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Engine Controls - System/component Tests - Carbureted Isuzu Amigo I

Testing & Diagnostics 22 illustrations ~3561 words

INTRODUCTION

Before testing separate components or systems, perform procedures in BASIC TESTING - CARBURETED article in this section. Since many computer-controlled and monitored components set a trouble code if they malfunction, also perform diagnostic procedures in the appropriate TESTS W/CODES - 2.3L CARBURETED article in this section.

Note. Testing individual components does not isolate shorts or opens. Perform all voltage tests with a Digital Volt-Ohmmeter (DVOM) with a minimum 10-megohm input impedance, unless stated otherwise in test procedure. Use ohmmeter to isolate wiring harness shorts or opens.

ELECTRONIC CONTROL MODULE (ECM)

Note. For ECM terminal identification, see WIRING DIAGRAMS article in this section.

Ground Circuit

Using an ohmmeter, check for continuity to ground on ECM connector terminal C46-13. (Scheme 12) ECM is located behind left kick panel. (Scheme 11) Resistance should be zero ohms. If not, repair open to ground.

Power Circuits

ECM should always have battery power to retain memory. Using a voltmeter, check for battery voltage at Red/White wire of ECM connector terminal C46-1. (Scheme 12) Terminal is powered by 10-amp dome light fuse (No. 3), in interior fuse box. Interior fuse box is located on left side of dash, behind panel.

Power Supply

ECM relay is activated by ignition switch and supplies battery power to ECM. Relay is powered by 10-amp fuse (No. 8) in interior fuse box. ECM relay should always have power at Black wire, powered by 60-amp main fuse. The main fuse is located on right side of engine compartment in fuse/relay box.

ENGINE SENSORS & SWITCHES

Note. Always inspect electrical connectors, vacuum connectors and hoses before testing or replacing any component.

COOLANT TEMPERATURE SENSOR

  1. Coolant temperature sensor is located on right side of engine. (Scheme 11) Drain coolant. Disconnect coolant temperature sensor connector, and remove sensor.
  2. Cool sensor to 68°F (20°C) in cold water. (Scheme 3) Using an ohmmeter, ensure resistance between sensor terminals is 2100-2900 ohms. If resistance is not within specification, replace sensor.

Scheme 3

Scheme 3
Scheme 3

EGR TEMPERATURE SENSOR (CALIFORNIA)

EGR temperature sensor is located below EGR valve. Measure sensor resistance at sensor connector terminals. Refer to the EGR TEMPERATURE SENSOR RESISTANCE table.

Temperature °F (°C)Ohms
32 (0)28,000
68 (20)12,100
104 (40)5800
176 (80)1700

EGR TEMPERATURE SENSOR RESISTANCE

IDLE (VACUUM) SWITCH

  1. Idle (vacuum) switch is located on right fenderwell. (Scheme 11) Disconnect idle switch connector and vacuum hose. Using an ohmmeter, check for continuity between switch connector terminals. Without vacuum applied, continuity should not exist.
  2. Apply 3.1-3.5 in. Hg of vacuum to idle (vacuum) switch. Continuity should exist between Blue and Black wire terminals. (Scheme 4) If continuity is not present, replace switch.

Scheme 4

Scheme 4
Scheme 4

IDLE (VACUUM) SWITCH & MAP CIRCUIT CHECK

  1. Connect dwell meter (4-cyl. scale) to mixture control solenoid dwell terminal. (Scheme 10) Run engine until dwell varies. Pinch off vacuum hoses at idle switch and MAP sensor.
  2. Disconnect vacuum hoses and, while still pinched, plug hoses. DO NOT create vacuum leak. Note dwell reading. If dwell is more than 10 degrees, go to next step. If dwell is less than 10 degrees, enrichment system is okay. Perform system performance check. See SYSTEM PERFORMANCE CHECK under FUEL CONTROL.
  3. If dwell is more than 10 degrees, disconnect idle and MAP sensor connector. Connect jumpers between harness connector terminals (not switch and sensor side) C61-1 to C61-2 and C59-1 to C59-2. (Scheme 5) Note dwell reading. If dwell is more than 10 degrees, go to next step. If dwell is less than 10 degrees, switch or connection is faulty. Repair as required.
  4. Connect jumper wires from ECM connector terminal C45-3 to C46-9 and C45-10 to C45-11. If dwell is still more than 10 degrees, ECM is faulty. If dwell changes to less than 10 degrees, check for open wire to ECM connector terminals C45-3, C46-9, C45-11, C45-10 and C46-2. If wiring is okay, replace ECM.

