.4.35 Valve Lifter Replacement”.
 9-258 Engine/Propulsion

5. Measure in the sequence shown in the figure after steps 1 and 2

are performed.

6. Rotate the crankshaft pulley 360° and measure the remaining

valve clearances in the sequence shown in the figure.
9-259 Engine/Propulsion

9.5.4 Repair Instructions - On Vehicle

9.5.4.1 Engine Oil and Oil Filter Replacement (1.5T) (208623)
Removal Steps
1. Raise the vehicle. Refer to “0.2.1.14 Vehicle Lifting and Jacking
Caution”.
2. For environmental protection, place a suitable container below the
engine to catch the engine oil.
3. Screw the oil pan drain bolt off with a wrench and drain the engine
oil.
Caution: Refer to “0.2.1.30 Fastener Caution”.
4. Install the oil pan bolt.
Tighten
Oil pan drain bolt: 25±5 N·m

5. Install oil filter remover/installer PT - 0184 to the oil filter to remove

and discard the oil filter.
Note: For environmental protection, place a suitable container below the
engine oil filter to catch the engine oil.
6. Inspect the oil filter bolt and replace it as necessary.
 9-260 Engine/Propulsion

Installation Procedure
Caution: Refer to “0.2.1.30 Fastener Caution”.
1. If oil filter mounting stud (1) is removed, first install the oil filter stud.
Tighten
Oil filter mounting stud: 22±2 N·m
2. Install oil filter (2) by first finger tightening it. Take care to ensure
installation at the correct position without damage to the part.
3. Install oil filter remover/installer PT - 0184 and then tighten the oil
filter with a monkey wrench.
Tighten
Oil filter: 20±2 N·m
9-261 Engine/Propulsion

9.5.4.2 Air Conditioning Compressor Bracket Replacement (1.5T) (48303)

Air Conditioning Compressor Bracket Replacement

Callout Component Name
Preliminary Procedure
1. Remove the compressor belt. Refer to “9.5.4.3 Compressor Belt Replacement”.
2. Remove the air conditioning compressor. Refer to “10.1.5.22 Air Conditioning Compressor Replacement”.
Air conditioning compressor bracket bolt (Qty.: 4)
Caution: Refer to “0.2.1.30 Fastener Caution”.
1
Tighten
35±4 N·m
2 Air conditioning compressor bracket
 9-262 Engine/Propulsion

9.5.4.3 Compressor Belt Replacement (1.5T)

Removal Steps
1. Lift the vehicle. Refer to “1.1.1.4 Lifting and Jacking the Vehicle”.
2. Remove the engine lower cover plate.
3. Install tool (1)—water pump belt remover PT - 0059.
4. Keep tool (1) fitting against the pulley and turn the pulley clockwise.
5. At the same time, pull belt (2) at the arrow - indicated locations
outwards to remove the belt.

Installation Procedure
1. Pass one end of belt (2) onto the water pump pulley.
2. Pass the other end onto upper of the steering pump pulley and
install (3) PT - 0060 belt installer.
3. Hold the belt and the tool, turn tool (3) clockwise with a wrench until
the belt seats correctly in the pulley groove.
9-263 Engine/Propulsion

9.5.4.4 Vacuum Pump Assembly Replacement (1.5T)

Removal Steps
1. Open the engine hood.
2. Remove the engine trim cover.
3. Remove the thermostat housing as necessary.
4. Loosen the vacuum pipe clamp and disconnect the vacuum pipe
from the vacuum pump.
5. Remove vacuum pump mounting bolt (4).
6. Remove engine harness bracket (3).
7. Remove vacuum pump assembly (2) and vacuum pump gasket (1).

Installation Procedure
1. Lubricate the vacuum pump assembly O - ring before installing the
vacuum pump.
2. Use bolt (4) to install vacuum pump gasket (1), vacuum pump
assembly (2) and harness bracket (3) to the cylinder head and the
exhaust camshaft.
3. Tighten vacuum pump bolt (4).
Tighten
Vacuum pump bolt (Qty.: 3): 22±2 N·m
4. Connect the vacuum pipe to the vacuum pump and tighten the
clamp.
5. Install the thermostat housing.
6. Install the engine trim cover.
7. Close the engine hood.
9.5.4.5 Piston Oil Nozzle Removal (1.5T)
1. Loosen and remove piston cooling nozzle mounting bolt (1).
2. Remove piston cooling nozzles (2) of cylinder 1 and cylinder 3 and
piston cooling nozzles (3) of cylinder 2 and cylinder 4.
Note: Piston nozzle of cylinder 1 or cylinder 3 is marked with “1 3” and
that of cylinder 2 or cylinder 4 is marked with “2 4”.
 9-264 Engine/Propulsion

9.5.4.6 Piston Oil Nozzle Installation (1.5T)

1. Apply oil on the seal ring and install piston nozzle (2).
2. Tighten piston cooling nozzle mounting bolt (1).
Tighten
Piston nozzle mounting bolt: 10±2 N·m
Note: The piston nozzles are identified to be those at the left and those
at the right side. Piston nozzle of cylinder 1 or cylinder 3 is marked with
“1” or “3” and that of cylinder 2 or cylinder 4 is marked with “2” or “4”. If
installation becomes difficult, you may have taken the left ones as the
right ones. Adjust the nozzle position and never continue installation by
force.
9-265 Engine/Propulsion

9.5.4.7 Drive Belt Tensioner Replacement (1.5T) (208598)

Drive Belt Tensioner Replacement

Callout Component Name
Preliminary Procedure
1. Remove the compressor belt. Refer to “9.5.4.3 Compressor Belt Replacement”.
2. Remove the drive belt. Refer to “Water Pump Belt Replacement”.
Drive belt tensioner bolt (Qty.: 1)
Caution: Refer to “0.2.1.30 Fastener Caution”.
1
Tighten
50±5 N·m
2 Drive belt tensioner
 9-266 Engine/Propulsion

9.5.4.8 Intake Manifold Replacement (1.5T) (208606)

Removal Steps
1. Open the engine hood.
2. Disconnect the fuel pump relay, start the engine, stop it and start it
again to run the engine for 10s so as to release the fuel pressure in the
fuel system.
3. Disconnect the battery negative cable. Refer to “0.2.1.21 Ignition OFF
When Disconnecting Battery Caution”. Wait for the engine to cool down.
4. Loosen intercooler air outlet pipe to throttle body pipe clamp (1) to
separate the intercooler air outlet pipe from the throttle body.

5. Disconnect throttle body harness connector (2).

6. Disconnect intake air temperature/pressure sensor assembly (high
pressure) harness connector (2). Remove the sensor as necessary.
Refer to “9.3.4.30 Intake Air Temperature Sensor Replacement”.
7. Disconnect canister solenoid valve harness connector (3).
8. Disconnect the engine harness to fuel rail connector (4).

9. Disconnect low - load positive crankcase ventilation pipe (1) from

the intake manifold end.
10. Fix a highly absorbent cloth under fuel rail (2) and loosen fuel feed
pipe (3) from the fuel rail.
Note: Block the disconnected joint with a plug to prevent pollutants from
entering.
11. Remove fuel vapourizer tube (4) from canister solenoid valve (5).
12. If necessary, press and loosen the quick - connect joints at both
ends of desorption rubber pipe (6) to remove desorption rubber pipe (6)
and remove canister solenoid valve (4) from the canister solenoid valve
bracket.
13. Remove desorption rubber pipe one - way valve (7) as necessary.
9-267 Engine/Propulsion

14. Loosen bolt (3) at intake manifold fuel rail electrostatic ground wire
to remove the fuel rail electrostatic ground wire.
15. Loosen and remove fuel rail bolts (1) and take down fuel rail
assembly (2).
Note: Take care not to spray fuel remaining in the fuel rail to the parts
around.

16. Raise the vehicle. Refer to “0.2.1.14 Vehicle Lifting and Jacking
Caution”.
17. Loosen and remove two intake manifold bracket to intake manifold
bolts (1).
18. Lower the vehicle.

19. Remove the remaining intake manifold mounting bolts and nuts in a
sequence opposite to that shown in the figure, take down the intake
manifold assembly and the gasket. Discard the gasket as necessary.
20. Remove the throttle body assembly from the intake manifold. Refer
to “9.3.4.10 Throttle Body Assembly Replacement”.
 9-268 Engine/Propulsion

Installation Procedure
1. Install the throttle body to the intake manifold. Refer to “9.3.4.10
Throttle Body Assembly Replacement” under Repair Instructions - Off
Vehicle.

2. Apply appropriate amount of grease on the intake air

temperature/pressure sensor seal ring, install the intake air
temperature/pressure sensor assembly and tighten one bolt (1) to 10±2
N·m.

3. Apply appropriate amount of grease on the four fuel injection nozzle

seal rings of fuel rail assembly, install to the intake manifold and tighten
the 2 bolts (2) to 18±2 N·m.
4. If the desorption rubber pipe one - way valve is removed, lubricate
one - way valve (3) seal ring and then install the valve to the intake
manifold.
9-269 Engine/Propulsion

Caution: Refer to “0.2.1.30 Fastener Caution”.

5. Clean the intake manifold and the cylinder head mating face.
6. Install the intake manifold with a new gasket to the cylinder head.
7. Place the fuel rail electrostatic ground to the corresponding bolt
hole.
8. Tighten the intake manifold bolts and nuts as per the sequence
shown in the figure.
Tighten
3 intake manifold bolts: 25±2 N·m
2 intake manifold nuts: 25±2 N·m

9. Raise the vehicle. Refer to “0.2.1.14 Vehicle Lifting and Jacking

Caution”.
10. Install the 2 intake manifold bracket bolts (1) and tighten to 20±2
N·m.

11. Lower and level the vehicle. Install the canister solenoid valve to
the canister solenoid valve bracket on the intake manifold.
12. Install the desorption rubber pipe (6) to the canister solenoid valve
and the intake manifold.
13. Connect fuel vapourizer tube (4) and install canister solenoid valve
(5).
14. Install fuel feed pipe (3) to the fuel rail.
15. Install low - load positive crankcase ventilation pipe (1)
disconnected from the intake manifold end to the intake manifold and
the oil - gas separator.
 9-270 Engine/Propulsion

16. Connect the engine harness to throttle body harness connector (2).
17. Connect the engine harness to intake air temperature/pressure
sensor assembly (high pressure) harness connector (2).
18. Connect the engine harness to canister solenoid valve harness
connector (3).
19. Connect the engine harness to fuel rail connector (4).

20. Connect the intercooler air outlet pipe to the throttle body and
tighten pipe clamp (1).
21. Connect the battery negative cable and the fuel pump relay.
22. Fill all kinds of fluids to the specified levels.
23. Inspection: Confirm that all harnesses and pipes are installed
properly without problems such as interference, missing, mistakes and
leakage.
24. Connect the battery negative cable. Refer to “0.2.1.21 Ignition OFF
When Disconnecting Battery Caution”.
9-271 Engine/Propulsion

9.5.4.9 Cylinder Head Replacement (1.5T) (208610)

Cylinder Head Replacement

Callout Component Name
Preliminary Procedure
1. Disconnect the battery negative cable. Refer to “9.1.4.2 Battery Negative Cable Disconnection and
Connection”.
2. Drain the coolant. Refer to “9.4.4.16 Cooling System Draining and Filling”.
3. Remove the camshaft. Refer to “9.5.4.16 Camshaft Replacement”.
4. Remove the intake manifold. Refer to “9.5.4.8 Intake Manifold Replacement”.
5. Remove the exhaust manifold. Refer to “Exhaust Manifold Replacement”.
Cylinder head bolt (Qty.: 10)
Caution: Refer to “0.2.1.30 Fastener Caution”.
1
Tighten
20 N·m (45°- 50°)
Cylinder head
2 Procedure
1. Clean the sealing surface of the cylinder head and the cylinder block.
Cylinder head gasket
3 Tip
Discard the used cylinder head gasket and replace it with a new one as necessary.
 9-272 Engine/Propulsion

9.5.4.10 Engine Flywheel Replacement (1.5T) (208612)

Removal Steps
1. Lift the engine stably with engine balancing stand PT - 0069.
Note: Take necessary protective measures to protect parts around the
engine from scratches and damage.
2. Raise the vehicle. Refer to “0.2.1.14 Vehicle Lifting and Jacking
Caution”.
3. Remove the transmission assembly. Refer to “17.3.5.1
Transmission Replacement”.

4. Use flywheel holder PT - 0192 to fix the flywheel.

5. You can also use flywheel fixing tool PT - 0324 or a similar tool to
fix the flywheel.

6. Loosen and remove the retaining bolt and remove the engine
flywheel.
7. Clean and inspect the flywheel. If any flywheel tooth is damaged,
inspect the starter for normal operation. If the starter drive mechanism is
excessively worn or damaged, replace the starter. Refer to “Starter
Replacement”.
9-273 Engine/Propulsion

Installation Procedure
1. Use special tool PT - 0066 to fix the engine flywheel.
2. Apply appropriate amount of thread locking adhesive on the
flywheel bolts and tighten the bolts in a sequence shown in the figure to
35 N·m +30°~35°. Do not depend on visual judgment wherever an angle
wrench is needed to tighten to the specified angle.
3. Install the transmission assembly. Refer to “17.3.5.1 Transmission
Replacement”.
4. Lower the vehicle evenly and remove the engine balancing stand.
Note: Apply appropriate amount of sealer on the fasteners when
installing the flywheel. Excessive usage of the sealer can lead to
incorrect component assembling or fastener loosening. If assembled
improperly, the component or fastener can loosen or fall off in which
case serious engine damage can result.
9.5.4.11 Crankshaft Rear Oil Seal Replacement (1.5T)
Removal Steps
1. Remove the flywheel. Refer to “9.5.4.10 Engine Flywheel
Replacement”.
2. Loosen and remove the 6 crankshaft rear oil seal seat bolts.
3. Loosen and remove the 2 oil pan to crankshaft rear oil seal seat
bolts (2).
4. Take down crankshaft rear oil seal seat (3).
5. Take down crankshaft rear oil seal seat locating pin (4).
6. Remove crankshaft rear oil seal (6) and discard it.
Note: If the crankshaft rear oil seal and the crankshaft rear oil seal seat
are replaced at the same time, do not remove the crankshaft rear oil
seal.
 9-274 Engine/Propulsion

Installation Procedure
1. Before installation, lubricate with engine oil the new crankshaft rear
oil seal to engine crankshaft mating surface.
2. Apply sealer on crankshaft rear oil seal seat to cylinder block
mating face. Take care to avoid the bolt holes while installing the
crankshaft rear oil seal (if it has been removed).
• Sealer diameter: 4±0.5 mm
• Distance from sealer center line to inside chamfer edge: 1±1 mm

Caution: Refer to “0.2.1.30 Fastener Caution”.

3. Install the crankshaft real oil seal seat to the cylinder block through
the crankshaft rear oil seal seat locating pin.
Tighten
Crankshaft rear oil seal seat bolt to: 10±2 N·m
Oil pan to crankshaft rear oil seal seat bolt to: 10±2 N·m

4. Use special tool (a) PT - 0058 to install the crankshaft rear oil seal.
5. Install the engine flywheel. Refer to “9.5.4.10 Engine Flywheel
Replacement”.
6. Install the transmission assembly. Refer to “17.3.5.1 Transmission
Replacement”.
9-275 Engine/Propulsion

9.5.4.12 Engine Front Cover with Oil Pump Replacement (1.5T) (208617)
Removal Steps
1. Open the engine hood, disconnect the fuel pump relay and start the
engine to release fuel pressure.
2. Disconnect the battery negative cable. Refer to “0.2.1.21 Ignition
OFF When Disconnecting Battery Caution”.
3. Lift the engine with engine balancing stand PT - 0069.
Note: Take necessary protective measures to protect parts around the
engine from scratches and damage.
4. Remove the air cleaner and the air cleaner outlet duct assembly.
Refer to “9.3.4.8 Air Cleaner Assembly Replacement” and “9.3.4.22 Air
Cleaner Outlet Duct Replacement”.
5. Remove the engine mount bracket. Refer to “Engine Mount Bracket
Replacement”. 6. Remove the camshaft cover. Refer to “9.5.4.15
Camshaft Cover Replacement”.
Note: Take care to protect camshaft parts from contamination.
7. Loosen and remove the engine HVAC water outlet pipe to water
pump bolt (1) and separate HVAC water outlet pipe (1).
8. Remove the water pump. Refer to “9.5.5.6 Water Pump Removal”.
 9-276 Engine/Propulsion

9. Raise the vehicle. Refer to “0.2.1.14 Vehicle Lifting and Jacking

Caution”.
10. Remove the air conditioning compressor. Refer to “10.1.5.22 Air
Conditioning Compressor Replacement”.
11. Place a container under the vehicle to catch engine oil.
12. Loosen and screw the oil pan drain bolt off and drain the engine oil.
Caution: Refer to “0.2.1.30 Fastener Caution”.
13. Install the oil pan drain bolt and tighten to 25±5 N·m.

