The Haynes Emissions Control Manual 1563922347, 9781563922343

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Digitized by the Internet Archive in 2022 with funding from Kahle/Austin Foundation

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cubblefield, Mike. ve Haynes emissions

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2005. 5405216847057 : 02/12/09

The Haynes

Emissions Control Vianual by Mike Stubblefield and John H Haynes Member of the Guild of Motoring Writers

The Haynes Automotive Repair Manual for emissions control systems (3K7 - 10210)

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Acknowledgements We are grateful to the following companies for providing test equipment shown in this manual: Rinda Technologies P.O. Box 860 Prospect Heights, IL 60070 The John Fluke Manufacturing Company P.O. Box 9090 Everett, WA 98206 The Actron Manufacturing Company 9999 Walford Avenue Cleveland, OH 44102 - 4696

Equus Products Inc. 17291 Mt. Hermann Fountain Valley, CA 92708 In addition, thanks are due to the Chrysler Corporation, Mazda Motor Corporation, Mitsubishi Motors Corporation, Nissan Motor Company, Toyota Motor Corporation and the Isuzu Motor Company for providing technical information and certain illustrations. Technical writers who contributed to this project include Larry Warren and Robert Maddox. © Haynes North America, Inc. 1994, 1997, 2001, 2005 With permission from J.H. Haynes & Co. Ltd.

A book in the Haynes Automotive Repair Manual Series Printed in the U.S.A. All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

ISBN 1 56392 234 7 Library of Congress Catalog Card Number 96-78643 While every attempt is made to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given

"Ford" and the Ford logo are registered trademarks of Ford Motor Company. Ford Motor Company is not a sponsor or affiliate of Haynes Publishing Group or Haynes North America, Inc. and is not a contributor to the content of this manual. 05-256

Contents Chapter 1

Introduction

Introduction to emissions control and engine management systems ....... Understanding the material in this Manual.........0..cc:ccesccesesesseeeeceeeceeeeeeeeeees The Federally-mandated emissions warranty - questions and answers...

Emissions-related routine Maintenance ..........:.ccccsecesseeeeeeeeetseeeesenseeseeees The Vehicle Emissions Control Information (VECI) label ...........::ccsccsseeeee TOSI S070 eRe ER els AS ee Olin ena | ee RE MA nee COMER? See EmiSsioOnS SYSteMS ANd’ COMPONENHS........d0is-.snccduecassssensesesssazoasecevsesanarvscss Basic vaertsin troubleshooting ca... ci... saccpee-sen Ree Mt asss vacenvashiortissease Checking electrical ConneGtOns: Feta cre bn. afi on ticked eaticelesecedaeveckaens Preparing for emissions Certification testing ...........ccccccccsscetssceesseeeeseeeeseeees Resetting emissions maintenance reminder timerS .............:cccceesseeeeeseeeees Can you modify an emissions-controlled vehicle? ............cccssccceeseeeeeseees

Chapter 2 Troubleshooting Symptom-based) troubleshooting), ssciss.HécccazesiesaassichsvncetssgervesSesnesesvasstacins Ree RONAN a a a oe ceed cae cea ange yee saa Mine das tb cbeceeeh Somputer trouble Code retrieval ...

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LIGHT

_ Note: To determine which models a code applies to, refer to the parenthetical reference (A, B and/or C) following the _ probable cause, then cross-reference the letter(s) with their corresponding models at the end of this chart. Code

Probable cause

Idle switch not turned on (1982 through 1984 1.8L with feedback carburetor)

No TACH signal to ECM (A, B and C) Idle switch not turned off (1982 through 1984 1.8L with feedback carburetor)

Oxygen sensor or circuit (A, B and C) Wide open throttle switch not turned on (1982 through 1984 1.8L with feedback carburetor)

Wide open throttle switch not turned off (1982 through 1984 1.8L with feedback carburetor) 14

Engine coolant temperature (ECT) sensor shorted (A) or grounded (B) or out of range (C)

Throttle position sensor (T)ES): voltage high (C) Throttle position sensor (TPS)- out of range (D)

Throttle position sensor (TPS) signal-voltage low(C

Ignition power transistor circuit -output terminal grounded (B

Intake Air Temperature (IAT) sensor voltage- high temperature indicated ©) Intake Air Temperature (IAT) sensor- out of range(D Coolant temperature sensor malfunction (1982 through 1984 1.8L with feedback carburetor)