Scheme 5

Scheme 5
Scheme 5

MAP SENSOR

  1. MAP sensor is located on right inside fenderwell. (Scheme 11) Start engine, and warm to operating temperature. Disconnect MAP sensor electrical connector. Disconnect and plug vacuum hose "A" at MAP sensor. (Scheme 6)
  2. Connect voltmeter leads between terminals No. 1 and No. 2 (harness side) of MAP sensor connector. Voltmeter should read more than 2.5 volts. Connect vacuum hose "A" to MAP sensor.
  3. Backprobe and measure voltage across terminals No. 1 and No. 2 at MAP sensor connector. Less than 2.5 volts should be indicated. If voltage readings are not as specified, replace MAP sensor. Also, see «IDLE (VACUUM) SWITCH & MAP CIRCUIT CHECK»(/isuzu/amigo/i-1989-1994/remont/testing-diagnostics/#engine-controls-systemcomponent-tests-carbureted__idle-vacuum-switch-map-circuit).

Scheme 6

Scheme 6
Scheme 6

OXYGEN SENSOR

Sensor range is .10 volt in lean condition and 1.0 volt in rich condition at 699°F (371°C). For additional testing, see Codes 13, 44 and 45 in TESTS W/CODES - 2.3L CARBURETED article in this section.

VEHICLE SPEED SENSOR

  1. Vehicle speed sensor is located within speedometer assembly. Use ohmmeter or circuit tester to check continuity between vehicle speed sensor terminals No. 1 and No. 2. (Scheme 7)
  2. Slowly turn speedometer inner shaft. Ensure circuit tester indicates continuity and open circuit alternately 4 times per revolution. If vehicle speed sensor is inoperative, replace speedometer assembly.

Scheme 7

Scheme 7
Scheme 7

ECM RELAY

  1. ECM relay is located on right side of engine compartment in fuse/relay box. (Scheme 11) ECM relay is powered by 10-amp fuse (No. 8) in interior fuse box. Remove relay from connector.
  2. Use an ohmmeter to check continuity between terminals No. 1 and 2, and terminals No. 1 and 3. Continuity should exist between terminals No. 1 and 2. Continuity should not exist between terminals No. 1 and 3. Apply 12 volts across ECM relay terminals No. 5 and 4. (Scheme 8)
  3. Check continuity between terminals No. 1 and 2, and terminals No. 1 and 3. Continuity should exist between terminals No. 1 and 3. Continuity should not exist between terminals No. 1 and 2. If ECM relay does not test as specified, replace ECM relay.

Scheme 8

Scheme 8
Scheme 8

FUEL-CUT (SLOW-CUT) SOLENOID

See FUEL CONTROL under FUEL SYSTEM.

MIXTURE CONTROL (DUTY) SOLENOID

See FUEL CONTROL under FUEL SYSTEM.

AIR (SWITCH) VENT SOLENOID

See FUEL EVAPORATION under EMISSION SYSTEMS & SUB-SYSTEMS.

CANISTER VACUUM SWITCHING SOLENOID VALVE

See FUEL EVAPORATION under EMISSION SYSTEMS & SUB-SYSTEMS.

FUEL DELIVERY

Note. For fuel system pressure testing, refer to the BASIC TESTING - CARBURETED article in the ENGINE PERFORMANCE Section.

Scheme 9

Scheme 9: FUEL CONTROL
Scheme 9: FUEL CONTROL

Note. System performance check tests feedback control system.