14. Remove the transmission assembly. Refer to “17.3.5.1

Transmission Replacement”.
15. Remove the oil pan and the strainer. Refer to “9.5.4.20 Oil Pan
Replacement”.
16. Remove the drive belt. Refer to “Water Pump Belt Replacement”.
17. Remove the crankshaft pulley. Refer to “9.5.5.57 Crankshaft Pulley
Removal”.
18. Loosen and remove the 13 engine front cover to cylinder block
bolts.
19. Remove the engine front cover assembly (with oil pump).

20. Remove the 7 oil pump cover bolts.

Note: As the pump cover screw is soft, attach the screwdriver firmly
against the screw head and then to remove. Otherwise, thread
loosening is likely to happen.
21. Remove the oil pump cover, the oil pump inner rotor and the oil
pump outer rotor.
22. Check all oil pump parts for damage and if any, replace the
damaged one(s).
9-277 Engine/Propulsion

Installation Procedure
1. Lubricate the oil pump chamber on the engine front cover with fresh
oil and then install the oil pump inner rotor, outer rotor and cover.
2. Tighten the 7 oil pump cover screws (5) diagonally.
Tighten torque: 10±2 N·m
3. Tighten relief valve plug (6) to: 42±2 N·m.
Note: Before installation, apply the oil pump chamber completely with
vaseline, especially on the gap between the inner and the outer rotors.
This can ensure immediate priming as the engine is started.

4. Thoroughly clean the remaining sealer on mating surface between

engine front cover and cylinder block & cylinder head with a clean cloth.
5. Apply sealer on the mating face of engine front cover and cylinder
block & cylinder head and fill sealer in the sealer groove.
• Sealer diameter: 4.5±0.5 mm
• Distance from sealer center line to inside chamfer edge: 1±1 mm
6. The sealer line should be continuous in the correct shape and
position, bypassing the bolt holes successively. During installation, take
care not to damage the sealer line and tighten the front cover bolts
within 20 minutes after sealer application.

7. Install the front cover to the cylinder head and the cylinder block.
Locate with the front cover locating pin and ensure installation in place
in one time.
Caution: Refer to “0.2.1.30 Fastener Caution”.
8. Tighten the 13 front cover bolts in the sequence shown in the figure
and re - tighten 3 bolts (4), (3) and (6) as necessary.
Tighten
Front cover bolt: 22±2 N·m
 9-278 Engine/Propulsion

9. If the crankshaft front oil seal is removed, replace it with a new one
and install the new one with crankshaft front oil seal installer PT - 0026.
Ensure that the oil seal surface contacts the special tool and the
concave surface faces the engine.

10. Install the strainer and oil pan assembly. Refer to “9.5.4.20 Oil Pan
Replacement”.
11. Install the transmission assembly. Refer to “17.3.5.1 Transmission
Replacement”.
12. Install the crankshaft pulley. Refer to “9.5.5.57 Crankshaft Pulley
Removal”.
13. Install the belt tensioner. Refer to “9.5.4.7 Drive Belt Tensioner
Replacement”.
14. Install the air conditioning compressor. Refer to “10.1.5.22 Air
Conditioning Compressor Replacement”.
15. Install the drive belt. Refer to “Water Pump Belt Replacement”.
16. Install the water pump and connect the HVAC water outlet pipe.
Refer to “9.5.5.36 Water Pump Installation”.
17. Install the engine mount bracket. Refer to “9.5.4.23 Engine Mount
Bracket Replacement”.
Caution: Refer to “0.2.1.30 Fastener Caution”.
18. Lower the vehicle evenly. Refer to “0.2.1.14 Vehicle Lifting and
Jacking Caution”.
19. Install the air cleaner and the air cleaner outlet duct assembly.
Refer to “9.3.4.8 Air Cleaner Assembly Replacement” and “9.3.4.22 Air
Cleaner Outlet Duct Replacement”.
20. Install the camshaft cover. Refer to “9.5.4.15 Camshaft Cover
Replacement”.
21. Remove the engine balancing stand and fill fresh oil until the level
reaches between the maximum and the minimum marks on the oil level
indicator.
22. Inspect and confirm that no defects such as missing parts,
installation mistakes, leakage and interference exist.
23. Connect the battery negative cable. Refer to “0.2.1.21 Ignition OFF
When Disconnecting Battery Caution”.
9-279 Engine/Propulsion

9.5.4.13 Oil Level Indicator Tube Replacement (1.5T) (208621)

Removal Steps
1. Open the engine hood and pull out oil level indicator (3).
2. Loosen and remove the oil level indicator tube to turbocharger
retaining bolt (1).
3. Remove oil level indicator tube (2).

Installation Procedure
1. Inspect and confirm the oil level indicator seal is intact and then
insert the oil level indicator tube into the oil pan corresponding hole.
Caution: Refer to “0.2.1.30 Fastener Caution”.
2. Tighten the oil level indicator tube bracket bolt and tighten to 10±2
N·m.

3. Wipe the oil level indicator clean and insert the indicator back to the
tube.
4. Confirm that the oil level is normal and close the engine hood.
 9-280 Engine/Propulsion

9.5.4.14 Oil Pressure Relief Valve Replacement (1.5T) (208624)

Removal Steps
1. Remove the oil pan. Refer to “9.5.4.20 Oil Pan Replacement”.
2. Loosen and remove oil pressure relief valve plug (1), take down oil
pressure relief valve spring (2) and oil pressure relief valve (3).

Installation Procedure
1. Install the oil pressure relief valve and spring.
Caution: Refer to “0.2.1.30 Fastener Caution”.
2. Install the oil pressure relief valve plug and tighten it. Tighten oil
pressure relief valve plug to: 42±2 N·m
3. Install the oil pan. Refer to “9.5.4.20 Oil Pan Replacement”.
9-281 Engine/Propulsion

9.5.4.15 Camshaft Cover Replacement (1.5T)

(208627)
Removal Steps

9. Remove the oil filler cap.

10. Remove the 12 bolts along the camshaft cover
edge and the two long bolts in the middle.
1. Open the engine hood. Remove the camshaft cover.
2. Remove the engine trim cover. 11. Remove all camshaft cover gaskets as
necessary.
3. Remove the ignition coil. Refer to “9.3.4.29
Ignition Coil Replacement”.
4. Remove the vacuum pump assembly. Refer to
“9.5.4.4 Vacuum Pump Assembly
Replacement”.
5. Remove PCV pipe assembly (high load), PCV
pipe assembly (low load) and breather hose
assembly. Refer to “9.5.5.66 Positive
Crankcase Ventilation Pipe Removal”.
6. Remove the oil - gas separator as necessary.
7. Remove the camshaft phase actuator solenoid
valve assembly (VVT assembly). Refer to
“9.3.4.18 Camshaft Position Actuator Solenoid
Valve Replacement”.

8. Remove the turbocharger water return pipe to

camshaft cover mounting bolt and disconnect the
pipe from the camshaft cover.
 9-282 Engine/Propulsion

Installation Procedure

5. Install the camshaft phase actuator solenoid valve

Caution: Refer to “0.2.1.30 Fastener Caution”. assembly (VVT assembly). Refer to “9.3.4.18
Camshaft Position Actuator Solenoid Valve
1. If all the gaskets have been removed before, Replacement”.
install them to the camshaft cover first.
6. Install the oil - gas separator.
2. Install the camshaft cover to the engine cylinder
head and tighten the 12 short bolts along the 7. Install PCV pipe assembly (high load), PCV pipe
edge and the two long bolts in the middle assembly (low load) and breather hose assembly.
diagonally. Tighten camshaft cover bolt to: 10±2 Refer to “9.5.5.65 Positive Crankcase
N·m. Ventilation Pipe Installation”.
Tighten sequence 8. Install the vacuum pump assembly. Refer to
“9.5.4.4 Vacuum Pump Assembly Replacement”.
7 3 2 6 10
12 13 14 11
8 4 1 5 9
3. Tighten oil filler cap (3).

4. Install the turbocharger water return pipe to

camshaft cover mounting bolt and tighten to 10±2
N·m.
9-283 Engine/Propulsion

9. Install the ignition coil. Refer to “9.3.4.29 Ignition 5. Remove the camshaft sprocket. Refer to “9.5.4.25
Coil Replacement”. Camshaft Timing Chain, Sprocket, and
10. Install the engine trim cover. Tensioner Replacement”.
11. Inspect and confirm that no defects such as 6. Loosen and remove the camshaft bearing cap
installation mistakes and missing components bolts in the sequence shown below, take down
exist, and that the harnesses and pipelines are all the camshaft cover and then the camshaft.
fixed in place without leakage. 4 5 9 8 1
12. Close the engine hood. 3 6 10 7 2
9.5.4.16 Camshaft Replacement (1.5T) (208628) FRT
Removal Steps 3 6 10 7 2
4 5 9 8 1

1. Rotate the crankshaft pulley so that the timing

notch mark on the crankshaft pulley aligns with “0”
point on the engine front cover. In this way,
cylinder 1 is at the top dead center position.
2. Remove the ignition coil. Refer to “9.3.4.29
Ignition Coil Replacement”.
3. Remove the camshaft cover. Refer to “9.5.4.15
Camshaft Cover Replacement”.
4. Remove the engine front cover. Refer to “9.5.4.12
Engine Front Cover with Oil Pump
Replacement”.
 9-284 Engine/Propulsion

Note: Take care not to damage the valve lifter or fall sequence below:
the bolts or tool into the cylinder head.
9 5 1 3 7
Installation Procedure 11 6 2 4 8
FRT
12 6 2 4 8
10 5 1 3 7
Tighten
Camshaft bearing cap bolt: 10±2 N·m.

1. Pre - lubricate the camshaft journal and bearing

seat with fresh oil.
2. Rotate the crankshaft until the woodruff key
groove on crankshaft faces up and the timing
mark faces down. Do not further rotate the
crankshaft.
3. Install the intake camshaft with the timing 7. Install the camshaft sprocket, timing chain and
sprocket locating pin facing up. tensioner. Refer to “9.5.4.25Camshaft Timing
4. Install the exhaust camshaft with the exhaust Chain, Sprocket, and Tensioner
timing sprocket locating pin facing up. Replacement”.
8. Lubricate the timing system with fresh oil and then
install the engine front cover. Refer to “9.5.4.12
Engine Front Cover with Oil Pump
Replacement”.

5. Install the camshaft bearing cap as per the marks

on the camshaft bearing cap.
← 1I 2I 3I 4I
FRT
← 1E 2E 3E 4E
Caution: Refer to “0.2.1.30 Fastener Caution”.
6. Tighten the camshaft bearing cap bolts in the
9-285 Engine/Propulsion

9. Install the camshaft cover. Refer to “9.5.4.15

Camshaft Cover Replacement”.
10. Install the ignition coil. Refer to “9.3.4.29 Ignition
Coil Replacement”. Inspection: Confirm that no
defects such as missing parts and wrongly
installed parts exist, and that the harnesses and
pipe clamps are all located correctly without
interference and leakage.
 9-286 Engine/Propulsion

9.5.4.17 Valve Clearance Adjustment (208629)

Removal Steps
1. Remove the camshaft cover. Refer to “9.5.5.8 Camshaft Cover
Removal”.
2. Rotate the pulley until the timing mark on the timing chain aligns
with that on the camshaft timing gear.

3. At the same time, align the timing notch mark on the crankshaft
pulley with the “0” point on the engine front cover.

4. Measure the valve clearance with a feeler gauge.

Intake valve: 0.075 mm~0.125 mm
Exhaust valve: 0.245 mm~0.295 mm
If the measured value is larger, replace with an appropriate valve lifter.
Refer to “9.5.4.35 Valve Lifter Replacement”.
9-287 Engine/Propulsion

5. Measure in the sequence shown in the figure after steps 1 and 2

are performed.

6. Rotate the crankshaft pulley 360° and measure the remaining

valve clearances in the sequence shown in the figure.
 9-288 Engine/Propulsion

9.5.4.18 Valve Stem Oil Seal and Valve Spring Replacement (1.5T) (208630)
Removal Steps
1. Open the engine hood.
2. Disconnect the fuel pump relay, start the engine, stop it and start it
again to run the engine for 10s so as to release the fuel pressure in the
fuel system.
3. Disconnect the battery negative cable. Refer to “0.2.1.21 Ignition OFF
When Disconnecting Battery Caution”. Wait for the engine to cool down.
4. Drain the coolant. Refer to “9.4.4.16 Cooling System Draining and
Filling”.
5. Remove the engine assembly. Refer to “9.5.4.34 Engine
Replacement”.
6. Remove the engine cylinder head. Refer to “9.5.5.13 Cylinder Head
Removal” under Repair Instructions - Off Vehicle.
7. Remove the valve collet, valve spring seat, valve spring and valve;
mark them as per the positions when they are removed and place them
in order. Refer to “9.5.5.16 Cylinder Head Disassemble” under Repair
Instructions - Off Vehicle.
9-289 Engine/Propulsion

8. Remove the valve oil seal using special tool PT - 0028.

Cleaning: Clean the carbon deposits on the valve guide, valve, valve
seat and combustion chamber surface.
 9-290 Engine/Propulsion

Installation Procedure
1. Install the valve oil seal using special tool PT - 0027: first install the
oil seal to the special tool and then install it to the cylinder head.
2. Install the valve to the original position as per the marks made
during removal. Pay attention to mark “I” on the intake valve and “E” on
the exhaust valve.

3. Install the valve spring, valve spring seat and valve collet using
valve spring installer PT - 0005.
Note: Take care to ensure that the valve spring marked end faces up.
4. Assemble the engine cylinder head. Refer to “9.5.5.18 Cylinder
Head Assemble” under Repair Instructions - Off Vehicle.
5. Install the engine cylinder head. Refer to “9.5.5.30 Cylinder Head
Installation” under Repair Instructions - Off Vehicle.
6. Install the engine assembly. Refer to “9.5.4.34 Engine
Replacement”.
7. Fill the coolant to an appropriate level. Refer to “9.4.4.16 Cooling
System Draining and Filling”.
8. Connect the fuel pump relay.
9. Connect the battery negative cable. Refer to “0.2.1.21 Ignition OFF
When Disconnecting Battery Caution”.
10. Check all fluids levels to see if they are within the specified range.
Confirm that no problems such as installation mistakes, missing
components and fluid leakage exist.
9-291 Engine/Propulsion

9.5.4.19 Valve Spring Inspection and Measurement (208632)

1. Inspect the valve spring end smoothness and if it is not smooth,
replace the valve spring.
2. Inspect the valve spring for bending and wear. If it bends or is worn,
replace the valve spring.
3. Measure the valve spring perpendicularity using a bevel gauge and
if the perpendicularity exceeds 2°or the offset exceeds 1.5 mm, replace
the valve spring.

Bevel gauge
Contact
4. Measure the valve spring free length and if it is less than 45.47 mm,
replace the valve spring.
 9-292 Engine/Propulsion

5. Inspect the valve spring load as it is compressed to the specified

height: when compressed to a height of 34 mm, the load should be
187±7.48 N. If the load is lower than the standard value, replace the
valve spring.

9.5.4.20 Oil Pan Replacement (1.5T) (208730)

Removal Steps

1. Raise the vehicle. Refer to “0.2.1.14 Vehicle
Lifting and Jacking Caution”.
2. For environmental protection, place a suitable
container below the engine to catch the engine
oil.
3. Screw the oil pan drain bolt off with a wrench and
drain the engine oil.
Refer to “0.2.1.30 Fastener Caution”.
4. Install the oil pan bolt.
Tighten
Oil pan drain bolt: 25±5 N·m
5. Remove the transmission assembly. Refer to
“17.3.5.1 Transmission Replacement”.
6. Loosen and remove the 18 oil pan bolts.
7. Use a small hammer to gently knock oil pan
special tool PT - 0031 into the joint seam along
the oil pan to engine cylinder block bottom edge
and then knock one side of the special tool. Take
care not to damage the mating surface.
9-293 Engine/Propulsion

Note: You can use a similar oil seal scrapper instead of

special tool PT - 0031, but never use tools like
screwdriver otherwise the mating surface can be
damaged.
8. Remove the oil pan.