Vehicle speed sensor (VSS) circuit fault (A and C)

6-50

Chapter 6 Code

Probable cause

Computer trouble codes

:

: Vehicle speed sensor (VSS) - no input signal (D)

Pressure regulator vacuum switching valve (1988 through 1994 2.3L) Random Access Memory (RAM) (1982 through 1984 1.8L with fleodneck carburetor) Air Injection Reactor(AIR) vacuum switch valve (VSV) circuit fault (1987 through 1989 1.5L; A and B) Intake air temperature (IAT) - high temperature indicated (C)

:

—

Canister vacuum switching valve (VSV) system for canister purge - circuit open or grounded (A and B) : Vacuum switching valve (VSV) - constant high voltage to ECM (A)

Canister purge vacuum switching valve (VSV) - faulty transistor or bad ground circuit (B) No ignition reference to ECM (A) Wastegate control circuit fault - turbo models (C) Exhaust Gas Recirculation (EGR) system failure (C) Fuel injector circuit fault - output terminal open iegrounded (B)

Manifold Absolute Pressure (MAP) sensor - voltage high (C) Manifold Absolute Pressure (MAP) sensor - out of range (D) Exhaust Gas Recirculation (EGR)/vacuum switching valve (VSV) - output terminal open or grounded (B)

Manifold Absolute Pressure (MAP) sensor - voltage low (C)

Ae

Exhaust Gas Recirculation (EGR) temperature sensor - electronic idle control oneal fault (A) Ignition power transistor - open circuit (B) Crank angle sensor (CAS) - no signal or faulty signal (B) Electronic spark timing circuit fault (C) Fuel cut-off relay malfunction or circuit fault (A) Electronic spark control (ESC)- knock circuit fault (C

Oxygen sensor- lean condition indicated (all models)

Oxygen sensor - rich condition indicated (all models) Fuel cut-off solenoid circuit shorted, or faulty ECM (A)

Bad Programmable Read-Only Memory (PROM) or incorrect PROM installation (1985 through 1989 1.5L |-Mark; ©)

;

Electronic Control Module (ECM) failure (B and D) Electronic Control Module (ECM) failure (A and B)

CALPAK error - faulty, incorrectly installed or wrong CALPAK (C) _

:

Faulty Eiserronic Control Module (ECM), or shorted air switching solenoid (ASS) or air injection system (A) Vacuum switching valve (VSV) - grounded or faulty power transistor (B)

Fuel pump circuit - low voltage (C)

6-51

The Haynes Emissions Control Manual Isuzu (continued) Code

Probable cause

54

Ignition power transistor - grounded or faulty power transistor (B)

54

- Shorted mixture control solenoid, or faulty ECM (1987 through 1989 1.5L |I-Mark; A)

65

_

Faulty Electronic Control Module (ECM) (A, B and C)

_

Air flow sensor (AFS) circuit fault - grounded, shorted or open HOW wire (B) . 2

_

Airflow sensor (AFS) circuit fault - broken COLD wire (B) Vehicle speed sensor (VSS) circuit - no signal input (B)

64

Fuel injector driver transistor circuit - grounded or faulty circuit (B)

5

A

1985 through 1989 1.5L engine (VIN 7) with feedback carburetor (FBC); 1983 1.8L truck engine with FBC; 1983 through 1986 2.0L engine (VIN A) with FBC; 1986 through 1994 2.3L engine (VIN L) with FBC

B

1985 through 1987 2.0L electronic fuel-injected (EFI) turbo engine (VIN F); 1983 through 1989 2.0L EFI engine (VIN A); 1988 and 1989 2.3L EFI (VIN L) engine; 1988 through 1994 2.6L EFI engine (VIN E)

C

1987 through 1989 1.5L electronic fuel-injected (EFI) turbo engine (VIN 9); 1989 1.6L EFI engine (VIN 5); 1991 and 1992 1.6L EFI turbo engine (VIN 4); 1989 through 1991 2.8L throttle body injection (TBI) engine (VIN R); 1991 through 1994 3.1L TBI engine (VIN Z)

D_

1990 and 1991 1.6L electronic fuel-injected (EFI) engine (VIN 7); 1992 through 1994 1.8L EFI engine (VIN 8); 1991 through 1994 2.3L EFI engine (VIN 5, VIN 6); 1992 through 1994 3.2L EFI engine (VIN V, VIN W)