Almera Tino V10 (2003 year). Manual — part 155

GLOW CONTROL SYSTEM

EC-1499

[YD (WITHOUT EURO-OBD)]

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7.

CHECK GLOW RELAY POWER SUPPLY CIRCUIT

1.

Turn ignition switch OFF.

2.

Disconnect glow relay.

3.

Check voltage between glow relay terminals 1, 3 and ground
with CONSULT-II or tester.

OK or NG

OK

>> GO TO 9.

NG

>> GO TO 8.

8.

DETECT MALFUNCTIONING PART

Check the following.

●

60A fusible link

●

Harness for open or short between glow relay and battery

>> Repair harness or connectors.

9.

CHECK GLOW RELAY OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1.

Disconnect ECM harness connector.

2.

Check harness continuity between ECM terminal 37 and glow relay terminal 2.
Refer to Wiring Diagram.

3.

Also check harness for short to ground and short to power.

OK or NG

OK

>> GO TO 11.

NG

>> GO TO 10.

10.

DETECT MALFUNCTIONING PART

Check the following.

●

Harness connectors F45, M71

●

Harness connectors E125, M82 (LHD models)

●

Harness connectors E145, M80 (RHD models)

●

Harness for open or short between glow relay and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

MBIB0916E

Voltage: Battery voltage

PBIB1413E

Continuity should exist.

EC-1500

[YD (WITHOUT EURO-OBD)]

GLOW CONTROL SYSTEM

11.

CHECK HARNESS CONTINUITY BETWEEN GLOW RELAY AND GLOW PLUG FOR OPEN AND

SHORT

1.

Disconnect glow plug harness connector.

2.

Check harness continuity between glow relay terminal 5 and glow plug harness connector.
Refer to Wiring Diagram.

3.

Also check harness for short to ground and short to power.

OK or NG

OK

>> GO TO 12.

NG

>> Repair open circuit or short to ground or short to power in harness or connectors.

12.

CHECK GLOW RELAY

Refer to

EC-1501, "Component Inspection"

.

OK or NG

OK

>> GO TO 13.

NG

>> Replace glow relay.

13.

CHECK GLOW PLUG

Refer to

EC-1501, "Component Inspection"

.

OK or NG

OK

>> GO TO 14.

NG

>> Replace glow plug.

14.

CHECK INTERMITTENT INCIDENT

Refer to

EC-1309, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT"

.

>> INSPECTION END

Continuity should exist.

GLOW CONTROL SYSTEM

EC-1501

[YD (WITHOUT EURO-OBD)]

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Component Inspection

EBS01519

GLOW RELAY

Check continuity between glow relay terminals 3 and 5 under the fol-
lowing conditions.

Operation takes less than 1 second.

GLOW PLUG

1.

Remove glow plug connecting plate.

2.

Check glow plug resistance.

NOTE:

●

Do not bump glow plug heating element. If it is bumped,
replace glow plug with a new one.

●

If glow plug is dropped from a height of 10 cm (3.94 in) or
higher, replace with a new one.

●

If glow plug installation hole is contaminated with car-
bon, remove it with a reamer or suitable tool.

●

Hand-tighten glow plug by turning it two or three times,
then tighten using a tool to specified torque.

Removal and Installation

EBS0151A

GLOW PLUG

Refer to

EM-142, "GLOW PLUG"

.

Conditions

Continuity

12V direct current supply between ter-
minals 1 and 2

Yes

No current supply

No

PBIB0428E

Resistance: Approximately 0.8

Ω

[at 25

°

C (77

°

F)]

: 20.1 N-m (2.1 kg-m, 15 ft-lb)

PBIB0429E

EC-1502

[YD (WITHOUT EURO-OBD)]

EGR VOLUME CONTROL SYSTEM

EGR VOLUME CONTROL SYSTEM

PFP:14710

Description

EBS0151B

SYSTEM DESCRIPTION

*: This signal is sent to the ECM through CAN communication line.

This system controls flow rate of EGR led from exhaust manifold to intake manifold. The opening of the EGR
by-pass passage in the EGR volume control valve changes to control the flow rate. A built-in step motor
moves the valve in steps corresponding to the ECM output pulses. The opening of the valve varies for opti-
mum engine control. The optimum value stored in the ECM is determined by considering various engine con-
ditions.
The EGR volume control valve remains close under the following conditions.