1. Install the strainer seal ring and oil strainer to the

9. If you need only to disassemble small oil pan (4),
drain the oil, loosen and remove the 9 oil pan
bolts (3) and then use the special tool and method
described in Step 7 to knock and take down small
oil pan (4).
oil pump assembly.
2. Tighten the strainer bolt to 10±2 N·m.
Tighten the strainer bracket bolt to 10±2 N·m.
3. Confirm that the new oil pan is intact and the
inside is clean without foreign materials.
4. Apply sealer on the oil pan.
○ Sealer diameter: 3.75±0.25 mm
○ Distance from sealer center line to inside
chamfer edge: 1±1 mm

10. Loosen and remove oil strainer bolt (2).

11. Loosen and remove strainer bracket bolt (1) and
then remove the oil strainer and O - ring.
Cleaning: Use a small knife to remove the sealer
remaining on the oil pan to cylinder block mating
surface, wash the oil pan bolts and clean the bolt
holes on the cylinder block.
Installation Procedure
 9-294 Engine/Propulsion

5. The sealer line should be continuous in the
correct shape and position, bypassing the bolt
holes successively. During installation, take care
not to damage the sealer line and tighten the oil
pan bolt within 20 minutes after sealer
application.
11. If you need only to install small oil pan (4), apply
sealer on the small oil pan mounting face as
directed in Step 2 and Step 3 and then install the
small oil pan to oil pan upper housing (5). Take
care not to damage the sealer line during
installation.
Tighten the 9 small oil pan bolts (3) in the
sequence below.
4 2
6 7
8 5
1 9 3
Tighten small oil pan bolt to: 10±2 N·m

6. Install the oil pan to the cylinder block correctly

through the oil pan locating pin. Take care not to
damage the sealer line during installation.
Refer to “0.2.1.30 Fastener Caution”.
7. Tighten the 18 oil pan bolts (1) in the sequence
below.
13 9 5 1 4 8 12
17 16
18 15
14 10 6 2 3 7 11
Tighten oil pan bolt to: 10±2 N·m
8. Install the transmission. Refer to “17.3.5.1
Transmission Replacement”.
9. Lower the vehicle evenly.
10. Fill engine oil to an appropriate level (about 4 L).
As the best, the level should be close to but not
exceed the maximum mark on the oil level
indicator.
9-295 Engine/Propulsion

9.5.4.21 Ignition Coil Cover Replacement (1.5T) (212125)

Removal Steps
1. Open the engine hood.
2. Remove the engine trim cover.
3. Remove the positive crankcase ventilation pipe assembly (high
load) and the positive crankcase ventilation pipe assembly (low load).
Refer to “9.5.5.66 Positive Crankcase Ventilation Pipe Removal”.
4. Remove the 8 oil - gas separator bolts.
5. Remove oil - gas separator (2).
6. Remove the oil - gas separator seal ring as necessary.

Installation Procedure
Caution: Refer to “0.2.1.30 Fastener Caution”.
1. Install the seal ring to oil - gas separator (2).
2. Install oil - gas separator (2) to the camshaft cover.

3. Tighten the 8 oil - gas separator bolts in the sequence shown in the
figure.
Tighten
Oil - gas separator bolt: 10±2 N·m
4. Install the positive crankcase ventilation pipe assembly (high load)
and the positive crankcase ventilation pipe assembly (low load). Refer to
“9.5.5.66 Positive Crankcase Ventilation Pipe Removal”.
6. Install the engine trim cover.
7. Close the engine hood.
 9-296 Engine/Propulsion

9.5.4.22 Oil Filler Cap Replacement (1.5T)

Oil Filler Cap Replacement

Callout Component Name
Preliminary Procedure
1. Remove the engine trim cover.
1 Oil filler cap
9-297 Engine/Propulsion

9.5.4.23 Engine Mount Bracket Replacement (1.5T)

Removal Steps
1. Lift the engine stably with engine balancing stand PT - 0069.
Note: Take necessary protective measures to protect parts around the
engine from scratches and damage.
2. Remove the air cleaner. Refer to “9.3.4.8 Air Cleaner Assembly
Replacement”.
3. Remove the drive belt. Refer to “Water Pump Belt Replacement”.
4. Remove the water pump pulley as necessary. Refer to “9.5.5.5
Water Pump Pulley Removal”.

5. Loosen and remove the 2 engine mount bracket to engine lift

bracket nuts (1) and 1 bolt (2).

6. Remove engine mount bracket studs (3) as necessary.

7. Loosen and remove the engine mount bracket to engine bolt (1),
and take down engine mount bracket (2).
 9-298 Engine/Propulsion

Installation Procedure
Caution: Refer to “0.2.1.30 Fastener Caution”.
1. If the engine mount bracket studs are removed, install them to the
engine mount bracket.
Tighten
2 engine mount bracket studs:
72±5 N·m
2. Install the engine mount bracket to the engine.
Tighten
3 engine mount bracket to engine bolts:
62±5 N·m

3. Tighten the engine mount bracket to engine lift bracket bolt and
nuts.
Tighten
● 2 engine mount bracket to engine lift bracket nuts: 110±10 N·m
● 1 engine mount bracket to engine lift bracket bolt: 110±10 N·m
4. Install the water pump pulley. Refer to “9.5.5.37 Water Pump Pulley
Installation”.
5. Install the drive belt idler.
6. Install the air cleaner. Refer to “9.3.4.8 Air Cleaner Assembly
Replacement”.
7. Remove engine balancing stand PT - 0069 and close the engine
hood.
9-299 Engine/Propulsion

9.5.4.24 Crankshaft Pulley Replacement (1.5T) (212375)

Crankshaft Pulley Replacement

Callout Component Name
Preliminary Procedure
1. Remove the drive belt. Refer to “Water Pump Belt Replacement”.
2. Remove the starter. Refer to “Starter Replacement”.
Note: Use the flywheel fixing bracket. Refer to “9.5.7.1 Special Tools”.
Crankshaft pulley bolt
Caution: Refer to “0.2.1.30 Fastener Caution”.
1 Tighten
1. Pre - tighten to 95 N·m (70 lbft)
2. Finally tighten to 55 N·m
2 Crankshaft pulley gasket
3 Crankshaft pulley
 9-300 Engine/Propulsion

9.5.4.25 Camshaft Timing Chain, Sprocket, and Tensioner Replacement (1.5T) (212378)
Removal Steps
1. Remove the camshaft cover. Refer to “9.5.4.15 Camshaft Cover
Replacement”.
2. Remove the engine front cover. Refer to “9.5.4.12 Engine Front
Cover with Oil Pump Replacement”.
3. Place (1) (socket head wrench of equivalent diameter) against the
locking pin, and compress the timing chain tensioner and use (2) (fine
iron wire, etc.) to seize it.

4. Loosen timing tensioner bolt (13) to remove timing tensioner (12)

(this step is unnecessary if only the timing chain is removed).
5. Loosen the intake side timing chain guide bolt to remove the intake
side timing chain guide (this step is unnecessary if only the timing chain
is removed).
6. Loosen the exhaust side timing chain guide bolt to remove the
exhaust side timing chain guide (this step is unnecessary if only the
timing chain is removed).
7. Remove timing chain (1).
9-301 Engine/Propulsion

8. Use a wrench to fix the camshaft, remove the intake and exhaust
camshaft sprocket bolts and then remove the intake/exhaust camshaft
sprockets (5) and (6).
9. Remove crankshaft sprocket (1) and take down woodruff key (2)
carefully.
 9-302 Engine/Propulsion

Installation Procedure
1. Install the camshaft sprocket to the camshaft. Position according to
the locating pin on the camshaft during installation.
2. Pre - tighten camshaft sprocket bolts (3) and (6).

3. Clean the timing chain thoroughly and pre - lubricate the timing
chain with fresh oil.
4. Install the timing chain to the camshaft sprocket and the crankshaft
sprocket. Ensure that the timing mark (dark color chain) on the timing
chain align with the timing mark (circular pit) on the camshaft sprocket
and that (circular pit) on the crankshaft sprocket respectively.
Note: Do not rotate the crankshaft if the timing chain is not installed.
9-303 Engine/Propulsion

5. Install the intake and exhaust timing chain guides.

Tighten the intake side timing chain guide bolt to 10±2 N·m; tighten the
exhaust side timing chain guide bolt to 10±2 N·m.

6. Place (1) against the locking pin and at the same time, compress
the tensioner and seize it with tool (2). Tools (1) and (2) should be clean
and of a diameter equivalent to that of the locking hole and certain
hardness, for example, hexagon head wrench.
Caution: Refer to “0.2.1.30 Fastener Caution”.
7. Install the timing chain tensioner.
Tighten
Timing chain tensioner bolt: 10±2 N·m

8. Tighten the camshaft sprocket bolt. Fix the camshaft with a monkey
wrench when tightening the bolt, as is shown in the figure.
Tighten
Camshaft sprocket bolt:
(32±2) N·m + (50°±2°)
9. Lubricate all locations of the timing system with fresh oil and then
install the camshaft cover. Refer to “9.5.4.15 Camshaft Cover
Replacement”.
10. Install the engine front cover. Refer to “9.5.4.12 Engine Front Cover
with Oil Pump Replacement”.
 9-304 Engine/Propulsion

9.5.4.26 Engine Mount Replacement (1.5T)

Engine Lift Bracket Replacement

Callout Component Name
Preliminary Procedure
1. Remove the air cleaner. Refer to “9.3.4.8 Air Cleaner Assembly Replacement”.
Engine shock absorber bolt (Qty.: 4)
Caution: Refer to “0.2.1.30 Fastener Caution”.
1
Tighten
Tighten to 62±5 N·m
Engine lift bracket to engine shock absorber nut
2 Tighten
Tighten to 110±10 N·m
Engine mount bracket to engine lift bracket nut (Qty.: 2)
3 Tighten
Tighten to 110±10 N·m
Engine mount bracket to engine lift bracket bolt
4 Tighten
Tighten to 110±10 N·m
5 Engine lift bracket
6 Engine shock absorber
9-305 Engine/Propulsion

9.5.4.27 Engine Oil Pressure Indicator Switch Replacement (1.5T)(212700)

Removal Steps
1. Disconnect the battery negative cable. Refer to “0.2.1.21 Ignition
OFF When Disconnecting Battery Caution”.
2. Disconnect the oil pressure switch connector.
3. Use special tool PT - 0065 to remove the oil pressure switch
assembly.

Installation Procedure
Caution: Refer to “0.2.1.30 Fastener Caution”.
1. Use special tool PT - 0065 to install the oil pressure switch
assembly.
Tighten
Oil pressure switch: 27±3 N·m
2. Connect engine harness and oil pressure switch connector, and
then connect the battery negative cable.
3. Inspect to confirm no conditions like leakage.
 9-306 Engine/Propulsion

9.5.4.28 Turbocharger Heat Shield Replacement (1.5T)

Turbocharger Heat Shield Replacement

Callout Component Name
Preliminary Procedure
1. Remove the turbocharger air outlet pipe heat shield. Refer to “9.7.3.9 Turbocharger Heat Shield
Replacement”.
Turbocharger heat shield bolt (Qty.: 2)
Caution: Refer to “0.2.1.30 Fastener Caution”.
1
Tighten
11±2 N·m
2 Turbocharger heat shield
9-307 Engine/Propulsion

9.5.4.29 Turbocharger Replacement (1.5T)

Removal Steps
1. Open the engine hood and disconnect the battery negative cable.
2. Remove the turbocharger air outlet pipe heat shield and the three -
way catalytic converter assembly. Refer to “Catalytic Converter
Replacement”.
3. Remove the oil level indicator tube. Refer to “9.5.4.13 Oil Level
Indicator Tube Replacement”.
4. Remove the turbocharger water inlet pipe and water outlet pipe.
5. Remove the turbocharger oil feed pipe and oil return pipe. Refer to
“9.4.4.29 Turbocharger Oil Feed Pipe Replacement”.
6. Loosen pipe clamp (1) and disconnect the intercooler air inlet pipe
from the turbocharger.
7. Loosen pipe clamp (2) and disconnect the air cleaner outlet duct
from the turbocharger.
8. Loosen quick - connect joint (3) and disconnect high - load PCV
pipe from the turbocharger.
9. Remove the turbocharger heat shield. Refer to “9.5.4.28
Turbocharger Heat Shield Replacement”.
10. Remove turbocharger nut (1), check the nut and stud for defects
like damaged thread. If any, replace the nut and the stud.
11. Take down turbocharger (3) and turbocharger gasket (2). Discard
the gasket.
Note: The turbocharger is required to be meticulously clean. For this
purpose, take care to avoid any foreign material entering the
turbocharger during removal/installation, and once the turbocharger is
removed, block all joints with appropriate covers so that no sundries can
enter the turbocharger.
 9-308 Engine/Propulsion

Note: It is strictly forbidden to pull the turbocharger bypass valve lever

(1) during removal/installation. As the bypass valve actuator pressure
has been preset, it is not allowed to pull the bypass valve lever in case
that the actuator sensitivity and reliability is affected.

12. Inspect all turbocharger (1) studs to see if damaged threads exist
and if any, remove turbocharger intake flange stud (2), turbocharger
exhaust flange stud (3) and turbocharger oil return pipe stud (4) to
replace the damaged stud(s) with new ones.
9-309 Engine/Propulsion

Installation Procedure
Caution: Refer to “0.2.1.30 Fastener Caution”.
Note: It is strictly forbidden to pull the turbocharger bypass valve lever.
1. Install stud (2) to the turbocharger intake flange.
2. Install stud (3) to the turbocharger exhaust flange.
3. Install turbocharger oil return pipe stud (4).
Tighten
Turbocharger intake flange stud (2): 17±2 N·m
Turbocharger exhaust flange stud (3): 20±2 N·m
Turbocharger oil return pipe stud (4): 6±1 N·m
4. You can first install the turbocharger heat shield to the turbocharger.
Refer to “9.5.4.28 Turbocharger Heat Shield Replacement”.
5. Install the turbocharger and the new turbocharger gasket.
6. Install turbocharger nut (1) and tighten it.
Tighten
Turbocharger nut (1): 33±3 N·m

7. Connect the intercooler air inlet pipe to the turbocharger and tighten
clamp (1) to 5±0.5 N·m.
8. Connect the air cleaner outlet duct to the turbocharger and tighten
clamp (2) to 3±0.5 N·m.
9. Connect quick - connect joint (3) and connect high - load PCV pipe
to the turbocharger.
10. Install the turbocharger oil feed pipe and oil return pipe. Refer to
“9.4.4.29 Turbocharger Oil Feed Pipe Replacement”.
11. Install the turbocharger water inlet pipe and water outlet pipe.
12. Install the turbocharger air outlet pipe heat shield and the three -
way catalytic converter. Refer to “Catalytic Converter Replacement”.
13. Connect the battery negative cable and close the engine hood.
 9-310 Engine/Propulsion

9.5.4.30 Turbocharger Oil Return Pipe Replacement (1.5T)

Removal Steps
1. Remove the 2 oil return pipe bolts (1) from the cylinder block and
the 2 oil feed pipe nuts (2) from the turbocharger.
2. Remove turbocharger oil return pipe (3) and take caution not to
contaminate the parts around with oil.
3. Remove cylinder block side gasket (4) and turbocharger side
gasket (5) of the turbocharger oil return pipe respectively.

Installation Procedure
Caution: Refer to “0.2.1.30 Fastener Caution”.
1. Install gasket (4) and gasket (5) to turbocharger oil return pipe (3).
2. Install turbocharger oil return pipe (3).
3. Tighten turbocharger oil return pipe nuts (2) and bolts (1).
Tighten
Turbocharger oil return pipe nut: 10±2 N·m
Turbocharger oil return pipe bolt: 10±2 N·m
9-311 Engine/Propulsion

9.5.4.31 Intake Manifold Support Replacement (1.5T)

Intake Manifold Bracket Replacement

Callout Component Name
Preliminary Procedure
1. Remove the heater water outlet hose. Refer to “Heater Inlet Hose Replacement” under HVAC.
Intake manifold bracket bolt (Qty.: 2)
Caution: Refer to “0.2.1.30 Fastener Caution”.
1
Tighten
Tighten intake manifold end bolt to 10±2 N·m
Intake manifold bracket bolt (Qty.: 1)
Caution: Refer to “0.2.1.30 Fastener Caution”.
2
Tighten
Tighten cylinder block end bolt to 20±2 N·m
3 Intake manifold bracket
4. HVAC water outlet pipe bracket
 9-312 Engine/Propulsion

9.5.4.32 Turbocharger Oil Feed Pipe Replacement (1.5T)

Removal Steps
1. Remove oil feed pipe bolt (1) from the turbocharger, remove the 2
gaskets at oil feed pipe to turbocharger joint and discard them.
2. Raise the vehicle, remove oil feed pipe bolt (2) from the engine oil
cooler adapter, remove the 2 gaskets at the joint and discard them.
3. Remove turbocharger oil feed pipe bracket bolt (3).
4. Remove turbocharger oil feed pipe (4).
Note: Take caution not to contaminate the parts around with the oil.

Installation Procedure
1. Install turbocharger oil feed pipe (4), place new gaskets at both
ends of the turbocharger end joint and pre - tighten with bolt (1), place
new gaskets at both ends of the engine oil cooling end joint and pre -
tighten with bolt (2). 2. Lower the vehicle, and tighten turbocharger oil
feed pipe bolt (1) at the turbocharger end, oil feed pipe bolt (2) at engine
oil cooler adapter end and oil feed pipe bracket bolt (3).
Tighten
Oil feed pipe bolt (1) at turbocharger end: 32±2 N·m
Oil feed pipe bolt (2) at adapter end: 32±2 N·m
Oil feed pipe bracket bolt (3): 10±2 N·m
9-313 Engine/Propulsion

9.5.4.33 Crankshaft Front Oil Seal Replacement (1.5T) (208614)

Removal Steps
1. Raise the vehicle and take necessary safety protection devices
during operation under the vehicle. Refer to “0.2.1.14 Vehicle Lifting and
Jacking Caution”.
2. Remove the engine right lower cover plate.
3. Remove the right front wheel. Refer to “16.6.3.3 Tire and Wheel
Removal and Installation”.

4. Remove the drive belt. Refer to “Water Pump Belt Replacement”.

5. If it is necessary to remove the starter, use flywheel holder PT -
0192 to fix the flywheel so that the crankshaft will not rotate.
 9-314 Engine/Propulsion

6. Use a common socket wrench to remove the crankshaft pulley bolt

and then remove the crankshaft pulley.