System Performance Check

  1. Set parking brake with transmission in Neutral and block wheels. Disconnect purge hose from canister and plug. Connect tachometer and start engine. Disconnect carburetor mixture control (duty) solenoid. Ground mixture control solenoid dwell terminal. (Scheme 10)
  2. Run engine at 3000 RPM. Hold throttle at a constant opening and reconnect duty solenoid. Note RPM reading. Remove ground from duty solenoid dwell terminal before returning to idle. If RPM decreases more than 100 RPM, go to next step. If RPM decreases less than 100 RPM or increases, check duty solenoid connections. If connections are okay, repair internal carburetor problem.
  3. If RPM decreased more than 100 RPM, connect dwell meter (4-cyl. scale) to duty solenoid dwell terminal. (Scheme 10) Run engine at part throttle until upper radiator hose is warm. Return engine to idle and note dwell reading. NOTE: O2 sensor may cool off at idle, causing dwell to change from varying to fixed. If this happens, run engine at fast idle to warm sensor.
  4. If dwell is varying, go to next step. If dwell is fixed under 10 degrees, go to TEST 1. If dwell is fixed between 10-80 degrees, go to TEST 2. If dwell is fixed over 80 degrees, go to TEST 3.
  5. If dwell varied in step 4), check dwell again at 3000 RPM. If dwell is varying between 10-80 degrees, go to next step. If dwell is not varying between 10-80 degrees, repair internal carburetor problem.
  6. If dwell is between 10-80 degrees at 3000 RPM, check duty solenoid connector terminals. If connector terminals are okay, check Air Injector Reactor (AIR) management system. See AIR INJECTION REACTOR (AIR) MANAGEMENT SYSTEM under «AIR INJECTION»(/isuzu/amigo/i-1989-1994/remont/testing-diagnostics/#engine-controls-systemcomponent-tests-carbureted) under EMISSION SYSTEMS & SUB-SYSTEMS. If AIR management valve checks okay, clear codes if present. Refer to the «TESTS W/CODES - 2.3L CARBURETED»(/isuzu/amigo/i-1989-1994/remont/testing-diagnostics/#engine-controls-tests-wcodes-23l-carbureted) article in this section.

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11: TEST 1 (Dwell Fixed Under 10 Degrees)
Scheme 11: TEST 1 (Dwell Fixed Under 10 Degrees)

Scheme 12

Scheme 12
Scheme 12
  1. Check vacuum hose connection at idle switch. (Scheme 4)and (Scheme 11). If okay, disconnect idle switch connectors and run engine at part throttle. Note dwell reading. If dwell is under 10 degrees, go to next step. If dwell varies, replace idle switch.
  2. If dwell is under 10 degrees, check for shorted or grounded MAP sensor and idle switch wires from ECM connector. If wiring is okay, run engine at part throttle and choke engine. If dwell increases, go to step 4). If dwell does not change, disconnect O2 sensor, and note dwell reading.
  3. If dwell increases, replace O2 sensor. If dwell is less than 10 degrees, check for grounded Violet wire to ECM connector terminal C45-8. (Scheme 12) If wire is not grounded, replace ECM.
  4. If dwell reading increased in step 2), check for intake vacuum leak, exhaust leak before O2 sensor and improper vacuum hose routing. If no leaks are found, check mixture control (duty) solenoid. See MIXTURE CONTROL (DUTY) SOLENOID under «FUEL CONTROL»(/isuzu/amigo/i-1989-1994/remont/testing-diagnostics/#engine-controls-systemcomponent-tests-carbureted). If mixture control solenoid is okay, repair or replace carburetor.

TEST 2 (Dwell Fixed Between 10-80 Degrees)

  1. Warm engine at part throttle. With engine idling, note dwell reading. Disconnect coolant temperature sensor. Connect jumper wire between coolant temperature sensor connector terminals. Note dwell reading. If dwell is not varying, go to step 3). If dwell is varying, check coolant temperature sensor resistance. See «COOLANT TEMPERATURE SENSOR»(/isuzu/amigo/i-1989-1994/remont/testing-diagnostics/#engine-controls-systemcomponent-tests-carbureted__coolant-temperature-sensor) under ENGINE SENSORS & SWITCHES or go to next step.
  2. If coolant temperature resistance is greater than 800 ohms, replace coolant temperature sensor. If resistance is less than 800 ohms, reconnect coolant temperature sensor, and note dwell reading at part throttle. If dwell is fixed, go to next step. If dwell is varying, check for poor coolant sensor connection. Clean or repair as necessary.
  3. If dwell is fixed, reconnect coolant temperature sensor and disconnect O2 sensor connector. Ground O2 sensor-to-ECM harness connector. Leave O2 sensor connector grounded for remainder of test. Note dwell reading. If dwell is not varying, go to next step. If dwell is fixed at less than 10 degrees, O2 sensor or connection is faulty. Clean or repair as necessary.
  4. If dwell is not varying in step 3), connect jumper between ECM connector terminals C45-16 and C45-8. (Scheme 12) Note dwell reading. If dwell is not varying, go to next step. If dwell is fixed at less than 10 degrees after 30 seconds, repair open in wire from ECM connector terminal C45-8 to O2 sensor.
  5. If dwell is not varying in step 4), connect jumper wire between ECM connector terminals C45-15 and C45-7. Note dwell reading. If dwell varies, repair open in wires to coolant temperature sensor. Reconnect O2 sensor connector. If dwell is not varying, ECM or connection is faulty. Repair as required.