●

Engine stopped

●

Engine starting

●

Low engine coolant temperature

●

Excessively high engine coolant temperature

●

High engine speed

●

Wide open throttle

COMPONENT DESCRIPTION
EGR Volume Control Valve

The EGR volume control valve uses a step motor to control the flow
rate of EGR from exhaust manifold. This motor has four winding
phases. It operates according to the output pulse signal of the ECM.
Two windings are turned ON and OFF in sequence. Each time an
ON pulse is issued, the valve opens or closes, changing the flow
rate. When no change in the flow rate is needed, the ECM does not
issue the pulse signal. A certain voltage signal is issued so that the
valve remains at that particular opening.

Sensor

Input Signal to ECM

ECM Function

Actuator

Crankshaft position sensor

Engine speed

EGR volume control

EGR volume control valve

Vehicle speed sensor*

Vehicle speed

Engine coolant temperature sensor

Engine coolant temperature

Ignition switch

Start signal

Accelerator pedal position sensor

Accelerator pedal position

Mass air flow sensor

Amount of intake air

Air conditioner switch*

Air conditioner operation

SEF908Y

SEF411Y

EGR VOLUME CONTROL SYSTEM

EC-1503

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CONSULT-II Reference Value in Data Monitor Mode

EBS0151C

Specification data are reference values.

ECM Terminals and Reference Value

EBS0151D

Specification data are reference values and are measured between each terminal and ground.

CAUTION:

Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.

MONITOR ITEM

CONDITION

SPECIFICATION

EGR VOL CON/V

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No-load

After one minute at idle

More than 10 steps

Revving engine from idle to 3,600 rpm

0 step

TERMI-

NAL

NO.

WIRE

COLOR

ITEM

CONDITION

DATA

(DC Voltage)

25
26
27
28

GY
W/L
OR/B
GY/B

EGR volume control valve

[Engine is running]

●

Warm-up condition

●

Idle speed

0.1 - 14V
(Voltage signals of each ECM
terminals differ according to the
control position of EGR volume
control valve.)

105

113

G
G

ECM relay (self-shutoff)

[Ignition switch ON]
[Ignition switch OFF]

●

For a few seconds after turning ignition switch
OFF

Approximately 1.2V

[Ignition switch OFF]

●

More than a few seconds after turning ignition
switch OFF

BATTERY VOLTAGE
(11 - 14V)

119

120

R
R

Power supply for ECM

[Ignition switch ON]

BATTERY VOLTAGE
(11 - 14V)

EC-1504

[YD (WITHOUT EURO-OBD)]

EGR VOLUME CONTROL SYSTEM

Wiring Diagram

EBS0151E

MBWA0622E

EGR VOLUME CONTROL SYSTEM

EC-1505

[YD (WITHOUT EURO-OBD)]

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Diagnostic Procedure

EBS0151F

1.

CHECK EGR VOLUME CONTROL SYSTEM OVERALL FUNCTION

1.

Turn ignition switch OFF.

2.

Set the oscilloscope probe between ECM terminals 25, 26, 27, 28 and ground.

3.

Start engine and let it idle.

4.

Check the oscilloscope screen when revving engine up to 3,200 rpm and return to idle.

OK or NG

OK

>> INSPECTION END

NG

>> GO TO 2.

2.

CHECK EGR VOLUME CONTROL VALVE POWER SUPPLY CIRCUIT-I

1.

Turn ignition switch OFF, wait at least 10 seconds and then turn ON.

2.

Check voltage between ECM terminals 119, 120 and ground
with CONSULT-II or tester.

OK or NG

OK

>> GO TO 3.

NG

>> Go

to

EC-1310,

"MAIN

POWER

SUPPLY

AND

GROUND CIRCUIT"

.

The pulse signal as shown in the figure should appear.

MBIB0617E

Voltage: Battery voltage

MBIB1096E

EC-1506

[YD (WITHOUT EURO-OBD)]

EGR VOLUME CONTROL SYSTEM

3.

CHECK EGR VOLUME CONTROL VALVE POWER SUPPLY CIRCUIT-II

1.

Turn ignition switch OFF.

2.

Disconnect EGR volume control valve harness connector.

3.

Turn ignition switch ON.

4.

Check voltage between EGR volume control valve terminals 2, 5
and ground with CONSULT-II or tester.

OK or NG

OK

>> GO TO 9.

NG

>> GO TO 4.

4.

CHECK EGR VOLUME CONTROL VALVE POWER SUPPLY CIRCUIT-III

1.

Turn ignition switch OFF.

2.

Disconnect ECM relay.

3.

Check voltage between ECM relay terminal 3 and ground with
CONSULT-II or tester.

OK or NG

OK

>> GO TO 6.

NG

>> GO TO 5.