7. Remove the crankshaft front oil seal and discard it.

9-315 Engine/Propulsion

Installation Procedure
1. Apply appropriate amount of oil on the oil seal lip and install the
new crankshaft front oil seal using crankshaft front oil seal installer (a)
PT - 0026 so that the front oil seal is flush with the engine front cover
end face.
● During installation, make the flat side go against the special tool
and the concave side face the engine.

Caution: Refer to “0.2.1.30 Fastener Caution”.

2. Install the crankshaft pullet and tighten the crankshaft pulley bolt to
100 N·m + (75°±5°). Do not depend on visual judgment wherever an
angle wrench is needed to tighten to the specified angle.

3. Install the drive belt. Refer to “Water Pump Belt Replacement”.

4. Inspect and test to confirm that the repair is successful without oil
leakage.
5. Install the right front wheel. Refer to “16.6.3.3 Tire and Wheel
Removal and Installation”.
6. Install the engine right lower cover plate.
7. Lower and place the vehicle evenly.
 9-316 Engine/Propulsion

9.5.4.34 Engine Replacement (1.5T) (208622)
Special Tools
9.5.7.1 Special Tools
Engine balancing stand PT - 006
Removal Steps
Caution: If the engine is replaced due to internal
damages, confirm that all foreign materials have been
flushed off the cooling system. In addition, the oil
cooling system should also be flushed. If the cooling
system is not flushed clean, engine damage can
result.
Warning: Refer to “0.2.1.21 Ignition OFF When
Disconnecting Battery Caution” under Preface.
15. Disconnect fuel vapourizer tube (9) from canister
solenoid valve.
16. Fix a highly absorbent cloth under fuel rail and
disconnect fuel feed pipe (10) from the fuel rail.
17. Note: Block the disconnected joint with a plug to
prevent pollutants from entering.
18. Disconnect high - load PCV pipe (12) from the air
cleaner outlet duct.
19. Remove the air cleaner outlet duct. Refer to
“9.3.4.22 Air Cleaner Outlet Duct Replacement”.
20. Remove the air cleaner. Refer to “9.3.4.8 Air
Cleaner Assembly Replacement”.
21. Remove the intercooler air inlet pipe to disconnect
it from the turbocharger.
22. Remove the left and right front wheels. Refer to
“16.6.3.3 Tire and Wheel Removal and Installation”.
23. Remove the air conditioning compressor. Refer to
“10.1.5.22 Air Conditioning Compressor
Replacement”.
24. Remove the battery assembly. Refer to “9.1.4.7
Battery Replacement”.
25. Remove the coolant reservoir.
26. Remove the engine control module. Refer to
“9.3.4.1 Engine Control Module Replacement”.

1. Remove the fuel pump fuse. Relieve the fuel

pressure.
2. Start the engine and wait for it to stall.
3. Disconnect the battery negative cable.
4. Remove the fuse block. Refer to “11.3.5.3 Front
Compartment Fuse Block Housing Replacement”.
5. Place an oil receiving tray under the vehicle to
receive the used oil during oil draining. Refer to
“9.5.4.1 Engine Oil and Oil Filter Replacement”.
6. Drain the engine coolant. Refer to “9.4.4.16
Cooling System Draining and Filling”.
7. Disconnect throttle body harness connector (1).
8. Disconnect knock sensor harness connector (2).
9. Disconnect intake air temperature/pressure
sensor assembly (high pressure) harness connector
(3).
10. Disconnect canister solenoid valve harness
connector (4).
11. Disconnect the engine harness to fuel rail
connector (5).
12. Disconnect the ignition coil harness connector (6).
13. Disconnect intake/exhaust VVT harness
connector (7).
14. Disconnect front oxygen sensor harness
connector (8).
9-317 Engine/Propulsion

27. Disconnect radiator water inlet hose (1) from the water pump. Refer
to “Radiator Inlet Hose Replacement”.

28. Disconnect radiator water outlet hose (1) from the thermostat. Refer
to “Radiator Outlet Hose Replacement”.
29. Disconnect surge tank return hose (2) from HVAC water outlet pipe
joint.
30. Remove heater outlet hose assembly (3). Refer to “Heater Outlet
Hose Replacement” under HVAC.
31. Disconnect surge tank inlet hose (4) from the turbocharger water
return pipe.

32. Disconnect intake camshaft position sensor harness connector (1).

33. Disconnect exhaust camshaft position sensor harness connector
(2).
34. Disconnect coolant temperature sensor harness connector (3).
35. Disconnect vehicle speed sensor harness connector (4).
36. Disconnect reverse gear switch harness connector (5).
37. Disconnect front oxygen sensor harness connector (6).
38. Disconnect crankshaft position sensor connector (7).
39. Disconnect neutral position switch connector (8).
 9-318 Engine/Propulsion

40. Disconnect the selector/shift lever cables (1) from the shift control
case and the selector and shift lever cable bracket.
41. Remove the front exhaust pipe. Refer to “9.7.3.7 Front Exhaust
Pipe Replacement”.
42. Remove the three - way catalytic converter. Refer to “Catalytic
Converter Replacement”.

43. Loosen pipe clamp (1) and hose clip (2) and then remove the
vacuum hose from the vacuum booster and the vacuum pump.
44. Disconnect knock sensor harness connector (1).
45. Disconnect starter electrical connector (2).
46. Disconnect the starter to battery cable connector (3). Refer to
“Starter Replacement”.
47. Disconnect generator harness connector (4).
48. Disconnect the generator to battery cable connector (5). Refer to
“Generator Replacement”.
49. Disconnect rear oxygen sensor connector (6).

50. Recycle the refrigerant. Refer to “10.1.5.43 Refrigerant Recovery

and Recharging”.
51. Disconnect compressor electrical connector (1).
52. Disconnect oil pressure sensor connector (2).
53. Loosen common bolt (3) shared by the compressor and the ground
wire and then disconnect the engine ground wire from the compressor.
54. Disconnect air suction pipe (4) and vent pipe (5) from the
compressor. Refer to “Air Conditioning Compressor and Condenser
Hose Replacement” and “Air Conditioning Compressor and Evaporator
Hose Replacement”.
9-319 Engine/Propulsion

55. Install and fix engine stand PT - 0069. Use rubber pad to prevent
vehicle damage. Seriously confirm that the engine has been lift stably.
56. Raise the vehicle to an appropriate height.
Caution: Refer to “0.2.1.14 Vehicle Lifting and Jacking Position
Caution”.
57. Drain the engine oil and the transmission fluid to suitable containers
respectively. Keep the fluids properly and move away the containers.
58. Remove the transmission rear mount bracket. Refer to “17.3.5.5
Transmission Rear Mount Bracket Replacement”.
59. Remove the transmission left side vibration isolator. Refer to
“17.3.5.4 Transmission Left Mount Replacement”.
60. Remove the left front drive shaft assembly. Refer to “Front Wheel
Drive Shaft Replacement”.
61. Remove the right front drive shaft assembly. Refer to “Front Wheel
Drive Shaft Replacement”.
62. Remove the engine lower cover plate.
63. Inspect around the engine transmission carefully and confirm again
that the harnesses and pipelines on engine have been disconnected or
removed.
64. Remove the transmission. Refer to “17.3.5.1 Transmission
Replacement”.
65. Support the engine from the bottom using a wooden bracket.
66. Lift the engine stably using a liftable engine hoist.
67. Remove the engine lift bracket. Refer to “9.5.4.23 Engine Mount
Bracket Replacement”. Take care to ensure safety and hold the engine
to prevent wobbling.
68. Remove the engine balancing stand PT - 0069.
69. Adjust the hoist in a way that the engine does not interfere with the
parts around.
70. Raise the vehicle slowly and adjust the hoist weight at the same
time. Observe to ensure that the engine does not interfere with the parts
around. Adjust until the engine can be moved out stably from below the
vehicle.
71. Install the engine to the engine stand.
 9-320 Engine/Propulsion

Installation Procedure
1. Remove the engine from the engine stand.
2. Place the engine in a wooden bracket and move it stably to a place
below the vehicle.
3. Take care to ensure safety and lower the vehicle slowly to an
appropriate height.
4. Raise the engine slowly and lift the engine over the engine
compartment and adjust the engine position until it is convenient to
install the engine lift bracket. Refer to “9.5.4.23 Engine Mount Bracket
Replacement”.
5. Install and fix the engine balancing stand PT - 0069, lift the engine
evenly and stably, and then remove the engine hoist.
6. Install the transmission. Refer to “17.3.5.1 Transmission
Replacement”.
7. Install the starter harness nut. Refer to “Starter Replacement”.
8. Install the engine lower cover plate and tighten the bolts to 6.5±2
N·m. Install relevant clips.
9. Install the right front drive shaft. Refer to “Front Wheel Drive Shaft
Replacement”.
10. Install the left front drive shaft. Refer to “Front Wheel Drive Shaft
Replacement”.
11. Install the transmission left side vibration isolator. Refer to “17.3.5.4
Transmission Left Mount Replacement”.
12. Install the transmission rear mount bracket. Refer to “17.3.5.5
Transmission Rear Mount Bracket Replacement”.
13. Fill transmission fluid until the fluid drips from the inspection hole
and then tighten the transmission fluid inspection hole bolt. Refer to
“Transmission Fluid Replacement”.
14. Lower the vehicle to an appropriate height.
15. Remove the engine balancing stand.
16. Connect the engine ground wire and the compressor, tighten
common bolt (3) shared by the compressor and the ground wire, and
then install the air conditioning compressor. Refer to “10.1.5.22 Air
Conditioning Compressor Replacement”.
17. Connect compressor electrical connector (1).
18. Connect oil pressure sensor electrical connector (2).
19. Connect air suction pipe (3) and vent pipe (4). Refer to “Air
Conditioning Compressor and Condenser Hose Replacement” and “Air
Conditioning Compressor and Evaporator Hose Replacement”.
9-321 Engine/Propulsion

20. Connect knock sensor harness connector (1).

21. Connect starter electrical connector (2).
22. Connect the starter to battery cable connector (3). Refer to “Starter
Replacement”.
23. Connect generator harness connector (4).
24. Connect the generator to battery cable connector (5). Refer to
“Generator Replacement”.
25. Connect rear oxygen sensor connector (6).

26. Install the vacuum hose on the vacuum booster and tighten pipe
clamp (1) and hose clip (2).
27. Install the front exhaust pipe. Refer to “9.7.3.7 Front Exhaust Pipe
Replacement”.
28. Install the three - way catalytic converter. Refer to “Catalytic
Converter Replacement”.

29. Connect the selector and shift lever cables (1) to the shift control
case and the selector and shift lever cable bracket.
 9-322 Engine/Propulsion

30. Connect intake camshaft position sensor harness connector (1).

31. Connect exhaust camshaft position sensor harness connector (2).
32. Connect coolant temperature sensor harness connector (3).
33. Connect vehicle speed sensor harness connector (4).
34. Connect reverse gear switch harness connector (5).
35. Connect front oxygen sensor harness connector (6).
36. Connect crankshaft position sensor connector (7).
37. Connect neutral position switch connector (8).

38. Connect radiator water outlet hose (1) to the thermostat. Refer to
“Radiator Outlet Hose Replacement”.
39. Connect surge tank return hose (2) to HVAC water outlet pipe joint.
40. Install heater outlet hose assembly (3). Refer to “Heater Outlet
Hose Replacement”.
41. Connect surge tank inlet hose (4) to the turbocharger water return
pipe.
9-323 Engine/Propulsion

42. Connect radiator water inlet hose (1) to the water pump. Refer to
“Radiator Outlet Hose Replacement”.
 9-324 Engine/Propulsion

43. Connect throttle body harness connector (1).

44. Connect knock sensor harness connector (2).
45. Connect intake air temperature/pressure sensor assembly (high
pressure) harness connector (3).
46. Connect canister solenoid valve harness connector (4).
47. Connect the engine harness to fuel rail connector (5).
48. Connect the ignition coil harness connector (6).
49. Connect intake/exhaust VVT harness connector (7).
50. Connect front oxygen sensor harness connector (8).
51. Connect fuel vapourizer tube (9) to canister solenoid valve.
52. Connect fuel feed pipe (10) to the fuel rail.
53. Connect high - load PCV pipe (12) to the air cleaner outlet duct.
54. Install the air cleaner outlet duct. Refer to “9.3.4.22 Air Cleaner
Outlet Duct Replacement”.
55. Install the air cleaner. Refer to “9.3.4.8 Air Cleaner Assembly
Replacement”.
56. Install the left and the right front wheels. Refer to “16.6.3.3 Tire and
Wheel Removal and Installation”.
57. Install the battery assembly. Refer to “9.1.4.7 Battery
Replacement”.
58. Install the coolant reservoir.
59. Install the engine control module. Refer to “9.3.4.1 Engine Control
Module Replacement”.
60. Fill engine coolant. Refer to “9.4.4.16 Cooling System Draining and
Filling”.
61. Fill engine oil. Refer to “9.5.4.1 Engine Oil and Oil Filter
Replacement”.
62. Fill the refrigerant. Refer to “10.1.5.43 Refrigerant Recovery and
Recharging”.
63. Install the battery and the tray.
64. Install the fuel pump relay/fuse.
65. Fill engine oil.
66. Inspect all harnessed and pipelines carefully to ensure they are all
clamped in place without interference and all the fasteners have been
wiped clean and free from oil contamination.
67. Connect the battery positive cable.
68. Connect the battery negative cable.
69. Test the engine performance.
9-325 Engine/Propulsion

9.5.4.35 Valve Lifter Replacement (1.5T) (208609)

Removal Steps
1. Remove the ignition coil. Refer to “9.3.4.29 Ignition Coil
Replacement”.
2. Remove the camshaft cover. Refer to “9.5.4.15 Camshaft Cover
Replacement”.
3. Measure the valve clearance and replace the valve lifter if the valve
clearance fails the specification. Refer to “9.5.3.19 Valve Clearance
Testing” for valve clearance testing.
4. Remove the camshaft. Refer to “9.5.4.16 Camshaft Replacement”.

5. Carefully remove the valve lifters to be replaced using a magnetic

tool and mark with the corresponding valves to prevent mistakes.
Note: Mark the valves as per the installation sequence and place the
them upside down to prevent oil loss. Keep the lifter extremely clean
while handling it and ensure no scratches or damage to the lifter
surface. Failure to obey these instructions can cause engine conditions.
 9-326 Engine/Propulsion

Installation Procedure
1. Measure thickness of the used lifter and select the appropriate new
one as per the measured value. New lifter thickness = used lifter
thickness + used valve clearance - standard valve clearance. Select the
appropriate new lifter as per the calculated new lifter thickness. The new
lifter is classified into 40 grades (01~40) and at an increment of 0.02
mm. The valve lifter grade and thickness are printed at the bottom from
inside of the lifter. For example, 01 - 312 refers to that the lifter is Grade
01 and 3.12 mm thick.

= 2. Lubricate the newly selected lifters with fresh engine oil and install
them to the corresponding positions as per the marks made during
removal.
3. Install the camshaft. Refer to “9.5.4.16 Camshaft Replacement”.
4. Install the camshaft cover. Refer to “9.5.4.15 Camshaft Cover
Replacement”.
5. Install the ignition coil. Refer to “9.3.4.29 Ignition Coil
Replacement”.
Inspection
Confirm that no defects such as missing parts and wrongly installed
parts exist, and that the harnesses and pipe clamps are all located
correctly without interference and leakage.
9-327 Engine/Propulsion

9.5.5 Repair Instructions - Off Vehicle

9.5.5.1 Engine Flywheel Removal (1.5T) (208642)
1. Use flywheel holder PT - 0192 to fix the flywheel.
2. You can also use flywheel fixing tool PT - 0324 or a similar tool to fix
the flywheel.

3. Remove the 6 flywheel retaining bolts.

4. Remove the flywheel assembly.

9.5.5.2 Exhaust Manifold Removal (1.5T) (208651)

1. Remove exhaust manifold heat shield (1). Refer to “9.5.5.51
Exhaust Manifold Heat Shield Removal”.
2. Loosen and remove the exhaust manifold to engine cylinder block
fastening nuts (4), take down exhaust manifold (3) and exhaust manifold
gasket (2).
 9-328 Engine/Propulsion

9.5.5.3 Engine Flywheel Removal (1.5T) (208642)

1. Install the flywheel to the engine. Take care to ensure that the side
with locating pin faces outward.
2. Use flywheel holder PT - 0192 to fix the flywheel.
3. You can also use flywheel fixing tool PT - 0324 or a similar tool to
fix the flywheel.

Caution: Refer to “0.2.1.30 Fastener Caution”.