TEST 3 (Dwell Fixed Over 80 Degrees)

  1. Run engine at part throttle for one minute. Return engine to idle, and remove canister purge hose to create vacuum leak. DO NOT stall engine. Note dwell reading. If dwell does not change, go to next step. If dwell decreases, go to step 3).
  2. If dwell does not change, disconnect O2 sensor and ground O2 sensor-to-ECM harness connector. If dwell decreases to less than 10 degrees, O2 sensor or connector is faulty. If dwell does not change, ECM or connector is faulty. Repair as required.
  3. If dwell decreased in step 1), check canister and purge valve for leaks or excess fuel. If canister and purge valves are okay, check carburetor duty solenoid. See SYSTEM PERFORMANCE CHECK under «FUEL CONTROL»(/isuzu/amigo/i-1989-1994/remont/testing-diagnostics/#engine-controls-systemcomponent-tests-carbureted) . If carburetor duty solenoid is okay, repair carburetor.

Choke Breaker (Pull-Off)

Apply vacuum to choke breaker. Diaphragm should hold vacuum. If diaphragm does not hold vacuum for a short time, replace choke breaker.

Choke (Coil) Heater

Use an ohmmeter to measure resistance between choke heater connector and ground (thermostat body). (Scheme 13) If resistance is not 1.1-3.1 ohms at 68°F (20°C), replace choke heater.

Scheme 13

Scheme 13: Choke (Coil) Heater
Scheme 13: Choke (Coil) Heater

Scheme 14

Scheme 14: Fuel-Cut (Slow-Cut) System
Scheme 14: Fuel-Cut (Slow-Cut) System
  1. Warm engine to operating temperature and connect tachometer. Connect voltmeter to Red and Black wires of fuel-cut solenoid harness. Increase engine speed to more than 3000 RPM and release accelerator.
  2. Voltmeter should read battery voltage at less than 2000 RPM and zero volts at more than 2000 RPM. If readings are not within specification, check ECM relay and related wiring. (Scheme 14) See ECM RELAY under «MODULES, RELAYS & SOLENOIDS»(/isuzu/amigo/i-1989-1994/remont/testing-diagnostics/#engine-controls-systemcomponent-tests-carbureted).
  3. If readings are within specification, check fuel-cut (slow-cut) solenoid. See FUEL-CUT (SLOW-CUT) SOLENOID below.

Inspect solenoid body and spring spool for excessive wear and damage. Use a ohmmeter to measure resistance between fuel-cut solenoid connector terminals. (Scheme 15) Resistance should be 31.9-43.3 ohms at 68°F (20°C). If resistance is not within specification, replace fuel-cut solenoid.

Scheme 15

Scheme 15: Fuel-Cut (Slow-Cut) Solenoid
Scheme 15: Fuel-Cut (Slow-Cut) Solenoid

Measure resistance between duty solenoid connector terminals. (Scheme 16) Resistance should be 34.7-46.9 ohms at 68°F (20°C). If resistance is not within specification, replace duty solenoid.

Scheme 16

Scheme 16: Mixture Control (Duty) Solenoid
Scheme 16: Mixture Control (Duty) Solenoid

Mixture Control (Duty) Solenoid Functional Check

  1. Disconnect O2 sensor and idle (vacuum) switch. With ignition on and engine off, check for repeated clicks from solenoid.
  2. If solenoid clicks, it passes functional test. If solenoid does not click, check solenoid connector for voltage using a test light. If voltage is not present, repair wiring problem. If voltage is present and solenoid does not click, replace duty solenoid.