MBIB0911E

Voltage: Battery voltage

PBIB0431E

MBIB0922E

Voltage: Battery voltage

PBIB0432E

EGR VOLUME CONTROL SYSTEM

EC-1507

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5.

DETECT MALFUNCTIONING PART

Check the following.

●

Harness connectors E125, M82 (LHD models)

●

Harness connectors E145, M80 (RHD models)

●

10A fuse

●

Harness for open or short between ECM relay and battery

>> Repair open circuit or short to ground or short to power in harness or connectors.

6.

CHECK EGR VOLUME CONTROL VALVE POWER SUPPLY CIRCUIT-IV

1.

Check harness continuity between ECM relay terminal 5 and EGR volume control valve terminals 2, 5.
Refer to Wiring Diagram.

2.

Also check harness for short to ground and short to power.

OK or NG

OK

>> GO TO 8.

NG

>> GO TO 7.

7.

DETECT MALFUNCTIONING PART

Check the following.

●

Harness connectors F45, M71

●

Harness for open or short between ECM relay and EGR volume control valve

>> Repair open circuit or short to ground or short to power in harness or connectors.

8.

CHECK ECM RELAY

Refer to

EC-1316, "Component Inspection"

.

OK or NG

OK

>> GO TO 9.

NG

>> Replace ECM relay.

9.

CHECK EGR VOLUME CONTROL VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1.

Turn ignition switch OFF.

2.

Disconnect ECM harness connector.

3.

Check harness continuity between ECM terminals and EGR volume control valve terminals as follows.
Refer to Wiring Diagram.

4.

Also check harness for short to ground and short to power.

OK or NG

OK

>> GO TO 10.

NG

>> Repair open circuit or short to ground or short to power in harness or connectors.

Continuity should exist.

ECM terminal

EGR volume control valve terminal

25

1

26

6

27

3

28

4

Continuity should exist.

EC-1508

[YD (WITHOUT EURO-OBD)]

EGR VOLUME CONTROL SYSTEM

10.

CHECK EGR VOLUME CONTROL VALVE

Refer to

EC-1508, "Component Inspection"

.

OK or NG

OK

>> GO TO 11.

NG

>> Replace EGR volume control valve.

11.

CHECK INTERMITTENT INCIDENT

Refer to

EC-1309, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT"

.

>> INSPECTION END

Component Inspection

EBS0151G

EGR VOLUME CONTROL VALVE

With CONSULT-II

1.

Disconnect EGR volume control valve harness connector.

2.

Check resistance between the following terminals.

●

terminal 2 and terminals 1, 3

●

terminal 5 and terminals 4, 6

If NG, replace EGR volume control valve.
If OK, go to next step.

3.

Remove EGR volume control valve from cylinder head.
(The EGR volume control valve harness connector should
remain connected.)

4.

Reconnect EGR volume control valve harness connector.

5.

Turn ignition switch ON.

MBIB0911E

Temperature

°

C (

°

F)

Resistance

Ω

20 (68)

13 - 17

MBIB0007E

EGR VOLUME CONTROL SYSTEM

EC-1509

[YD (WITHOUT EURO-OBD)]

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6.

Perform “EGR VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Check that EGR volume control
valve shaft moves smoothly forward and backward according to the valve opening.

If NG, replace the EGR volume control valve.

Removal and Installation

EBS0151H

EGR VOLUME CONTROL VALVE

Refer to

EM-123, "INTAKE MANIFOLD"

.

SEF819Y

EC-1510

[YD (WITHOUT EURO-OBD)]

TC BOOST CONTROL SOLENOID VALVE

TC BOOST CONTROL SOLENOID VALVE

PFP:14956

Description

EBS0151I

The load from the turbocharger boost control solenoid valve controls
the actuator. By changing the variable nozzle vane opening through
the rods, the intake air volume is adjusted.

The turbocharger boost control solenoid valve is moved by ON/OFF
pulse from the ECM. The longer the ON pulse, the charge air pres-
sure rises.

ECM Terminals and Reference Value

EBS0151J

Specification data are reference valves, and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.

CAUTION:

Do not use ECM ground terminals when measuring input/output voltage. Doing so may damage the
ECM's transistor. Use a ground other than ECM terminals, such as the ground.

*: YD22DDTi engine models

MBIB0626E

MBIB0921E

TER-

MINAL

NO.