4. Apply appropriate amount of thread locking adhesive on the bolts
and tighten them in a sequence shown in the figure.
Tighten
Flywheel bolt:
35 N·m + (30°~45°). Do not depend on visual judgment wherever an
angle wrench is needed to tighten to the specified angle.
9-329 Engine/Propulsion

9.5.5.4 Draining Fluids and Oil Filter Removal (1.5T) (208635)

1. For environmental protection, place a suitable container below the
engine to catch the engine oil.
2. Screw the oil pan drain bolt off with a wrench and drain the engine
oil.
Caution: Refer to “0.2.1.30 Fastener Caution”.
3. Install the oil pan bolt.
Tighten
Oil pan drain bolt: 25±5 N·m

4. Install oil filter remover/installer PT - 0184 to the oil filter to remove

and discard the oil filter. Remove the oil filter mounting bolt only when
necessary.
Note: For environmental protection, place a suitable container below the
engine oil filter to catch the engine oil.

9.5.5.5 Water Pump Pulley Removal (1.5T) (208638)

1. Remove the drive belt. Refer to “Water Pump Belt Replacement”.
2. Remove the 3 water pump pulley bolts and take down the water
pump pulley.
 9-330 Engine/Propulsion

9.5.5.6 Water Pump Removal (1.5T) (208640)

1. Remove the water pump pulley. Refer to “Water Pump Belt
Replacement”.
2. Remove the turbocharger water inlet pipe.
3. Remove the 2 water pump bolts (1).
4. Remove the 3 water pump bolts (2).
5. Remove water pump (1) and water pump seal ring (4).

9.5.5.7 Ignition Coil Removal (1.5T) (208643)

Note: Clean around the engine carefully to prevent any other part or
object entering the engine cylinder block during removal.
1. Remove ignition coil bolt (1) of each cylinder.
2. Remove ignition coil (2) of each cylinder.

9.5.5.8 Camshaft Cover Removal (1.5T) (208644)

1. Remove the vacuum pump. Refer to “9.5.4.4 Vacuum Pump
Assembly Replacement”.
2. Remove the low - load and the high - load PCV pipes. Refer to
“9.5.5.66 Positive Crankcase Ventilation Pipe Removal”.
3. Remove oil filler cap (3).
4. Remove the 12 bolts along the camshaft cover edge and the two
long bolts in the middle.
5. Remove the camshaft cover.
9-331 Engine/Propulsion

9.5.5.9 Camshaft Timing Chain Removal (1.5T) (208647)

1. Remove the engine front cover. Refer to “9.5.5.76 Engine Front
Cover and Oil Pump Removal”.
2. Loosen timing tensioner bolt (13) to remove timing tensioner (12).
3. Loosen and remove timing chain intake side guide (4).
4. Remove the timing chain.

9.5.5.10 Timing Chain Guide Removal (1.5T) (208648)

1. Remove the engine front cover. Refer to “9.5.4.12 Engine Front
Cover with Oil Pump Replacement”.
2. Loosen timing tensioner bolt (13) to remove timing tensioner (12).
3. Loosen and remove timing chain intake side guide (4).
 9-332 Engine/Propulsion

9.5.5.11 Timing Chain Tensioner Removal (1.5T) (208649)

1. Remove the engine front cover. Refer to “9.5.4.12 Engine Front
Cover with Oil Pump Replacement”.
2. Loosen timing tensioner bolt (13) to remove timing tensioner (12).

9.5.5.12 Camshaft Sprocket Removal (1.5T) (208650)

1. Remove the timing chain. Refer to “9.5.5.9 Camshaft Timing Chain
Removal”.
2. Loosen and remove intake camshaft sprocket bolt (3) and then
remove intake camshaft sprocket (5).
3. Loosen and remove exhaust camshaft sprocket bolt (4) and then
remove exhaust camshaft sprocket (6).
Note: The intake and the exhaust camshaft sprockets are identical.
9-333 Engine/Propulsion

9.5.5.13 Cylinder Head Removal (1.5T) (208652)

1. 9.5.7.1 Special Tools
Use special tool PT - 0023 to remove engine cylinder head bolt (1) (Qty.:
10).
2. Remove engine cylinder head (2) and then take down and discard
cylinder head gasket (3).

9.5.5.14 Piston, Connecting Rod, and Bearing Removal (1.5T) (208653)

1. Mark the pistons and connecting rods as per the cylinder sequence
to prevent mistakes during assemble.
2. Loosen and remove the connecting rod bolt and then take down the
connecting rod cap and the connecting rod bearing shell.
3. Take out the piston connecting rod assembly from upper of the
cylinder block. Assemble the connecting rod cap and the connecting rod
in the correct sequence and place them in place.
Note: Take great care not to scratch the cylinder wall as the connecting
rod big end contacts the cylinder wall when taking out the piston
connecting rod.
 9-334 Engine/Propulsion

9.5.5.15 Crankshaft and Bearing Removal (1.5T) (208655)

1. Loosen and remove main bearing cap bolt (6), remove main
bearing cap (5) and lower main bearing shell (4). Set aside in order
removed.
2. Take down crankshaft (3), upper main bearing shell (1) and thrust
washer (2).
9-335 Engine/Propulsion

9.5.5.16 Cylinder Head Disassemble (1.5T)

1. Remove valve spring cotter (1), valve spring seat (2), valve spring
(3) and valve (4).
Note: Mark in order removed to prevent mistakes during installation.

2. Remove the valve oil seal using valve oil seal remover PT - 0028.
 9-336 Engine/Propulsion

3. Remove intake manifold stud (1) and exhaust manifold stud (2) as
necessary.

9.5.5.17 Cylinder Head Cleaning and Inspection (1.5T) (208657)

Note: Take care not to scrape, scratch or damage the cylinder head
surface, to prevent fine particles falling into the cylinder head and to
maintain the cylinder head clean.
1. Inspect the cylinder head for the following conditions:
• Warping, cracked, damaged or pitting cylinder head
• Debris in oil galleries (clean all the oil galleries until no debris
exists)
• Coolant leakage
• Damaged threaded hole
• Cracked, restricted, corroded, rusted, damaged or leaking
water passages, air passages, oil galleries and combustion
chambers
Remove the condition or replace the cylinder head if any of the above
conditions exists. It is suggested to replace if the cracks or damage
cannot be repaired by welding.
2. Inspect the valve seat for good condition.
3. Clean the residues on the cylinder head and carbon deposits in the
combustion chamber.
4. Measure the cylinder head flatness using a ruler and a feeler gauge
in 6 directions. Condition the head with fine sandpaper as necessary.
5. Inspect the cylinder head height at several positions. The standard
value is 121.3±0.1 mm. Replace as necessary.
9-337 Engine/Propulsion

9.5.5.18 Cylinder Head Assemble (1.5T) (208658)

Caution: Refer to “0.2.1.30 Fastener Caution”.
1. If the intake manifold stud is replaced, install the new intake
manifold stud (1); if the exhaust manifold stud is replaced, install the
new exhaust manifold stud (2).
Tighten
• Intake manifold stud: 15±2 N·m
• Exhaust manifold stud: 20±2 N·m

2. Install the valve oil seal using valve oil seal installer PT - 0027: first
install the oil seal to the special tool and then install it to the cylinder
block.
 9-338 Engine/Propulsion

3. Install the valve, valve spring, valve spring seat and valve collet
using valve spring installer PT - 0024.
Note: The marked end of the valve spring should face up; the intake and
the exhaust valves should be installed at the original positions; the
intake valve is marked with “I” and the exhaust valve is marked with “E”.
9-339 Engine/Propulsion

9.5.5.19 Engine Block Disassemble

1. Remove cylinder head locating pin (1).

2. Remove oil pressure switch (1).

3. Remove crankshaft position sensor bolt (3).
4. Remove crankshaft position sensor (2).
 9-340 Engine/Propulsion

5. Remove knock sensor fastener (1).

6. Remove knock sensor (2).
7. Clean the fastener threads.

8. Remove oil flow check valve (1).

9-341 Engine/Propulsion

9.5.5.20 Engine Block Assemble

Caution: Refer to “0.2.1.30 Fastener Caution”.
1. Install and tighten oil flow check valve (1).
Tighten to: 15 N·m (11 lbft)

2. Install knock sensor (2).

3. Install and tighten knock sensor bolt (1).
Tighten to: 25 N·m (18 lbft)
 9-342 Engine/Propulsion

4. Install crankshaft position sensor (2).

5. Install and tighten crankshaft position sensor bolt (3).
Tighten to: 10 N·m (89 lbin)
6. Install oil pressure switch (1).
Tighten to: 27 N·m (20 lbft)

7. Install cylinder head locating pin (1).

9-343 Engine/Propulsion

9.5.5.21 Piston and Connecting Rod Disassemble (1.5T) (208663)

1. Remove the piston pin retainer using a pair of circlip pliers and
discard the retainer.
2. Remove the piston pin and separate the piston from the connecting
rod assembly.

3. Remove the piston ring set using a piston ring expander.

Note: Worn piston rings are very sharp, so take great care to prevent
hand cutting.
 9-344 Engine/Propulsion

9.5.5.22 Piston, Connecting Rod, and Bearing Cleaning and Inspection (1.5T) (208664)
1. Measure the piston outer diameter at the place 15 mm up from the
bottom.
Piston outer diameter: 73.784±0.007 mm
Replace the piston if it is necessary as the measured value is lower than
the standard value.

2. Measure the cylinder inner diameter at the place 50 mm down from

the cylinder block surface.
cylinder inner diameter: 73.84±0.011 mm
Replace the cylinder if it is necessary as the measured value is greater
than the standard value
3. Determine the piston to cylinder bore gap by deducting the value
measured at Step 1 from that at Step 2.
Piston to cylinder bore gap: intake/exhaust side: 0.041~0.071;
primary/auxiliary thrust side: 0.038~0.074 mm. Replace the affected
parts if the calculation result exceeds the standard value.

4. Measure the piston ring clearance and side clearance.

• Ring I close clearance and side clearance:
0.15 mm~0.3mm/intake/exhaust side: 0.766~1.074;
primary/auxiliary thrust side: 0.765~1.076
• Ring II close clearance and side clearance:
0.35mm~0.5mm/intake/exhaust side: 0.816~1.124;
primary/auxiliary thrust side: 0.815~1.126
• Oil ring close clearance and side clearance:
0.2mm~0.7mm/intake/exhaust side: 0.766~1.274;
primary/auxiliary thrust side: 0.764~1.27
Replace the piston ring set as necessary.
9-345 Engine/Propulsion

5. Measure the piston pin diameter.

Piston pin diameter: 19+0/ - 0.003 mm
6. Measure the connecting rod small end to piston pin gap.
Connecting rod small end to piston pin gap: 0.007~0.020 mm
7. Replace the affected parts if it is necessary as the measured value
is greater than the standard value.

8. Measure the connecting rod journal to shell gap.

 9-346 Engine/Propulsion

Method I
1. First measure and record the connecting rod inner diameter with
the bearing shell assembled.
2. Then measure and record the connecting journal diameter.
Connecting rod journal diameter: 43 ( - 0.005/ - 0.021) mm
Replace the crankshaft if it is necessary as the measured value is
greater than the standard value
3. Determine the connecting rod journal to connecting rod bearing
shell gap by deducting the value measured at Step (2) from that at Step
(1). Standard value:
0.018~0.050 mm. Replace the bearing shell as necessary so that the
gap is within the specified range.
Method II
1. Apply a small amount of engine oil on the connecting rod journal
and bearing shell; cut a plastic measurement bar as long as the width of
the bearing shell; place the bar between the connecting rod journal and
bearing shell. Keep the bar parallel to the journal and avoid the oil hole.
Caution: Refer to “0.2.1.30 Fastener Caution”.
2. Install the connecting rod cap and the connecting rod bearing shell.
Tighten
connecting rod bolt: 20 N·m + (90°±4°)
3. Remove the connecting rod cap and the bearing shell; use the
provided ruler to measure the width of the plastic measurement bar to
get the connecting rod journal to bearing shell gap. Standard value:
0.018~0.050 mm. Replace the bearing shell or relevant parts as
necessary.
9.5.5.23 Piston and Connecting Rod Assemble (1.5T) (208665)
1. Apply a small amount of engine oil on the piston pin, piston pin hole
and connecting rod small end.
2. Install the piston connecting rod and a new retainer at each end of
the piston pin.
Note: When installing the piston, take care to ensure that the forward
mark on the piston aligns with that on the connecting rod; if the
connecting rod is a new one, ensure that the weight grade mark on the
new one should be consistent with those on others.
3. Install the piston rings and keep the openings arranged like an
equilateral triangle; the oil ring set openings should also be arranged
alternately. Replace the air ring and oil ring set together with the piston
ring.
9-347 Engine/Propulsion

9.5.5.24 Intake Manifold Cleaning and Inspection (1.5T) (208667)

1. Inspect the intake manifold to cylinder head sealing surface and the
seal for damages. Replace the seal as necessary.
2. Inspect the air inlet passage for restriction, leakage, cracks, etc.
Replace the intake manifold as necessary.
3. Clean the carbon deposits and foreign materials on the intake
manifold using special cleaning materials and tools, dredge the air inlet
passage and clean outer surface of the intake manifold.
 9-348 Engine/Propulsion

9.5.5.25 Crankshaft and Bearing Cleaning and Inspection (1.5T) (208669)

1. Clean the crankshaft main journal, the connecting rod journal
thoroughly to see if burns, scratches or uneven wear exists on the
surface; clean the oil hole and oil gallery and dredge the hole and
gallery in case of restriction. Replace the crankshaft as necessary.
2. Inspect the crankshaft elbow, the oil hole and other locations for
cracks. If any, replace the crankshaft.
3. Inspect the main bearing shell for deformation, abnormal wear,
cracks, etc. if any, replace the main bearing shell.
4. Measure runout of the main journal and that of the connecting rod
journal by rotating the crankshaft slowly for one round clockwise or
anticlockwise. Standard value: 0.04 mm. Correct or replace the
crankshaft as necessary.
5. Measure the journal diameter. Standard value:
Main journal diameter: 49 ( - 0.005/ - 0.021) mm
Connecting rod journal diameter: 43 ( - 0.005/ - 0.021) mm
If the measured value exceeds the standard value:
Measure the main journal to main bearing shell gap, and select an
appropriate main bearing shell. Refer to “Main Journal to Main Bearing
Shell Gap Measurement” in this section. Measure the connecting rod
journal to connecting rod bearing shell gap. Refer to relevant information
given in “9.5.5.22 Piston, Connecting Rod, and Bearing Cleaning and
Inspection”.
9-349 Engine/Propulsion

6. Measure the crankshaft out - of - roundness and taper. Standard

values:
Out - of - roundness: 0.005 mm
Taper: 0.005 mm
As is shown in the figure, measure the dimensions at the four different
points of each main journal and connecting rod journal: the dimension
difference between “X” and “Y” on the plane indicated by “A” and “B”
represents the out - of - roundness; that between “A” and “B” on the
plane indicated by “X” and “Y” represents the taper. If the measured
value exceeds the standard value, correct or replace the crankshaft. In
case of crankshaft correction, measure each journal to shell gap after
correction.

7. Measure the main journal to main bearing shell gap. Standard

value:
Main journal to main bearing shell gap: 0.018 mm~0.050 mm
Method I
Install the crankshaft main bearing cap, the upper and lower main
bearing shells to the cylinder block and tighten the main bearing cap bolt
to 30 N·m + (51°~59°). Measure the main bearing shell inner diameter.
The difference between the main bearing shell inner diameter and the
main journal diameter is the main journal to main bearing shell gap. If
the measured value exceeds the standard value, replace the main
bearing shell to get the appropriate gap.
 9-350 Engine/Propulsion

Method II
Apply a small amount of engine oil on the main journal and the main
bearing shell; cut a plastic measurement bar as long as the width of the
bearing shell; place the bar between the main journal and the main
bearing shell. Keep the bar parallel to the journal and avoid the oil hole.
Install the bearing cap and tighten the crankshaft main bearing cap bolt
to 30 N·m + (51°~59°). Remove the main bearing cap and the main
bearing shell, use the provided measuring rule to measure the plastic
measurement bar width which represents the gap. If the gap exceeds
the standard value, replace the main bearing shell to get the appropriate
gap.

8. Measure the crankshaft end gap. Standard value: 0.08~0.29 mm.

After installing the crankshaft to the cylinder block, move the crankshaft
back and forth and then measure the maximum clearance between the
crankshaft thrust washer and the crank arm. If the measured value
exceeds the standard value, replace the thrust washer with an
appropriate one so that the gap meets the requirements. Replace the
crankshaft as necessary.