IGNITION SYSTEM

Note. For basic ignition checks, refer to the BASIC TESTING - CARBURETED article in the this section.

Centrifugal Advance (Weights & Springs)

Remove distributor cap. Turn rotor to right and left by hand. Rotor should turn slightly to left and then return to its original position when released. Rotor should not turn to right. If rotor does not return to its original position, inspect governor (advance) weights and return springs, located below breaker plate.

Vacuum Advance

Apply vacuum to diaphragm. Ensure vacuum advance moves and holds vacuum. If no movement occurs, replace vacuum advance. Ensure breaker plate is not binding.

Air Injection Reactor (AIR) Management System

  1. Start and warm engine to normal operating temperature. Observe direction of airflow within first 3 seconds. Air should flow to exhaust ports for first 3 seconds. After 3 seconds, air should switch to air cleaner. (Scheme 17)
  2. If system does not operate as described, go to next step. If system operates as described, AIR management system is functioning properly. Check for manifold vacuum signal at AIR management valve with engine idling. Vacuum should be 10 in. Hg. Repair as required.
  3. If AIR management system does not function as described in step 1), turn ignition on and engine off. Disconnect AIR management valve electrical connector, and connect a test light between connector terminals. If test light does not light, go to next step. If test light lights, check for short in wire from AIR management valve solenoid to ECM. Replace wire if shorted. If wire is okay, replace ECM.
  4. If test light does not light as described in step 3), install jumper wire between White and Black wires of diagnostic connector, located behind left kick panel, near ECM. (Scheme 12)
  5. If test light still does not light, go to next step. If test light lights, check for a poor AIR management valve solenoid electrical connector or faulty solenoid. If connector and solenoid are okay, replace AIR management valve.
  6. If test light still does not light, connect test light between AIR management valve solenoid terminal "A" (White/Yellow wire) and ground. (Scheme 17) If test light does not light, check for blown 10-amp fuse (No. 8) in interior fuse box. If test light lights, go to next step.
  7. If test light lights in step 6), check for an open in wire from solenoid to ECM (Light/Green Black wire). If wire is okay, check resistance of solenoid windings. If resistance is less than 20 ohms, replace AIR management valve.

Scheme 17

Scheme 17
Scheme 17

AIR Management Valve

See AIR INJECTION REACTOR (AIR) MANAGEMENT SYSTEM under AIR INJECTION .

Check Valve

Remove check valve from air manifold. Blow air into valve from air pump side and manifold side. If check valve is working properly, air should pass only from air pump side. A small amount of air leakage is acceptable.

EARLY FUEL EVAPORATION (EFE)

Note. If EFE heater assembly is cracked or otherwise damaged, replace the entire assembly.

  1. Disconnect EFE harness connector at carburetor. (Scheme 18) Start engine. Using a test light, test for voltage on harness side of connector. Test light should glow when coolant temperature is less than approximately 158°F (70°C). When temperature range is more than 158°F (70°C), test light should not glow.
  2. Connect an ohmmeter to terminals on carburetor side of EFE connector. Ohmmeter should show resistance greater than zero but not infinite. If no resistance, or infinite resistance exist, replace EFE heater unit.
VehicleLocation
Amigo & PickupIn relay box, near battery

EFE HEATER RELAY LOCATION

EGR Backpressure Transducer (BPT)

  1. Remove EGR backpressure transducer valve. Plug port which supplies vacuum to EGR valve, and connect a vacuum pump to upper vacuum signal port on opposite side of valve. Plug auxiliary vacuum supply port.
  2. Blow into lower exhaust gas pressure supply port. Operate vacuum pump and verify vacuum holds. Release pressure at exhaust gas pressure supply port and verify vacuum on gauge drops.

EGR Thermal Vacuum Valve (TVV)

  1. Place thermo sensing portion of TVV in 115-129°F (46-54°C) hot water. Blow air into top hose connector. TVV should be closed and air should not pass.
  2. Raise water temperature to 140°F (60°C). TVV should open within 3 minutes. Replace TVV if port does not open within specified temperature and time.