WIRE

COLOR

ITEM

CONDITION

DATA

(DC voltage and Pulse signal)

6

L

Turbocharger boost control
solenoid valve*

[Ignition switch ON]

●

Warm-up condition

●

Idle speed

0 - 12.5V

[Ignition switch ON]

●

Warm-up condition

●

Engine speed is 2,000 rpm

0 - 12.5V

MBIB0889E

MBIB0890E

TC BOOST CONTROL SOLENOID VALVE

EC-1511

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Wiring Diagram

EBS0151K

MBWA0624E

EC-1512

[YD (WITHOUT EURO-OBD)]

TC BOOST CONTROL SOLENOID VALVE

Diagnostic Procedure

EBS0151L

1.

CHECK OVERALL FUNCTION

1.

Start engine and let it idle.

2.

Make sure that turbocharger control actuator rod moves slightly
when engine is started.

OK or NG

OK

>> INSPECTION END

NG

>> GO TO 2.

2.

CHECK TURBOCHARGER BOOST CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT

1.

Turn ignition switch OFF.

2.

Disconnect turbocharger boost control solenoid valve harness
connector.

3.

Turn ignition switch ON.

4.

Check voltage between turbocharger boost control solenoid
valve terminal 2 and ground with CONSULT-II or tester.

OK or NG

OK

>> GO TO 4.

NG

>> GO TO 3.

3.

DETECT MALFUNCTIONING PART

Check the following.

●

Harness connectors F45, M71

●

Harness for open or short between ECM relay and turbocharger boost control solenoid valve

●

Harness for open or short between ECM and turbocharger boost control solenoid valve

>> Repair open circuit or short to ground or short to power in harness or connectors.

PBIB1936E

MBIB0921E

Voltage: Battery voltage

MBIB0010E

TC BOOST CONTROL SOLENOID VALVE

EC-1513

[YD (WITHOUT EURO-OBD)]

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4.

CHECK TURBOCHARGER BOOST CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR

OPEN AND SHORT

1.

Turn ignition switch OFF.

2.

Disconnect ECM harness connector.

3.

Check harness continuity between ECM terminal 6 and turbocharger boost control solenoid valve terminal
1. Refer to Wiring Diagram.

4.

Also check harness for short to ground and short to power.

OK or NG

OK

>> GO TO 5.

NG

>> Repair open circuit or short to ground or short to power in harness or connectors.

5.

CHECK TURBOCHARGER BOOST CONTROL SOLENOID VALVE

Refer to

EC-1513, "Component Inspection"

.

OK or NG

OK

>> GO TO 6.

NG

>> Replace turbocharger boost control solenoid valve.

6.

CHECK INTERMITTENT INCIDENT

Refer to

EC-1309, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT"

.

>> INSPECTION END

Component Inspection

EBS0151M

TURBOCHARGER BOOST CONTROL SOLENOID VALVE

1.

Disconnect turbocharger boost control solenoid valve harness
connector.

2.

Apply 12V direct current between turbocharger boost control solenoid valve terminals.

3.

Check air passage continuity of turbocharger boost control sole-
noid valve under the following conditions.

Operation takes less than 1 second.

If NG, replace turbocharger boost control solenoid valve.

Removal and Installation

EBS0151N

TURBOCHARGER BOOST CONTROL SOLENOID VALVE

Refer to

EM-128, "EXHAUST MANIFOLD AND TURBOCHARGER"

.

Continuity should exist.

MBIB0921E

CONDITIONS

Air passage continuity

between A and B

Air passage continuity

between A and C

12V direct current supply
between terminals 1 and 2

Yes

No

No supply

No

Yes

MBIB0996E

EC-1514

[YD (WITHOUT EURO-OBD)]

BRAKE SWITCH

BRAKE SWITCH

PFP:25230

Description

EBS0151O

The stop lamp switch is installed to brake pedal bracket. The switch
senses brake pedal position and sends an ON-OFF signal to the
ECM. The ECM uses the signal to control the fuel injection control
system.

CONSULT-II Reference Value in Data Monitor Mode

EBS0151P

Specification data are reference values.

ECM Terminals and Reference Value

EBS0151Q

Specification data are reference values and are measured between each terminal and ground.

CAUTION:

Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.

MBIB0903E

MONITOR ITEM

CONDITION

SPECIFICATION

BRAKE SW

●

Ignition switch: ON

Brake pedal: Fully released

OFF

Brake pedal: Slightly depressed

ON

TERMI-

NAL

NO.

WIRE

COLOR

ITEM

CONDITION

DATA

(DC Voltage)

100

R/G

Stop lamp switch

[Ignition switch ON]

●

Brake pedal: Fully released

Approximately 0V

[Ignition switch ON]

●

Brake pedal: Depressed

BATTERY VOLTAGE
(11 - 14V)