9.5.5.26 Oil Pump Disassemble (1.5T)

1. Loosen and remove oil pump cover bolts (5).
2. Remove the oil pump cover, the oil pump inner rotor and the oil
pump outer rotor.
9-351 Engine/Propulsion

9.5.5.27 Oil Pan Cleaning and Inspection (1.5T) (208671)

1. Clean the oil residues and foreign materials in the oil pan, scrape
the sealer residue on the oil pan to cylinder block mating surface.
Scrape outwards to prevent the sealer residue falling into the oil pan.
Note: Take care not to scratch or damage the mating surface.
2. Clean the sealer residues on the bolt and in the bolt hole.
3. Inspect the oil pan for cracks, the mating surface for damages, the
oil baffle bolt for looseness. Replace relevant parts as necessary.
 9-352 Engine/Propulsion

9.5.5.28 Crankshaft and Bearing Installation (1.5T) (208672)

1. Apply engine oil on the upper main bearing shell (a hole that
corresponds to the cylinder block main bearing seat oil hole is on the
upper main bearing shell) (1) surface. Thoroughly clean the back side
other than coat engine oil on it.
2. Install upper main bearing shell (1) to the corresponding main
bearing seat on cylinder block (3). The positioning bulge on upper main
bearing shell (1) should match the notch on the main bearing seat and
all oil holes should align.
3. Install thrust washers (2) to both sides of the third main bearing seat
on cylinder block (3). The oil groove on thrust washer (2) should face
outwards, opposite to the crankshaft. The positioning bulge on thrust
washer (2) should match the notch on the main bearing seat.
4. Install the crankshaft to the cylinder block.
5. Apply engine oil on the lower main bearing shell surface.
Thoroughly clean the back side other than coat engine oil on it.
6. Install the lower main bearing shell to the main bearing cap in the
order removed and position as per the mark on the bearing shell.
Caution: Refer to “0.2.1.30 Fastener Caution”.
7. The arrow on the main bearing cap should face engine front end.
Install the main bearing caps and the lower main bearing shells to the
main bearing seats as per the number on the main bearing caps.
Tighten the main bearing cap bolts in the sequence shown in the figure.
Tighten
Main bearing cap bolt: 30 N·m + (51°~59°). Do not depend on visual
judgment wherever an angle wrench is needed to tighten to the
specified angle.
8. After installation is completed, the crankshaft should rotate freely.
Check the crankshaft end gap and it should remain within the standard
range.
9-353 Engine/Propulsion

9.5.5.29 Piston, Connecting Rod, and Bearing Installation (1.5T) (208673)

1. If the connecting rod bearing shell is replaced with a new one, apply
engine oil on the connecting rod bearing shell surface. Thoroughly clean
the back side other than coat engine oil on it. Install the connecting rod
bearing shell to the connecting rod cap and the connecting rod
respectively. The positioning bulge on the bearing shell should align with
the notch on the connecting rod and that on the connecting rod cap
respectively. All the oil holes should also align.
2. Install the piston connecting rod assembly to the cylinder block
using special tool PT - 00. Take care not to scratch the cylinder bore
inner wall and the connecting rod journal with the connecting rod big
end.
Note: During installation, ensure that the forward marks on the piston
and the connecting rod face the engine front end.
Caution: Refer to “0.2.1.30 Fastener Caution”.
3. Install the connecting rod cap (with connecting rod bearing shell).
Tighten
Connecting rod bolt: 20 N·m + (90°±4°). Do not depend on visual
judgment wherever an angle wrench is needed to tighten to the
specified angle.
 9-354 Engine/Propulsion

Note: During installation, ensure that the forward marks on the

connecting rod caps face the engine front end and match all the
connecting rod caps with the connection rods as per the marks made in
order removed. To replace the connecting rod cap, replace the whole
connecting rod assembly. After replacement, the connecting rod weight
grade must keep in consistence with that of the other connecting rods.

9.5.5.30 Cylinder Head Installation (1.5T) (208674)

2. Install the cylinder head to the cylinder block and position as per the
cylinder head locating pin.
Caution: Refer to “0.2.1.30 Fastener Caution”.
3. Tighten cylinder head bolts (1) in the sequence below:
9 5 1 4 8
←Engine front end
10 6 2 3 7
Tighten
Cylinder head bolt:
30 N·m +70° +60°. Do not depend on visual judgment wherever an
angle wrench is needed to tighten to the specified angle.

1. Install cylinder gasket (3).

During installation, thoroughly
clean the cylinder head to
cylinder block mating surface.
Ensure that the cylinder gasket
position is correct by positioning
it as per the cylinder head
locating pin.
9-355 Engine/Propulsion

9.5.5.31 Camshaft Sprocket Installation (1.5T)

1. Install the camshaft sprocket to the camshaft. Position according to
the locating pin on the camshaft during installation.
2. Install the camshaft sprocket bolts and pre - tighten camshaft
sprocket bolts (3) and (4).
Tighten
Tighten the bolts after timing chain installation. Refer to “9.5.5.33
Camshaft Timing Chain Installation”.
3. After installation, the timing mark on the camshaft sprocket should
face up.

9.5.5.32 Timing Chain Tensioner Installation (1.5T) (208676)

1. Place (1) against the locking pin and at the same time, compress
the tensioner and seize it with tool (2). Tools (1) and (2) should be clean
and of a diameter equivalent to that of the locking hole and certain
hardness, for example, hexagon head wrench of a comparatively small
size.
Caution: Refer to “0.2.1.30 Fastener Caution”.
2. Install the timing chain tensioner.
Tighten
Timing chain tensioner bolt: 10±2 N·m
3. Remove tools (1) and (2).
 9-356 Engine/Propulsion

9.5.5.33 Camshaft Timing Chain Installation (1.5T) (208677)

1. Clean the timing chain thoroughly and pre - lubricate the timing
chain with fresh oil.
2. Install the timing chain to the camshaft sprocket and the crankshaft
sprocket. Ensure that the timing mark on the timing chain align with the
timing mark on the camshaft sprocket and that on the crankshaft
sprocket respectively.
Note: Do not rotate the crankshaft if the timing chain is not installed.
3. Install the intake side timing chain guide and the timing chain
tensioner. Refer to “9.5.5.32 Timing Chain Tensioner Installation”.

Caution: Refer to “0.2.1.30 Fastener Caution”.

4. Tighten the camshaft sprocket bolt. Fix the camshaft with a monkey
wrench or a similar tool when tightening the bolt, as is shown in the
figure.
Tighten
Camshaft sprocket bolt: (32±2) N·m + (50°±2°)

9.5.5.34 Camshaft Cover Installation (1.5T) (208681)

1. Confirm that the camshaft cover seal ring is intact and fully seated
in the camshaft cover, and that the mating surface with the cylinder
head is clean and free of damage.
2. Install the camshaft cover to the engine cylinder head and tighten
the 12 short bolts along the edge and the two long bolts in the
middle diagonally.
Tighten sequence
7 3 2 6 10
12 13 14 11
8 4 1 5 9
9-357 Engine/Propulsion

Tighten Camshaft cover bolt (long): 10±2 N·m

Camshaft cover bolt (short): 10±2 3. Tighten oil filler cap (3).
N·m
9.5.5.35 Ignition Coil Installation (1.5T) (208682)
1. Insert the ignition coil assembly to the corresponding hole and
ensure that the bolt hole on the ignition coil aligns with the
corresponding bolt hole on the camshaft cover.
Caution: Refer to “0.2.1.30 Fastener Caution”.
2. Install the ignition coil bolts and tighten them.
Tighten
Ignition coil bolt: 10±2 N·m

9.5.5.36 Water Pump Installation (1.5T) (208685)

1. Install the water pump seal.
Caution: Refer to “0.2.1.30 Fastener Caution”.
2. Install the water pump assembly to the corresponding position of
engine front cover.
Tighten
Water pump bolt (2) (Qty.: 2): 22±2 N·m
Water pump bolt (3) (Qty.: 3): 22±2 N·m
3. Inspect again to ensure no water pump seal is left not installed.
 9-358 Engine/Propulsion

9.5.5.37 Water Pump Pulley Installation (1.5T) (208687)

1. Install water pump pulley (2).
Caution: Refer to “0.2.1.30 Fastener Caution”.
2. Install water pump pulley bolt (1) and tighten to 22±2 N·m.

9.5.5.38 Drive Belt Tensioner Installation (1.5T)

1. Install drive belt tensioner (2).
Caution: Refer to “0.2.1.30 Fastener Caution”.
2. Install drive belt tensioner bolt and tighten it to 50±5 N·m.

9.5.5.39 Exhaust Manifold Installation (1.5T) (208692)

1. Inspect the exhaust manifold gasket and replace it as necessary.
2. Install the exhaust manifold gasket.
Refer to “0.2.1.30 Fastener Caution”.
3. Install the exhaust manifold and tighten the exhaust manifold nuts
in the sequence below. Re - tighten 1 - 3 exhaust manifold nuts as
necessary.
8 4 1 5
7 2 3 6
9-359 Engine/Propulsion

Tighten
Exhaust manifold nuts (Qty.: 8): 22±2
N·m
9.5.5.40 Drive Belt Tensioner Removal (1.5T) (208598)
1. Remove tensioner bolt (1).
2. Remove tensioner (2).

9.5.5.41 Crankshaft Sprocket Removal (1.5T) (208696)

1. Remove the timing chain. Refer to “9.5.5.9 Camshaft Timing Chain
Removal”.
2. Remove crankshaft sprocket (1) and woodruff key (2).
 9-360 Engine/Propulsion

9.5.5.42 Throttle Body Assembly Removal (1.5T) (208700)

1. Remove the 4 throttle body bolts (3) and take down throttle body
assembly (2).
2. Remove throttle body gasket 1 and discard it.

9.5.5.43 Engine Block Cleaning and Inspection (1.5T) (208704)

= 1. Clean inside of the cylinder with a clean cloth.
2. Inspect the cylinder block for cracks, and burns and abnormal wear
inside. Replace as necessary.
3. Measure the cylinder to get the following values:
cylinder inner diameter: 73.84±0.011 mm
Roundness: 0.005 mm
Cylindricity: 0.008 mm
Replace the cylinder block if it is necessary as the measured values are
greater than the standard values.
9-361 Engine/Propulsion

9.5.5.44 Throttle Body Assembly Installation (1.5T) (208711)

Caution: Refer to “0.2.1.30 Fastener Caution”.
1. Install throttle body (1) to intake manifold bolt (3) (Qty.: 4).
Tighten to: 10±2 N·m

9.5.5.45 Crankshaft Sprocket Installation (1.5T) (208713)

1. Install crankshaft sprocket key (2) to the corresponding position on
the crankshaft.
2. Install crankshaft sprocket (1) with the timing mark facing down.
 9-362 Engine/Propulsion

9.5.5.46 Crankshaft Rear Oil Seal Removal (1.5T) (208716)

1. Remove the engine flywheel. Refer to “9.5.5.1 Engine Flywheel
Removal”.
2. Loosen and remove the 6 crankshaft rear oil seal seat bolts.
3. Loosen and remove the 2 oil pan bolts (2).
4. Take down crankshaft rear oil seal seat (3).
5. Take down crankshaft rear oil seal seat locating pin (4).
6. Take down crankshaft rear oil seal (6) and discard it.
Note: Replace the crankshaft rear oil seal assembly (with seat) as
necessary. Do not remove the crankshaft rear oil seal if not only the
crankshaft rear oil seal is to be replaced.

9.5.5.47 Timing Chain Guide Installation (1.5T) (208718)

1. Clean the timing chain thoroughly and pre - lubricate the timing
chain with fresh oil.
2. Install the timing chain to the camshaft sprocket and the crankshaft
sprocket. Ensure that the timing mark on the timing chain align with the
timing mark on the camshaft sprocket and that on the crankshaft
sprocket respectively.
Note: Do not rotate the crankshaft if the timing chain is not installed.
3. Install the intake timing chain guide.
9-363 Engine/Propulsion

9.5.5.48 Crankshaft Rear Oil Seal Installation (1.5T) (208719)

1. Apply sealer on crankshaft rear oil seal seat to cylinder block
mating face. Take care to avoid the bolt holes.
Sealer diameter: 4±0.5 mm
Distance from sealer center line to inside chamfer edge: 1±1 mm

Caution: Refer to “0.2.1.30 Fastener Caution”.

2. Install the crankshaft real oil seal seat to the cylinder block through
the crankshaft rear oil seal seat locating pin.
Tighten
Crankshaft rear oil seal seat bolt: 10±2 N·m
Oil pan to crankshaft rear oil seal seat bolt: 10±2 N·m

3. 9.5.7.1 Special Tools

Use special tool (a) PT - 0058 to install the crankshaft rear oil seal.
 9-364 Engine/Propulsion

9.5.5.49 Camshaft Timing Chain Adjustment (1.5T) (212380)

1. Align the timing mark on the camshaft sprocket and that on the
timing chain, and then install the timing chain.
2. Align the timing mark on the crankshaft sprocket and that on the
timing chain.

3. Place (1) against the locking pin and at the same time, compress
the tensioner and seize it with tool (2). Tools (1) and (2) should be clean
and of a diameter equivalent to that of the locking hole and certain
hardness, for example, hexagon head wrench.
Caution: Refer to “0.2.1.30 Fastener Caution”.
4. Install the timing chain guide.
Tighten
Exhaust timing chain guide bolt: 10±1 N·m
Intake timing chain guide bolt: 10±1 N·m
Timing chain tensioner bolt: 10±1 N·m
5. Remove tools (1) and (2).

9.5.5.50 Engine Water Outlet Adapter Installation (1.5T) (205010)

1. Install engine water outlet seat seal (2) correctly.
Caution: Refer to “0.2.1.30 Fastener Caution”.
2. Install the engine water outlet support.
Tighten
Water outlet support bolt: 22±2 N·m
3. Apply sealer on the coolant temperature sensor threads and install
it to the water outlet support.
Tighten
Coolant temperature sensor: 17.5±2.5 N·m
9-365 Engine/Propulsion

9.5.5.51 Exhaust Manifold Heat Shield Removal (1.5T) (205206)

1. Loosen and remove the 4 exhaust manifold heat shield bolts (1)
and then remove exhaust manifold heat shield (2).
2. Place the exhaust manifold heat shield carefully to prevent hand
cutting.

9.5.5.52 Exhaust Manifold Heat Shield Installation (1.5T) (205207)

Caution: Refer to “0.2.1.30 Fastener Caution”.
1. Install the exhaust manifold heat shield to the exhaust manifold.
Tighten
Exhaust manifold heat shield bolt: 11±2 N·m
 9-366 Engine/Propulsion

9.5.5.53 Turbocharger Removal (1.5T)

1. Remove the turbocharger heat shield. Refer to “9.5.4.28
Turbocharger Heat Shield Replacement”.
2. Remove turbocharger mounting nut (1).
3. Remove turbocharger nut (1), check the nut and stud for defects
like damaged thread. If any, replace the nut and the stud.
4. Take down turbocharger (3) and turbocharger gasket (2). Discard
the gasket.
Notes: 1. It is strictly forbidden to pull the turbocharger bypass valve
lever (1) during removal/installation.
2. The turbocharger is required to be meticulously clean. For this
purpose, take care to avoid any foreign material entering the
turbocharger during removal/installation, and once the turbocharger is
removed, block all joints with appropriate covers so that no sundries can
enter the turbocharger.
5. Inspect all turbocharger (1) studs to see if damaged threads exist
and if any, remove turbocharger intake flange stud (2), turbocharger
exhaust flange stud (3) and turbocharger oil return pipe stud (4) to
replace the damaged stud(s) with new ones.
9-367 Engine/Propulsion

9.5.5.54 Turbocharger Installation (1.5T)

Notes: 1. It is strictly forbidden to pull the turbocharger bypass valve
lever. 2. The turbocharger is required to be meticulously clean. For this
purpose, take care to avoid any foreign material entering the
turbocharger during removal, and once the turbocharger is removed,
block all joints with appropriate covers so that no sundries can enter the
turbocharger.
1. Install stud (2) to the turbocharger intake flange.
2. Install stud (3) to the turbocharger exhaust flange.
3. Install turbocharger oil return pipe stud (4).
Tighten
Turbocharger intake flange stud (2): 17±2 N·m
Turbocharger exhaust flange stud (2): 20±2 N·m
Turbocharger oil return pipe bolt: 6±1 N·m
4. You can first install the turbocharger heat shield to the
turbocharger. Refer to “9.5.4.28 Turbocharger Heat Shield
Replacement”.
5. Install turbocharger gasket (2) and turbocharger (3).
6. Tighten turbocharger nut (1).
Tighten
Turbocharger nut (1): 33±3 N·m

9.5.5.55 Crankshaft Position Sensor Removal (1.5T)

Procedure
1. Remove the crankshaft position sensor bolt.
2. Take down the crankshaft position sensor.
Note: Disconnect all the electrical connectors when necessary.
 9-368 Engine/Propulsion

9.5.5.56 Crankshaft Position Sensor Installation (1.5T)

Procedure
1. Install the crankshaft position sensor bolt.
Refer to “0.2.1.30 Fastener Caution”.
Tighten
10±2 N·m
Note: Disconnect all the electrical connectors when necessary.

9.5.5.57 Crankshaft Pulley Removal (1.5T) (257930)

1. Remove the drive belt. Refer to “9.5.5.5 Water Pump Pulley
Removal”.
2. Fix the flywheel using flywheel holder PT - 0192. Refer to “9.5.5.1
Engine Flywheel Removal”.
3. Loosen and remove crankshaft pulley bolt (2) and then taken down
crankshaft pulley (1).

9.5.5.58 Starter Removal (1.5T)

1. Remove the 2 starter bolts (3).
2. Remove starter (4).
9-369 Engine/Propulsion

9.5.5.59 Crankshaft Pulley Installation (1.5T) (257935)

1. Fix the flywheel using flywheel holder PT - 0066 to prevent the
crankshaft from rotating. Refer to “9.5.5.3 Engine Flywheel Installation”.
Caution: Refer to “0.2.1.30 Fastener Caution”.
2. Install the crankshaft pulley and tighten the pulley bolt.
Tighten
Crankshaft pulley bolt:
100 N·m + (75°± 5°). Do not depend on visual judgment wherever an
angle wrench is needed to tighten to the specified angle.