EGR Valve

Check EGR diaphragm function by applying vacuum with hand-held vacuum pump to tube. Diaphragm should move to full up position at 3.9 in. Hg and should not leak down. If diaphragm leaks down, check for cracks in diaphragm. Check valve and seat for deformation and carbon deposits. Clean or replace as required.

Scheme 18

Scheme 18: EGR Valve
Scheme 18: EGR Valve

Scheme 19

Scheme 19: FUEL EVAPORATION
Scheme 19: FUEL EVAPORATION

Use an ohmmeter to measure resistance between solenoid terminals. (Scheme 21) Resistance should be 25.1-34.1 ohms at 68°F (20°C). If resistance is not within specification, replace air (switch) vent solenoid valve.

Scheme 20

Scheme 20: Air (Switch) Vent Solenoid
Scheme 20: Air (Switch) Vent Solenoid

Canister Purge Control Valve

  1. Apply 7.25 psi (0.51 kg/cm 2 ) to VC port. Ensure diaphragm does not leak down.
  2. Apply and maintain 14.96 in. Hg to PURGE port. Gradually apply vacuum to VC port. If purge control valve begins to open at 7.1-8.7 in. Hg as negative gauge reading falls, purge control valve is okay. If problem is found, replace canister.

Canister Vacuum Switching Solenoid Valve (VSV)

Apply battery voltage and ground to the canister VSV terminals. Ensure air does not flow freely through ports "X" and "Y". (Scheme 22) Disconnect battery voltage. Ensure air flows freely through ports "X" and "Y". If problem is found, replace canister VSV.

Scheme 21

Scheme 21: Canister Vacuum Switching Solenoid Valve (VSV)
Scheme 21: Canister Vacuum Switching Solenoid Valve (VSV)

Ventilation Valve

With no vacuum applied to port "A", ensure air flows freely through ventilation valve ports "B" and "C". (Scheme 23) Apply 1.57-1.77 in. Hg to port "A" with vacuum pump. Ensure air does not flow freely through ventilation valve ports "B" and "C". If problem is found, replace ventilation valve.

Scheme 22

Scheme 22: Ventilation Valve
Scheme 22: Ventilation Valve

Mixture Control Valve (MCV) Inspection

  1. Disconnect large rubber hose (1) connecting MCV and intake manifold. (Scheme 24) Plug intake manifold side.
  2. If MCV is functioning properly, secondary air should continue to blow from MCV for a few seconds when throttle is opened completely and released quickly. If secondary air continues to blow out for more than 5 seconds, replace MCV.

Scheme 23

Scheme 23
Scheme 23

PCV Valve

Remove PCV valve from valve cover. Attach clean hose to PCV valve. Blow through hose on valve cover side. Ensure air passes easily. Switch clean hose to intake manifold side of valve. Blow through hose. Air should not pass easily. If PCV valve fails either test, replace PCV valve.

Hot Idle Compensator (HIC)

HIC is located in bottom of air cleaner. Remove vacuum hose from intake manifold. Check temperature at HIC with thermometer. Temperature should be 115-126°F (46-52°C) for testing. Air should pass through HIC when air is blown into vacuum hose at specified temperature. If HIC does not function as indicated, replace hot idle compensator.

Vacuum Motor & Hot Air Control

  1. Connect vacuum motor directly to intake manifold vacuum with a vacuum hose. see scheme 23 Look through air intake side of air cleaner. Ensure air control valve is open to fresh air.
  2. Start engine, and let idle. Ensure air control valve closes completely at 100°F (38°C) to hot air delivery and moves smoothly.

Scheme 24

Scheme 24
Scheme 24

Thermosensor

  1. Remove air cleaner from engine. Attach thermocouple-type thermometer to sensor, and replace cover. Install air cleaner on engine. Allow engine to cool.
  2. Start engine. Look through air intake side of air cleaner. Ensure hot air switching valve begins to block fresh air intake side when engine is started.
  3. Check thermometer reading when valve begins to open outside air passage. Watch valve move by looking into fresh air entrance. Take measurement several times to obtain an average value. Thermometer reading may vary with each test.
  4. Thermosensor should transmit vacuum to vacuum motor when air temperature is less than 100°F (38°C). Fresh air is bled from vacuum motor when air temperature is greater than 111°F (44°C). If temperature opening deviates from range, replace thermosensor assembly.

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