9.5.5.60 Timing Chain Cleaning and Inspection (1.5T) (257940)

1. Remove the engine front cover. Refer to “9.5.5.76 Engine Front
Cover and Oil Pump Removal”.
2. Inspect the timing chain for abnormal wear, cracks, looseness, etc.
If any, replace the chain.
3. Inspect the timing chain guide for abnormal wear and if any, replace
the timing chain guide.
4. Clean the foreign materials on the timing chain.
 9-370 Engine/Propulsion

9.5.5.61 Engine Installation to Stand (1.5T)

1. Remove the engine assembly. Refer to “9.5.4.34 Engine
Replacement”.
2. Install the engine to the engine overhaul stand.
9-371 Engine/Propulsion

9.5.5.62 Engine Pre - lubrication (1.5T)

1. Remove the oil pressure switch.
Note: Take care not to damage the oil pressure switch.

2. Use 1~2 L clean engine oil of the model as specified in the Owner’s
Manual.
3. Install an appropriate adapter to the oil pressure switch position and
pump engine oil to pre - lubricate the engine using oil pumping device
(available in the market).
 9-372 Engine/Propulsion

4. Remove the adapter and the oil pumping device.

Caution: Refer to “0.2.1.30 Fastener Caution”.
5. Install the oil pressure switch.
Tighten
Oil pressure switch: 27±3 N·m
6. Install the engine assembly to the complete vehicle and then fill
new oil to the specified scale.

9.5.5.63 Generator Installation (1.5T)

Caution: Refer to “0.2.1.30 Fastener Caution”.
1. Install generator (2) to the generator bracket and then install
generator bolts (1)and tighten to 40±5 N·m.

9.5.5.64 Generator Removal (1.5T)

1. Screw off the 3 generator bolts (1) and remove generator (2).
9-373 Engine/Propulsion

9.5.5.65 Positive Crankcase Ventilation Pipe Installation (1.5T)

1. Install the low - load PCV pipe assembly 1 (the positive crankcase
ventilation pipe assembly) with one end connected to the intake
manifold and the other to the oil - gas separator.
2. Install the high - load PCV pipe assembly 2 (the positive crankcase
ventilation pipe assembly) with one end connected to the oil - gas
separator and the other to the turbocharger.
3. Install the breather hose assembly with one end connected to the
camshaft cover and the other to the air cleaner inlet duct.
4. Clamp the PCV pipe assembly (high - load) and the breather hose
tight using a separation pipe clamp. Opening of the separation pipe
clamp should face down.
9.5.5.66 Positive Crankcase Ventilation Pipe Removal (1.5T)
1. Press the quick - connect joints connected to the oil - gas separator
and to the intake manifold respectively at both ends of low - load
positive crankcase ventilation pipe assembly (1) and pull off the low -
load positive crankcase ventilation pipe assembly (1).
2. Remove the separation pipe clamp.
3. Press the quick - connect joints connected to the oil - gas separator
and to the turbocharger respectively at both ends of high - load positive
crankcase ventilation pipe assembly (2) and pull off the high - load
positive crankcase ventilation pipe assembly (2).
4. Press the quick - connect joints connected to the camshaft cover
and the air cleaner outlet duct respectively at both ends of breather hose
assembly (3) and pull off breather hose assembly (3).
9.5.5.67 Starter Installation (1.5T)
Note: First install the engine assembly and the transmission assembly to
the vehicle and then install the starter.
1. Install starter (2).
Caution: Refer to “0.2.1.30 Fastener Caution”.
2. Install starter bolt (1) and tighten it to 25±4 N·m.
3. Refer to “Starter Replacement” for other information.
 9-374 Engine/Propulsion

9.5.5.68 Engine Coolant Thermostat Housing Removal (1.5T) (208637)

1. Loosen and remove thermostat housing retaining bolt (3).
2. Remove thermostat housing (1).
3. Remove thermostat (2).

9.5.5.69 Engine Coolant Thermostat Housing Installation (1.5T) (208691)

1. Install thermostat (1) to thermostat housing. Seat the seal ring in
the thermostat housing locating slot and take care to ensure correct
mating.
Caution: Refer to “0.2.1.30 Fastener Caution”.
2. Install thermostat housing (2) to the water pump with the thermostat
housing locating slot facing upward.
Tighten
Thermostat housing bolt: 10±2 N·m
9-375 Engine/Propulsion

9.5.5.70 Intake Manifold Removal (1.5T) (208641)

1. Remove the throttle body assembly. Refer to “9.3.4.10 Throttle
Body Assembly Replacement”.
2. Remove the low - load PCV pipe (positive crankcase ventilation
pipe). Refer to “9.5.5.66 Positive Crankcase Ventilation Pipe Removal”.
3. Loosen and remove two intake manifold bracket to intake manifold
bolts (1).

4. Remove the remaining intake manifold mounting bolts and nuts in a

sequence opposite to that shown in the figure.
5. Take down the intake manifold assembly and the gasket. Discard
the gasket as necessary.

9.5.5.71 Intake Manifold Installation (1.5T) (208684)

1. Thoroughly clean the intake manifold to cylinder head mating
surface. Inspect and confirm that the seal is intact.
Caution: Refer to “0.2.1.30 Fastener Caution”.
2. Install the intake manifold to the cylinder head and tighten relevant
fasteners in the sequence shown in the figure to:
Intake manifold bolt (Qty.: 3): 25±2 N·m
Intake manifold nut (Qty.: 2): 25±2 N·m
 9-376 Engine/Propulsion

9.5.5.72 Camshaft Cleaning and Inspection (1.5T) (208717)

1. Inspect the camshaft for cracks and if any, replace the camshaft.
2. Measure the camshaft runout. Standard value:
Camshaft runout: 0.04 mm
If the measured value exceeds the standard value, correct or replace
the camshaft.

3. Measure the camshaft height. Standard value:

Camshaft height:
Intake: (24.85+17) ± 0.05 mm
Exhaust: (24.2+17) ± 0.05 mm

4. Measure the camshaft journal diameter. Standard value:

Camshaft journal diameter:
Front end: 32 ( - 0.05/ - 0.066) mm
Other: 23 ( - 0.04/ - 0.061) mm
Replace the affected parts if it is necessary as the measured value is
lower than the standard value.
9-377 Engine/Propulsion

9.5.5.73 Crankshaft Front Oil Seal Installation (1.5T) (208720)

1. Install the crankshaft front oil seal using crankshaft front oil seal
installer PT - 0026. Ensure that the flat surface leans against the special
tool and the concave surface faces the engine. Refer to “9.5.7.1 Special
Tools”.
Note: Discard the removed oil seal and replace with a new one.

9.5.5.74 Crankshaft Front Oil Seal Removal (1.5T) (208715)

1. Remove the crankshaft pulley. Refer to “9.5.5.57 Crankshaft Pulley
Removal”.
2. Remove the crankshaft front oil seal and discard it.
 9-378 Engine/Propulsion

9.5.5.75 Engine Front Cover and Oil Pump Installation (1.5T) (208679)
1. Thoroughly clean the remaining sealer on mating surface between
engine front cover and cylinder block & cylinder head with a clean cloth.
2. Apply new engine front cover sealer on the mating surface between
cylinder block & cylinder head and engine front cover.

Sealer diameter: 4.5±0.5 mm

Distance from sealer center line to inside chamfer edge: 1±1 mm
3. The sealer line should be continuous in the correct shape and
position, bypassing the bolt holes successively. During installation, take
care not to damage the sealer line and tighten the front cover bolts
within 20 minutes after sealer application.
4. Install the front cover to the cylinder head and the cylinder block.
Locate with the front cover locating pin and ensure installation in place
in one time.
Caution: Refer to “0.2.1.30 Fastener Caution”.
5. Tighten the 13 front cover bolts in the sequence shown in the figure
and re - tighten 3 bolts (4), (3) and (6) as necessary.
Tighten
Front cover bolt: 22±2 N·m
9-379 Engine/Propulsion

9.5.5.76 Engine Front Cover and Oil Pump Removal (1.5T) (208646)
1. Remove the camshaft cover. Refer to “9.5.5.8 Camshaft Cover
Removal”.
2. Remove the water pump. Refer to “9.5.5.6 Water Pump Removal”.
3. Loosen and remove the engine mount bracket to engine front cover
bolt (1), and take down engine mount bracket (2).

4. Remove the oil pan and the strainer. Refer to “9.5.4.20 Oil Pan
Replacement”.
5. Remove the drive belt. Refer to “Water Pump Belt Replacement”.
6. Remove the crankshaft pulley. Refer to “9.5.5.57 Crankshaft Pulley
Removal”.
7. Loosen and remove the 13 engine front cover to cylinder block
bolts.
8. Remove the engine front cover assembly (with oil pump).

9.5.5.77 Oil Pan Installation (1.5T) (208680)

1. Thoroughly clean the remaining glue, dirt and other foreign
materials on the oil pan to cylinder block mating surface. Wipe the
surface clean with a clean cloth.
2. Apply sealer on the oil pan.
○ Sealer diameter: 3.75±0.25 mm
○ Distance from sealer center line to inside chamfer edge:
1±1 mm
3. The sealer line should be continuous in the correct shape and
position, bypassing the bolt holes successively. During installation,
take care not to damage the sealer line and tighten the oil pan bolt
within 20 minutes after sealer application.
 9-380 Engine/Propulsion

Tighten
Tighten small oil pan bolt to: 10±2 N·m

4. Install the oil pan to the cylinder block correctly

through the oil pan locating pin. Take care not to
damage the sealer line during installation.
Refer to “0.2.1.30 Fastener Caution”.
5. Tighten the 18 oil pan bolts (1) in the sequence
below.
13 9 5 1 4 8 12
17 16
18 15
14 10 6 2 3 7 11
Tighten
Oil pan bolt: 10±2 N·m

6. If you need only to install small oil pan (4), apply

sealer on the small oil pan mounting face as directed
in Step 2 and Step 3 and then install the small oil pan
to oil pan upper housing (5). Take care not to damage
the sealer line during installation.
Tighten the 9 small oil pan bolts (3) in the sequence
below.
4 2
6 7
8 5
1 9 3
9-381 Engine/Propulsion

9.5.5.78 Oil Pan Removal (1.5T) (208645)

1. Loosen and remove the 18 oil pan bolts.
2. Use a small hammer to gently knock oil pan special tool PT - 0031
into the joint seam along the oil pan to engine cylinder block bottom
edge and then knock one side of the special tool. Take care not to
damage the mating surface. Refer to “9.5.7.1 Special Tools”.
Note: You can use a similar oil seal scrapper instead of special tool PT -
0031, but never use tools like screwdriver otherwise the mating surface
can be damaged.
3. Remove the oil pan.
4. If you need only to disassemble the small oil pan, drain the oil,
loosen and remove the 9 oil pan bolts and then use the special tool and
method described in Step 2 to knock and take down the small oil pan.

9.5.5.79 Valve Lifter Installation (1.5T) (208710)

1. Clean the valve lifter thoroughly and pre - lubricate the valve lifter
with fresh oil.
2. Install the valve lifters to the corresponding positions as per the
marks made in order removed. If any new lifter is used for replacement,
mark it and ensure no malposition during installation.
Note: Do not allow gloves or other devices to contact the lifter.
 9-382 Engine/Propulsion

9.5.5.80 Valve Lifter Removal (1.5T) (208701)

1. Remove the camshaft. Refer to “9.5.4.16 Camshaft Replacement”.
2. Remove the valve lifters carefully using a magnetic tool and place
them upside down in order removed to prevent oil loss. Take care not to
damage any valve lifter.

9.5.5.81 Oil Level Indicator and Tube Removal (1.5T) (208698)

1. Drain the oil. Refer to “9.5.5.4 Draining Fluids and Oil Filter
Removal”.
2. Loosen and remove the oil level indicator tube to turbocharger
retaining bolt (1) and take down oil level indicator tube (2).
3. Pull out the oil level indicator from the oil level indicator tube.
9-383 Engine/Propulsion

9.5.5.82 Oil Level Indicator and Tube Installation (1.5T) (208709)

1. Confirm that the seal ring at oil level indicator tube to oil pan joint is
intact. Replace the seal ring if necessary.
2. Insert the oil level indicator into the corresponding position on the
oil pan.
Caution: Refer to “0.2.1.30 Fastener Caution”.
3. Tighten the oil level indicator tube bracket bolt.
Tighten
Oil level indicator tube bracket bolt: 10±2 N·m
4. Thoroughly wipe the oil level indicator clean using a clean cloth and
install the oil level indicator into the oil level indicator tube and push it
tight.
 9-384 Engine/Propulsion

9.5.6 Description and Operation opening

9.5.6.1 Cleaning and Maintenance Low Large High
An automobile engine is a combination of many High Small Low
machined, honed, polished, and lapped surfaces with Consequence of abnormal operation:
tolerances that are measured in 0.01 mm. This makes
A plugged valve or hose may cause the following
engine cleaning and maintenance of great
conditions:
importance—during engine part service, the affected
parts should be protected from contamination; before • Rough idle
installation, they should be fully lubricated with clean • Stalling or low idle speed
engine oil; when operating with a tool, care should be • Extremely high engine crankcase pressure
taken not to damage the part surface.
• Oil leaks
9.5.6.2 Crankcase Ventilation System
Description (210572) • Oil in the air cleaner
The compressed combustion gas which has entered • Sludge in the engine
the crankcase through the piston ring is called the • Oil consumption
blown - by gas. The blow - by gas contains a large • Excessive exhaust emission
amount of carbon monoxide and hydrocarbons. The
positive crankcase ventilation (PCV) system prevents A leaking valve or hose may cause the following
the blown - by gas from being discharged into the conditions:
atmosphere. The positive crankcase ventilation • Rough idle
system leads blow - by gas from the crankcase back • Stalling
to the intake system, so that the blown - by gas enters
• High idle speed
the combustion chamber for combustion. The positive
crankcase ventilation system consists of the following • Abnormal engine crankcase pressure
components: • Excessive exhaust emission
• Positive crankcase ventilation valve 9.5.6.3 Engine Component Description (208722)
• Crankcase vent pipe or air inlet duct 1.5T engine is a high - performance engine that is
• Intake air filter or separator (if used) developed based on 1.5L engine. As 1.5T engine is
equipped with a turbocharger, the air intake quantity
• Hose and joint
is greater under high load when compared with that of
Operation the previous 1.5L engine. Under this condition, ECM
The main control device for blown - by gas from the controls to inject more fuel for mixture combustion, the
engine crankcase is the positive crankcase ventilation pressure generated by the mixture increases greatly
valve. The positive crankcase ventilation valve and the thermal load in the combustion chamber also
calculates the blown - by gas flow according to the increases remarkably. Therefore, the engine
manifold vacuum signal. mechanical components are structurally strengthened
The PCV valve part below the lower O - ring is and designed in a manner that ensures high
exposed in the manifold vacuum; the part between temperature resistance.
the lower and upper O - rings is exposed in the
crankcase gas. The positive crankcase ventilation
valve allows some vacuum pressure to pass through
the orifice in the valve, forming a low - pressure state
in the crankcase. Then, blown - by gas in the
crankcase is absorbed into the intake system and
burned during the normal combustion process. The
blown - by gas volume flowing into the intake manifold
is accurately controlled to keep the idling quality. Be
sure to use the correct positive crankcase ventilation
valve which has been calibrated properly. The
relationship between the blown - by gas flow and
engine manifold vacuum degree is shown in the
following table:
Positive crankcase ventilation valve operation:
Positive
Manifold vacuum Blown - by gas
crankcase
degree flow
ventilation valve
9-385 Engine/Propulsion
Cylinder Head and Cylinder Gasket
The cylinder head is made of aluminum alloy. It
adopts cross flow type intake ports and exhaust ports.
The spark plug is installed in the middle of each
combustion chamber. The cylinder head is double
over head camshaft (DOHC) type.
Crankshaft
The crankshaft uses 8 balance weights to balance the
crankshaft rotation. The oil hole passes the crankshaft
center and provides oil for the connecting rod, the
bearing, the piston and other components. A thrust
washer is installed at the middle journal.
Timing Chain
The timing chain transfers crankshaft rotation to the
camshaft and at the same time, it coordinates the
movement of camshaft and that of crankshaft in a way
that the opening/closing of valve is realized according
to the preset rules. The timing chain tensioner can
keep the chain in tension automatically and it
supports self - locking. In this way, slippage off the
gear is reduced effectively.
Oil pump
The rotor - type oil pump is installed on the engine
front cover and it inputs oil into all locations of the
engine once oil is extracted. The oil pump is provided
with a pressure relief valve which opens when the
pressure gets extremely high. In this case, the
redundant oil flows back to the oil pan.
Intake manifold
As the vehicle is equipped with a turbocharging
system, the intake manifold pressure is comparatively
high. For this reason, plastic of a relatively high
strength is used to make the intake manifold. Besides,
due to the turbocharging system, the air intake
quantity increases greatly. For this reason, no
variable intake manifold (VIM) and Port De - activation
Valve (PDA) are installed on the intake manifold.
Exhaust Manifold
The exhaust manifold is of a one - piece type the rear
end of which is connected to front end of the exhaust
pipe muffler. The front oxygen sensor is installed on
the exhaust manifold.
Camshaft
With a dual overhead camshaft (DOHC) structure, the
exhaust manifold not only controls opening/closing of
the intake port and the exhaust port separately, but
also shorten the distance between the camshaft to the
valves. In this way, valve lifter and rocker arm are no
longer used and the camshaft - to - valve drive
mechanism is simplified. As a result, the engine
structure becomes more compact. What’s more
important, this kind of installation reduces the
reciprocating motion mass of the whole system and
enhance the drive efficiency as a result.
Piston
Dovetail joints are adopted for piston to connecting
rod connection of the supercharged engine. This
provides comparatively large contact area between
the pistons and between the piston pin and the
connecting rod. As a result, the load of the piston pin
and the connecting rod is reduced.
Engine oil cooler
An oil cooler is installed to the supercharged engine in
addition. It is installed below the oil filter and forced
cooling is realized via the coolant.
Piston Cooling Nozzle
An oil cooling nozzle is installed to the supercharged
engine in addition. It is installed below the cylinder
bore with the nozzle facing up. Oil cooled by the oil
cooler passes the oil filter and flows first to the main
oil gallery and then to the 4 nozzles. Thus piston
cooling is realized.
9.5.6.4 Separating Parts (208725)
Note:
• Disassembly of the piston, and installation of the
piston pin and the connecting rod may create
scoring or damage to the piston pin and piston
pin bore. If the piston, pin, and connecting rod
have been disassembled, replace the
components as an assembly.
• Many internal engine components will develop
specific wear patterns on their friction surfaces.
• When disassembling the engine, internal
components must be separated, marked,
organized in a way to ensure installation to their
original location and position.
Separate, mark or organize the following
components:
• Piston and the piston pin;
• Piston to the specific cylinder bore;
• Piston rings to the piston;
• Connecting rod to the crankshaft journal;
• Connecting rod to the bearing cap—a mark pen
is recommended for marking;
• Crankshaft main and connecting rod bearings;
• Camshaft, valve lifters and valves;
• Valve spring and shim to the cylinder head
location;
• Camshaft bearing cap location and direction.
9.5.6.5 Tools and Equipment
Special tools are listed and illustrated throughout this
section with a complete listing at the end of the
section. These tools, or their equivalents, are
specially designed to quickly and safely accomplish
the operations for which they are intended. The use of
these special tools will also minimize possible
damage to engine components. Some precision
measuring tools are required for inspection of certain
 9-386 Engine/Propulsion

critical components. Torque wrenches and a torque

angle meter are necessary for the proper tightening of
various fasteners.
To properly service the engine assembly, the
following items should be readily available:
• Approved eye protection and safety gloves
• A clean, well - lit work area
• A suitable parts cleaning tank
• A compressed air supply
• Trays or storage containers to keep parts and
fasteners organized
• An adequate set of hand tools
• An approved engine repair stand
• An approved engine lifting device that will
adequately support the weight of the components
9-387 Engine/Propulsion

9.5.7 Special Tools and Equipment Illustration Tool Number/Description

9.5.7.1 Special Tools (208729)
Illustration Tool Number/Description

PT - 0069
Engine balancing stand
PT - 0023
Cylinder head bolt
extended wrench

PT - 0067
Clutch centering tool
T - 0024
Valve spring installer

PT - 0026
Crankshaft front oil seal
installer
SE - 0001
Engine turning stand
(purchased from market)

PT - 0028
Valve oil seal remover

PT - 0031
Oil pan remover
 9-388 Engine/Propulsion

Illustration Tool Number/Description

PT - 0068
Piston ring installer

PT - 0192
Flywheel holder

PT - 0184
Oil filter remover/installer
9-389 Engine/Propulsion

9.7 Exhaust
9.7.1 Specifications
9.7.1.1 Fastener Tightening Specifications
Fastener Specifications
Specification
Application
Metric
Exhaust pipe to catalytic converter
30±5 N·m
connector
Front muffler to exhaust pipe connector 30±5 N·m
Front muffler to rear muffler connector 30±5 N·m
Catalytic converter bracket bolt (1.5L) 55±5 N·m
Catalytic converter to exhaust manifold
50±5 N·m
nut (1.5L)
Catalytic converter to exhaust manifold
43±7 N·m
bolt (1.8L)
Muffler heat shield mounting bolt 7±1 N·m
Exhaust manifold nut (1.8L) 25±3 N·m
Exhaust manifold heat shield bolt (1.8L) 11±2 N·m
Exhaust manifold nut (1.5L) 22±2 N·m
Exhaust manifold heat shield bolt (1.5L) 11±2 N·m
 9-390 Engine/Propulsion

9.7.2 Diagnostic Information and Procedures

9.7.2.1 Exhaust Leakage (37907)
Exhaust System Leakage
Condition Operation
Warning: The exhaust system temperature is very high while the engine is running. Do not touch the hot exhaust
system in case you are scalded.
Definition: An exhaust leak may show stains at the area of the leak. The leak may be felt by holding a hand close to
the suspected areas or using a smoke pencil. The leak may make a popping or hissing noise.
Refer to “6.2.2.6 Diagnostic Procedure Instructions” prior to beginning this table.
Align and tighten the exhaust system components to the required
Misaligned or incorrectly installed exhaust
specifications.
system components
Refer to “9.7.1.1 Fastener Tightening Specifications”.
Exhaust leaks at the following connections:
Tighten the affected components to the required specifications. Refer
● Exhaust manifold to pipe flange
to “9.7.1.1 Fastener Tightening Specifications”.
● Pipe clamp
Seals or gaskets leaking
● Exhaust manifold to cylinder head
● Exhaust pipes to exhaust manifold
Replace the leaking seal or gasket. Refer to the repair procedure of the
● Catalytic converter connection affected component.
● Oxygen sensor and vacuum pipe
connected to exhaust manifold or cylinder
head
Irregularities at the mating surfaces on the Repair as required or replace the affected component. Refer to the
flange connections repair procedure of the affected component.
Replace the exhaust manifold. Refer to “Exhaust Manifold
Exhaust manifold cracked or broken
Replacement”.
Exhaust system component connection Replace the leaking component. Refer to “9.7.3.8 Rear Exhaust
welds leaking Muffler Replacement”.
Replace the affected pipe. Refer to “9.7.3.8 Rear Exhaust Muffler
Pipe damage or joint leaks
Replacement”.
9-391 Engine/Propulsion

9.7.2.2 Exhaust Noise (37853)

Exhaust System Noise
Condition Operation
Definition: An audible or physical noise due to a faulty component or damaged components which cause a loose or
misaligned

exhaust system and further results in a rattle or vibration noise (for example: buzzing, whining and humming).
Refer to “6.2.2.6 Diagnostic Procedure Instructions” prior to beginning this table.
Popping or hissing noise The exhaust system leaks. Refer to “9.7.2.1 Exhaust Leakage”.
1. Compare to a known good vehicle.
Loud exhaust noise 2. Inspect for a damaged or failed muffler.
3. Replace the faulty muffler.
1. Inspect for a bent or loose hanger, loose heat shield, or loose
clamp
External rattle or vibration noise 2. Inspect for an exhaust pipe causing interference.
3. Repair or replace the affected component. Refer to the repair
procedure of the affected component.
1. Test the components by tapping with a rubber mallet to confirm a
rattle.
2. Replace the faulty catalytic converter, or muffler. Refer to one of
Internal rattle
the following procedures:
Catalytic Converter Replacement
Exhaust System
9.7.2.3 Symptoms - Engine Exhaust (37994) • Exhaust popping Refer to “9.7.2.1 Exhaust
• Review the exhaust system description and Leakage”.
operation in order to familiarize yourself with the • Exhaust rattle Refer to “9.7.2.2 Exhaust Noise”.
system functions. Refer to “9.7.4.1 Exhaust • Loud exhaust noise Refer to “9.7.2.2 Exhaust
System Description”. Noise”.
• All diagnosis on a vehicle should follow a logical • Exhaust buzz, groan or hum Refer to “9.7.2.2
process. Strategy based diagnostics is a uniform Exhaust Noise”.
approach for repairing all systems. The diagnostic
flow is the place to start when repairs are
necessary. It may always be used in order to
resolve a system problem.
Visual/Physical Inspection
• Inspect for aftermarket or non - OEM devices
including but not limited to exhaust tail pipe
extension, header and exhaust interrupter. These
could affect the operation and normal
performance of the exhaust system.
• Verify the exact operating conditions under which
the concern exists. Note factors such as engine
RPM, engine temperature, engine load, and
frequency of concern.
• Inspect the easily accessible or visible system
components for obvious damage or conditions
which could cause any symptom.
Intermittent
Test the vehicle under the same conditions that the
customer reported in order to verify the system is
operating as designed.
Symptom List
• Exhaust hissing Refer to “9.7.2.1 Exhaust
Leakage”.
 9-392 Engine/Propulsion

9.7.3 Repair Instructions

9-393 Engine/Propulsion
9.7.3.2Exhaust Manifold Replacement (1.5T)
(37850)
Removal Steps
Note: The exhaust manifold is hot and sharp, so
please wear labor protective articles such as safety
goggles and anti - cutting gloves during operation.
1. Open the engine hood to make sure the engine is
cool enough.
2. Disconnect the battery negative pole.
3. Remove the exhaust manifold heat shield. Refer
to “Exhaust Manifold Heat Shield Replacement”.
4. Remove the 8 exhaust manifold nuts (1) to
remove the exhaust manifold and gasket (2) . Discard
the gasket as necessary.
5. Place the exhaust manifold carefully.
Installation Procedure
1. Inspect to confirm that the exhaust manifold
gasket is intact and not lost.
Caution: Refer to “0.2.1.30 Fastener Caution”.
2. Install the exhaust manifold and tighten the
exhaust manifold nuts in the sequence below. Re -
tighten 1 - 3 exhaust manifold nuts as necessary.
8 4 1 5
7 2 3 6
Tighten
Exhaust manifold nuts (Qty.: 8): 22±2 N·m
 9-394 Engine/Propulsion

9.7.3.4 Exhaust Manifold Heat Shield Replacement (1.5L Turbocharged Engine) (64786)

Exhaust Manifold Heat Shield Replacement (1.5L Turbocharged Engine)

Callout Component Name
Preliminary Procedure
Note: The exhaust manifold heat shield is hot and sharp, so please wear labor protective articles such as safety
goggles and anti - cutting gloves during operation.
1. Open the engine hood to make sure the engine is cool enough.
2. Remove the turbocharger air outlet pipe heat shield. Refer to “9.5.4.28 Turbocharger Heat Shield
Replacement”.
3. Remove the turbocharger assembly. Refer to “9.5.4.29 Turbocharger Replacement”.
Exhaust manifold heat shield bolt (Qty.: 4)
Caution: Refer to “0.2.1.30 Fastener Caution”.
1
Tighten
11±2 N·m
2 Exhaust manifold heat shield
9-395 Engine/Propulsion

9.7.3.5 Exhaust Muffler Heat Shield Replacement

Exhaust Front Muffler Heat Shield Replacement

Callout Component Name
Preliminary Procedure
1. Remove the front exhaust pipe. Refer to “9.7.3.7 Front Exhaust Pipe Replacement”.
Muffler heat shield mounting bolt (Qty.: 3)
Caution: Refer to “0.2.1.30 Fastener Caution”.
1
Tighten
7±1 N·m
2 Muffler front heat shield
 9-396 Engine/Propulsion

9.7.3.6 Intermediate Pipe Replacement

Exhaust Muffler Replacement—Intermediate

Callout Component Name
Preliminary Procedure
Warning: Refer to “0.2.1.32 Exhaust System Inspection Warning”.
1. Lift the vehicle. Refer to “1.1.1.4 Lifting and Jacking the Vehicle”.
2. Disconnect the intermediate exhaust muffler from rear end of the exhaust front pipe. Refer to “9.7.3.7 Front
Exhaust Pipe Replacement”.
3. Disconnect the intermediate exhaust muffler from front end of the rear muffler. Refer to “9.7.3.8 Rear Exhaust
Muffler Replacement”.
Intermediate exhaust muffler hanger (Qty.: 3)
1 Procedure
1. Replace the aged rubber hanger.
2 Intermediate exhaust muffler
9-397 Engine/Propulsion

9.7.3.7 Front Exhaust Pipe Replacement

Front Exhaust Pipe Replacement

Callout Component Name
Preliminary Procedure
Caution: Refer to “0.2.1.36 Hot Exhaust System Warning”.
1. Lift the vehicle. Refer to “1.1.1.4 Lifting and Jacking the Vehicle”.
2. Disconnect the exhaust muffler from the middle. Refer to “9.7.3.6 Intermediate Pipe Replacement”.
Catalytic converter to exhaust pipe welding assembly nut (Qty.: 3)
Caution: Refer to “0.2.1.30 Fastener Caution”.
1
Tighten
30±5 N·m
Rear oxygen sensor
Caution: Refer to “0.2.1.30 Fastener Caution”.
2
Tighten
50±10 N·m
3 Front exhaust pipe
Intermediate muffler to exhaust pipe welding assembly nut (Qty.: 2)
Caution: Refer to “0.2.1.30 Fastener Caution”.
4
Tighten
30±5 N·m
 9-398 Engine/Propulsion

9.7.3.8 Rear Exhaust Muffler Replacement

Rear Exhaust Muffler Replacement

Callout Component Name
Preliminary Procedure
1. Lift the vehicle. Refer to “1.1.1.4 Lifting and Jacking the Vehicle”.
1 Tail lug (Qty.: 2)
2 Intermediate lug
Rear muffler to front end nut (Qty.: 2)
Caution: Refer to “0.2.1.30 Fastener Caution”.
3
Tighten
Nut to 30±5 N·m
Gasket
4
Discard the seriously corroded gasket.
Warning: Refer to “0.2.1.36 Hot Exhaust System Warning”.
5
Tail exhaust muffler
9-399 Engine/Propulsion

9.7.3.9 Turbocharger Heat Shield Replacement (1.5T)

Turbocharger Heat Shield Replacement

Callout Component Name
Preliminary Procedure
1. Remove the turbocharger air outlet pipe heat shield.
Turbocharger heat shield bolt (Qty.: 2)
Caution: Refer to “0.2.1.30 Fastener Caution”.
1
Tighten
11±2 N·m
2 Turbocharger heat shield
9-400 Engine/Propulsion
9-401 Engine/Propulsion

9.7.3.11 Catalytic Converter Replacement (1.5T) (37817)

Catalytic Converter Replacement (1.5T Turbocharged Engine)

Callout Component Name
Preliminary Procedure
Warning: Refer to “0.2.1.36 Hot Exhaust System Warning”.
Warning: Refer to “0.2.1.7 Protective Goggles and Glove Warning”. Caution: Refer to “0.2.1.30 Fastener Caution”.
1. Lift the vehicle. Refer to “1.1.1.4 Lifting and Jacking the Vehicle”.
2. 1. Remove the turbocharger air outlet pipe heat shield. Refer to “9.7.3.9 Turbocharger Heat Shield
Replacement”.
Notes:
1. Discard the seal ring as necessary.
2. Confirm that the seal ring is intact without damage during installation.
Front oxygen sensor
1 Tighten
50±10 N·m
Catalytic converter to turbocharger nut (Qty.: 3)
2 Tighten
50±5 N·m
3 Seal ring
Catalytic converter to front muffler nut (Qty.: 3)
4 Tighten
50±5 N·m
 9-402 Engine/Propulsion

Catalytic Converter Replacement (1.5T Turbocharged Engine)(Cont’d)

Callout Component Name
5 Seal ring
Catalytic converter bracket bolt (Qty.: 1)
6 Tighten
50±5 N·m
7 Catalytic converter assembly
 Table of Contents

9.7.4 Description and Operation

9.7.4.1 Exhaust System Description (37949)
Exhaust System
The main function of the exhaust system is to collect
the engine exhaust generated in all the cylinders
during combustion, clean the exhaust (through the
catalytic converter), reduce the exhaust noise
(through the muffler) and then channel the processed
exhaust into the atmosphere.
Catalytic Converter
Catalytic converter is an important component which
ensures standard - level exhaust emission quality by
mainly reducing the content of hydrocarbons (HC),
carbon monoxide (CO) and nitrogen oxides (NOx) in
the engine exhaust. The catalytic converter requires
usage of unleaded gasoline, otherwise the Palladium
(Pd), Platium (Pt) and Rhodium (Rh) in the converter
can get “poisoned” and as a result, the converter will
fail to provide the expected performance.
Muffler
Muffler is a device that can restrict sound
transmission and allow air flow to pass. It is mainly
used to reduce the noise generated as the engine
exhaust is discharged. This vehicle is equipped with
a front muffler and a rear muffler.
Muffler Bracket and Rubber Hanger
One end of the muffler bracket is welded on the
muffler and the other end hooked on the rubber
hanger. The bracket is mainly used to bear the
exhaust system weight. Two holes are perforated on
the rubber hanger: one is hooked to the muffler, the
other is hooked at the vehicle body bottom.